Safe Work Method Statement

Drilling and Piling Safe Work Method Statement

Comprehensive Australian WHS Compliant SWMS

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Overview

What this SWMS covers

Drilling and piling operations are fundamental civil construction activities that establish the load-bearing foundations for bridges, buildings, retaining walls, and other major infrastructure across Australia. These specialised operations involve the use of sophisticated drilling rigs, pile boring equipment, and associated machinery to create deep foundation systems capable of transferring structural loads through weak surface soils to competent bearing strata below. The complexity of drilling and piling work, combined with the severe hazards inherent in the activity, makes comprehensive Safe Work Method Statements essential for protecting workers, ensuring structural integrity, and maintaining regulatory compliance under Australian WHS legislation. Drilling and piling encompasses a range of foundation construction techniques including bored piling where drilling equipment excavates cylindrical shafts into which reinforcement cages and concrete are placed; driven piling where hydraulic or diesel hammers drive prefabricated piles into the ground; continuous flight auger (CFA) piling that uses hollow-stem augers to drill and simultaneously place concrete; and micropiling for restricted access locations or underpinning applications. Projects requiring drilling and piling operations range from small residential developments with a handful of piles to major infrastructure projects involving hundreds of large-diameter foundation elements extending 30 metres or more below ground level. The drilling and piling sector employs specialised operators, riggers, concreters, steel fixers, geotechnical engineers, and supervisors who must work cohesively to achieve safe and successful foundation installation. Work typically occurs in challenging environments including confined urban sites adjacent to existing structures, remote locations with limited access, waterfront areas requiring marine piling techniques, and contaminated land requiring specialised handling procedures. The scale of equipment involved—with drilling rigs often exceeding 20 tonnes and operating heights of 15-25 metres—creates significant hazards that demand rigorous planning and control.

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Why this SWMS matters

Drilling and piling operations are classified as high-risk construction work under the Work Health and Safety Regulations 2011, specifically Schedule 3 which mandates SWMS for work involving excavation to a depth greater than 1.5 metres, work on or near energised electrical installations, work on or near pressurised gas mains or piping, and work involving the use of cranes or hoists. Most drilling and piling projects trigger multiple Schedule 3 criteria simultaneously, making SWMS development a legal obligation rather than a recommended practice. Persons conducting a business or undertaking (PCBUs) who fail to prepare, implement, or follow SWMS for high-risk construction work face substantial penalties under WHS legislation. The safety implications of drilling and piling work extend beyond the immediate work crew to encompass surrounding workers, the public, and existing infrastructure. Incidents involving drilling rigs have resulted in multiple fatalities across Australia, with common causal factors including rig instability leading to tip-overs, contact with overhead powerlines during rig raising or lowering, workers being caught in rotating components, and excavation collapse burying workers in unstable boreholes. The consequences of such incidents are typically severe given the mass and height of drilling equipment, the depth of excavations, and the limited opportunity for intervention once an incident sequence begins. From an operational perspective, effective SWMS enhance project efficiency by establishing clear procedures that reduce uncertainty and minimise delays caused by safety incidents or regulatory interventions. Major infrastructure clients and principal contractors now require comprehensive SWMS as a precondition for contractor engagement, with tender evaluations specifically assessing the quality and completeness of safety documentation. Contractors with demonstrated capability in developing and implementing effective SWMS gain competitive advantages in securing work on high-value projects where safety performance is a key selection criterion.

Reinforce licensing, insurance, and regulator expectations for Drilling and Piling Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Drilling Rig Tip-Over and Instability

high

Drilling rigs with mast heights of 15-25 metres and operating weights exceeding 20 tonnes can tip over when operating on unstable ground, uneven surfaces, or slopes exceeding manufacturer specifications. Tip-overs occur when the rig's centre of gravity shifts beyond the stability triangle, often during mast raising or lowering operations, when drilling on slopes, when ground conditions beneath outriggers deteriorate, or when sudden lateral loads are applied. The catastrophic nature of rig tip-overs means operators have minimal opportunity to escape, with the operator cabin potentially being crushed. Nearby workers also face severe crushing hazards from the falling rig and mast. Wind loading on extended masts significantly reduces stability margins, particularly for older rigs without automatic wind speed monitoring and shutdown systems.

