Anodising Process Operations SWMS

Anodising process operations involve immersing aluminium components into electrified sulfuric or chromic acid baths to grow a controlled oxide layer, with rinse, sealing and dye stages running in parallel. The work exposes operators to concentrated mineral acids, hexavalent chromium mist (Group 1 IARC carcinogen), hydrogen evolution at the cathode, and high-current DC rectifier circuits typically running at 12–24V but at hundreds of amps. Under WHS Regulation 2025 a SWMS is mandatory because the task constitutes High Risk Construction Work and High Risk Work under multiple section 291 categories, including work involving energised electrical installations, work where workers may inhale a hazardous chemical, and work near a substance under pressure or at extreme temperature. PCBUs operating anodising lines must document hazard identification, control selection against the hierarchy, and worker consultation before any tank charging, parts loading, or rectifier energisation occurs. This SWMS template provides the editable, jurisdiction-neutral framework required.

Hazards identified

7 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Elimination — Eliminate chromic acid anodising where possible by substituting Type II sulfuric anodising or Type III hard anodising for non-aerospace specifications.
2. 2Elimination — Remove manual jig transfer by installing automated hoist-and-rail systems that index parts between tanks without operator presence over the bath surface.
3. 3Substitution — Replace hexavalent chromium sealing with trivalent chromium or nickel acetate sealants where corrosion specifications permit, eliminating IARC Group 1 carcinogen exposure.
4. 4Engineering — Install lateral push-pull LEV on every acid and etch tank achieving 0.5 m/s capture velocity, ducted to a packed-bed scrubber per AS 1668.2 design criteria.
5. 5Engineering — Fit rectifiers with insulated busbar covers, residual current devices, lockable isolators and interlocked guards preventing energisation while loading doors are open.
6. 6Engineering — Install bunded flooring with 110% containment, acid-resistant grating, and continuous hydrogen gas monitoring with alarm at 10% LEL above each tank.
7. 7Administrative — Implement permit-to-work for tank charging, dilution and decanting; restrict to trained operators with documented competency reviewed annually under AS/NZS 2865.
8. 8Administrative — Conduct pre-start atmospheric monitoring for chromium VI per AS 3640 with results recorded and reviewed against the WES of 0.05 mg/m³ TWA.
9. 9PPE — Provide acid-resistant PVC or neoprene gauntlets, chemical splash apron, full face shield over safety glasses, and acid-rated rubber boots compliant with AS/NZS 2210.
10. 10PPE — Supply powered air-purifying respirators with combined acid-gas/HEPA cartridges for chromic acid line operators, fit-tested per AS/NZS 1715 and 1716.

Applicable Codes of Practice

Worked example

At a mid-sized architectural aluminium anodising facility, the day-shift leading hand opens the pre-start brief at 6:45am beside the sulfuric line. Three operators are scheduled to run a 2,400-piece extrusion batch through degrease, etch, desmut, anodise and dye stages. The leading hand walks the team through this SWMS section by section. Under hazard identification, the team flags that today's batch includes a small chromic seal run scheduled for 2pm — triggering the PAPR requirement and additional LEV check. Controls are confirmed live: the hydrogen LEL sensor above Tank 4 reads 0%, LEV manometer shows design pressure, and the rectifier RCD test button is pressed and reset. Each operator signs onto the SWMS register, with the new third-year apprentice signing under direct-supervision endorsement only. Mid-shift, an operator reports the etch tank temperature has drifted to 64°C, above the 60°C control limit specified in the SWMS. Work pauses, the SWMS dynamic-review section is consulted, and the team agrees to reduce dwell time and notify maintenance — the variation is initialled on the live document before resuming. At handover, the signed SWMS is filed against the batch traveller as required under the company's chromium health monitoring program.

Related legislation

• WHS Act 2011 (model)
• WHS Regulation 2025
• AS/NZS 3000 — Electrical installations

Frequently asked questions