Consequence: Fatal crushing injuries to operators and nearby workers, destruction of drilling equipment valued at hundreds of thousands of dollars, damage to surrounding structures and services, and extended project delays while investigations are conducted.

Contact with Overhead Powerlines

high

Drilling rigs with vertical masts extending 15-25 metres above ground level can contact overhead powerlines during transport, setup, operation, or demobilisation phases. Contact typically occurs when rigs are raised or lowered near powerlines, when rigs are moved between pile locations without lowering masts, or when operators lose spatial awareness of powerline proximity during drilling operations. Even indirect contact through dust, moisture, or proximity can cause arcing of high-voltage electricity through the rig structure, electrocuting the operator and any workers in contact with the equipment. Low-voltage powerlines (415V and below) still present fatal electrocution risks despite being less hazardous than transmission lines.

Consequence: Electrocution causing immediate death or severe burns to operators and nearby workers, ignition of hydraulic fluids causing equipment fires, damage to electrical distribution infrastructure affecting surrounding areas, and potential for arc flash injuries to bystanders.

Borehole Collapse and Worker Burial

high

Drilling operations create deep cylindrical excavations that can collapse suddenly, burying workers who enter boreholes for inspection, reinforcement installation, or problem-solving. Collapse occurs when unstable soil or rock formations fail under lateral pressure, when groundwater ingress undermines bore walls, when drilling spoil is stockpiled too close to bore edges creating surcharge loads, or when vibration from nearby activities triggers failure. The vertical-sided nature of boreholes provides no opportunity for workers to escape once collapse begins, with burial occurring within seconds. Rescue operations are extremely difficult as conventional excavation equipment cannot be used without risking further collapse or injuring buried workers.

Consequence: Fatal asphyxiation of workers buried in collapsed boreholes, severe crush injuries from falling soil and rock, extended rescue operations requiring specialised confined space rescue teams, and traumatic psychological impacts on crew members witnessing the incident.

Entanglement in Rotating Drilling Components

high

Drilling operations involve continuous rotation of augers, drill stems, kelly bars, and casing sections at speeds of 10-60 RPM. Workers can become entangled when clothing, gloves, or tools contact rotating components during drilling, when attempting to clean or adjust equipment without proper shutdown procedures, or when approaching rotating machinery to conduct measurements or inspections. The high torque of drilling equipment means that even momentary contact can draw workers into the rotating assembly, causing severe traumatic injuries before emergency stops can be activated. Entanglement risks increase during problem-solving activities when workers focus on technical issues while machinery remains operational.

Consequence: Traumatic amputation of limbs, degloving injuries where skin is stripped from underlying tissue, crushing injuries as workers are drawn into confined spaces between rotating and stationary components, and potential fatality if vital body areas are impacted.

Underground Service Strikes During Drilling

high

Drilling operations penetrate deep into the ground, creating risks of striking underground services including high-voltage electrical cables, pressurised gas mains, water pipes, telecommunications infrastructure, and sewer lines. Service strikes occur when dial-before-you-dig information is inaccurate or incomplete, when services are located horizontally outside the predicted vertical alignment, when ground-penetrating radar cannot detect certain service types, or when drilling deviates from planned verticality. The rotating, percussive action of drilling equipment can penetrate service protection and insulation, causing immediate energisation of drilling equipment, gas releases, or flooding of excavations. Deep service lines may not be identified during shallow trial pits, appearing only when drilling reaches depth.

Consequence: Electrocution from struck electrical cables energising drilling equipment, gas explosions from ruptured high-pressure mains, flooding and service disruption from damaged water infrastructure, contamination exposure from struck sewer lines, and substantial financial liability for damaged services and consequential losses.

Manual Handling of Reinforcement Cages and Drilling Components

medium

Piling operations require manual handling of steel reinforcement cages weighing 200-2,000 kilograms, drill bits and augers weighing 50-500 kilograms, and drilling tools and accessories. Manual handling occurs during cage fabrication and installation, drill tooling changes, and equipment maintenance. Workers experience back injuries from lifting heavy components, crush injuries when reinforcement or tooling shifts unexpectedly, and musculoskeletal disorders from repetitive handling and awkward postures. The cylindrical shape of reinforcement cages makes them unstable and prone to rolling, while drill bits and augers have sharp cutting edges that increase handling risks. Confined workspace around drilling rigs limits opportunities for mechanical handling aids, forcing reliance on manual methods.

Consequence: Acute lower back injuries requiring extended time off work, chronic musculoskeletal disorders affecting long-term capacity, crush injuries to hands and feet from dropped components, and laceration injuries from sharp edges on reinforcement and drill tooling.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Geotechnical Investigation and Ground Preparation

Elimination

Conducting comprehensive geotechnical investigations prior to drilling operations eliminates uncertainty about subsurface conditions, allowing selection of appropriate drilling methods and identification of hazards before work commences. Detailed ground preparation including leveling, stabilisation, and proof testing ensures stable working platforms that prevent rig tip-overs and equipment instability throughout drilling operations.

Implementation

1. Engage qualified geotechnical engineers to conduct bore sampling and soil testing across the project site, with bore locations strategically placed to characterise soil stratification, groundwater conditions, and bearing capacity. 2. Review geotechnical reports to identify hazardous conditions including soft or collapsible soils, artesian groundwater pressures, contaminated ground, and depth to competent bearing strata. 3. Prepare level working platforms for each pile location using compacted fill material or engineered hardstands, ensuring minimum 3-metre diameter level area around each pile position. 4. Proof roll working platforms using loaded trucks or compaction equipment to verify adequate bearing capacity for drilling rig outrigger loads (typically 150-200 kPa). 5. Install drainage systems to prevent water ponding on working platforms, maintaining trafficable conditions throughout drilling operations. 6. Conduct platform inspections daily and after rain events, with re-leveling or reinforcement conducted before rig positioning if settlement or deterioration is detected. 7. Document all geotechnical findings, platform preparation activities, and proof testing results in project records accessible to drilling crews.

Powerline Proximity Assessment and Exclusion Zones

Elimination

Identifying overhead powerlines before work commences and establishing absolute exclusion zones eliminates the risk of powerline contact during drilling operations. Where exclusion zones cannot be maintained, elimination through powerline de-energisation or relocation removes the electrical hazard entirely, providing the highest level of protection for drilling crews.

Implementation

1. Conduct site surveys identifying all overhead powerlines within 100 metres of planned drilling locations, documenting voltage, height, and horizontal clearances using survey-grade equipment. 2. Calculate minimum approach distances based on powerline voltage in accordance with AS/NZS 4836, with typical exclusion zones of 3 metres for low voltage (<1000V), 6 metres for high voltage (1000V-132kV), and 8 metres for transmission voltage (>132kV). 3. Contact electricity network operators to arrange powerline de-energisation for pile locations where exclusion zones cannot be maintained with mast height and operating radius. 4. Alternatively, request powerline relocation or temporary diversion for long-duration projects where de-energisation is not feasible. 5. Install highly visible markers including bunting, witches hats, and warning signage at exclusion zone boundaries to provide clear visual reference for operators. 6. Prohibit rig positioning or mast raising within exclusion zones through exclusion zone maps provided to all operators and included in site inductions. 7. Appoint trained spotters with direct communication to rig operators for any work conducted within 10 metres of powerlines (even outside exclusion zones), with authority to stop work if approach distances reduce.

Rig Stability Monitoring and Operating Limits

Engineering

Modern drilling rigs incorporate stability monitoring systems including inclinometers that measure mast angle, load moment indicators that calculate tip-over risk in real-time, and outrigger pressure sensors that detect inadequate ground support. These engineering controls provide continuous feedback to operators, automatically shutting down operations when stability thresholds are exceeded and preventing the human error that leads to tip-over incidents.

Implementation

1. Specify drilling rigs equipped with automatic stability monitoring systems including inclinometers measuring mast angle in both axes, load moment indicators calculating real-time stability margins, and outrigger pressure sensors detecting ground settlement. 2. Calibrate stability monitoring systems before project commencement and weekly during operations, with calibration certificates maintained in equipment files. 3. Configure automatic shutdown limits at 80% of manufacturer-specified maximum operating angles and loads, ensuring safety margins before critical stability thresholds are reached. 4. Install audible and visual alarms in operator cabins providing progressive warnings as stability margins reduce, with distinct alarm patterns for different hazard types. 5. Require operators to immediately stop work and retract mast if stability alarms activate, with resumption only after ground conditions are improved or rig position adjusted. 6. Prohibit override or disabling of stability monitoring systems except during specific maintenance activities under direct supervision of competent persons. 7. Download and review stability monitoring data weekly to identify trends or recurring issues requiring corrective action, with data retained for incident investigation purposes.

Temporary Casing Installation for Borehole Stability

Engineering

Installing temporary steel casing as drilling progresses provides continuous support to borehole walls, preventing collapse that could bury workers during reinforcement installation or concrete placement. Casing creates a robust engineered barrier between unstable ground and the open borehole, eliminating the reliance on soil self-supporting characteristics that can fail unpredictably.

Implementation

1. Select casing diameter and wall thickness appropriate for soil conditions and pile diameter, with minimum 50mm clearance between reinforcement cage and casing internal diameter. 2. Install casing progressively as drilling advances, maintaining minimum 2 metres of casing penetration below current drill depth to prevent bottom blowout. 3. Use casing oscillators or vibrators to advance casing through dense or obstructive strata, avoiding excessive extraction force that could cause ground heave. 4. Monitor groundwater levels inside casing during drilling, maintaining water level at or above external groundwater table to prevent piping and base heave. 5. Conduct casing integrity inspections before each use, checking for deformation, corrosion perforation, or joint damage that could compromise support capacity. 6. Prohibit worker entry into boreholes even with casing installed unless specific confined space entry procedures are implemented including atmospheric testing and emergency retrieval systems. 7. Extract casing progressively during concrete placement using controlled pull rates that prevent void formation or concrete contamination with soil.

Drilling Shutdown Procedures and Isolation

Administrative

Implementing mandatory shutdown procedures before workers approach drilling equipment eliminates entanglement hazards by ensuring all rotating components have stopped and cannot restart unexpectedly. Formal isolation procedures including lockout/tagout provide verification that equipment is safe to approach, preventing the assumption-based approaches that lead to entanglement incidents.

Implementation

1. Develop standard shutdown procedures requiring operators to disengage all drives, return hydraulic controls to neutral, shut down prime movers, and apply parking brakes before leaving operator stations. 2. Require operators to visually confirm complete stoppage of all rotating components including augers, drill stems, and kelly bars before signaling that approach is safe. 3. Implement lockout/tagout procedures for maintenance, adjustment, or problem-solving activities requiring sustained access to drilling equipment, with personal locks applied to isolation points by each worker involved. 4. Install guards around exposed rotating components including driveshafts, hydraulic motors, and auger connections, with guards remaining in place during all operations. 5. Prohibit approach to drilling equipment while rotating, with minimum 2-metre exclusion zones marked around drill stems and kellys during operation. 6. Conduct daily toolbox meetings reviewing isolation procedures and recent entanglement incidents from industry sources, reinforcing the critical importance of proper shutdown. 7. Discipline workers who approach rotating equipment without following shutdown procedures, escalating consequences for repeat violations up to and including removal from site.

Service Location and Positive Identification Protocol

Administrative

Systematic service location procedures combining dial-before-you-dig requests, electromagnetic and ground-penetrating radar surveys, and trial excavations provide multiple verification layers that significantly reduce service strike risks. Positive identification through physical exposure of services before drilling commences eliminates reliance on potentially inaccurate service plans and provides certainty about service locations.

Implementation

1. Submit dial-before-you-dig requests minimum 5 business days before drilling, obtaining responses from all service authorities with infrastructure in the project area. 2. Engage qualified service locators using electromagnetic cable locators and ground-penetrating radar to physically mark service locations, with services marked using colour-coded spray paint matching AS 5488 standards. 3. Conduct trial excavations using vacuum excavation equipment at planned pile locations, physically exposing services within 5 metres of pile positions to confirm location and depth. 4. Photograph and document all exposed services, measuring horizontal and vertical clearances to planned pile positions and updating site plans with confirmed locations. 5. Adjust pile locations if services are found within 2 metres horizontally of planned positions, unless engineering assessment confirms adequate clearance. 6. Implement drilling watch zones within 3 metres of confirmed service locations, requiring reduced penetration rates, continuous monitoring, and supervisor attendance during drilling. 7. Contact service authorities immediately if services are encountered during drilling, suspending operations until damage assessment and clearance is provided before resuming work.

Mechanical Handling Equipment and Lifting Procedures

Engineering

Deploying mechanical handling equipment including excavators with cage handling attachments, mobile cranes for drill tool changes, and purpose-built cage insertion frames eliminates manual handling of heavy reinforcement cages and drilling components. Engineering controls provide the capacity to safely manipulate heavy components while workers remain clear of suspended loads and pinch points.

Implementation

1. Specify excavators equipped with purpose-designed cage handling attachments including adjustable grabs or hydraulic clamps rated for maximum cage weight (typically 2,000 kg). 2. Engage mobile cranes rated for drill tooling lifts when changing augers, drill bits, or casing sections, with crane capacity exceeding tool weight by minimum 25% safety margin. 3. Install cage insertion frames on drilling rigs where applicable, allowing controlled lowering of reinforcement cages without manual guidance or stabilisation. 4. Conduct pre-lift planning for all mechanical handling operations, identifying lift weights, lift radius, ground conditions, and exclusion zones before commencing lifts. 5. Appoint trained doggers to attach and release lifting gear, with dogger remaining clear of suspended loads during lifting operations. 6. Implement exclusion zones of minimum 5 metres radius around mechanical handling operations, preventing unauthorised personnel from approaching suspended loads. 7. Inspect lifting gear including slings, shackles, and attachment points before each use, removing damaged or worn items from service and replacing with certified components.

Download complete control procedures

Personal protective equipment

Hard Hat with Chin Strap

Requirement: Class E electrical protection rated hard hat complying with AS/NZS 1801, fitted with chin strap to prevent dislodgement

When: Mandatory for all personnel within drilling work area due to overhead hazards from drill tooling, reinforcement cages, and mobile plant activities. Chin straps required when working beneath suspended loads or in windy conditions.

Steel Toe-Capped Safety Boots

Requirement: Steel toe-capped boots meeting AS/NZS 2210.3 with penetration-resistant midsole and ankle support

When: Required for all site personnel due to risks from dropped drill tools, reinforcement components, and mobile plant operations. Ankle support essential when working on uneven ground around drilling locations.

High-Visibility Clothing Class D/N

Requirement: High-visibility vest, shirt, or coveralls meeting AS/NZS 4602.1 Class D (day) and AS/NZS 4602.1 Class N (night) for operations near traffic or during night works

When: Mandatory for all personnel in drilling areas to ensure visibility to mobile plant operators, crane operators, and truck drivers. Reflective strips essential for night works or low-light conditions.

Heavy-Duty Work Gloves

Requirement: Cut-resistant gloves rated to AS/NZS 2161.2 Level 5 for handling steel reinforcement, with non-slip grip for handling drill tools

When: Required when handling reinforcement cages, drill bits, augers, or any components with sharp edges. Must not be worn when near rotating machinery due to entanglement risk.

Hearing Protection

Requirement: Class 5 earmuffs meeting AS/NZS 1270 providing minimum 30dB attenuation, or custom-moulded earplugs for extended exposure

When: Mandatory when within 5 metres of operating drilling rigs due to noise levels exceeding 85dB(A). Particularly critical during pile driving or percussive drilling operations which can exceed 110dB(A).

Safety Glasses with Side Shields

Requirement: Impact-resistant safety glasses meeting AS/NZS 1337 with side shields to protect from flying debris and drilling spoil

When: Required for all personnel in drilling areas due to risks from drilling spoil ejection, reinforcement handling, and general construction activities. Face shields required when working directly above drilling operations.

Arc-Rated Face Shield and Clothing

Requirement: Arc-rated face shield and flame-resistant clothing meeting AS/IEC 61482 when working within 3 metres of overhead powerlines

When: Required for emergency response personnel or workers conducting powerline proximity work under utility permits. Provides protection against arc flash in event of inadvertent powerline contact.

Inspections & checks

Before work starts

✓Inspect drilling rig for hydraulic leaks, structural damage, outrigger function, and emergency stop operation before commencing work each day
✓Verify stability monitoring systems are operational by conducting calibration checks and confirming alarm functions activate correctly
✓Check working platform for levelness, stability, and adequate bearing capacity by visual inspection and comparison to proof roll documentation
✓Confirm all overhead powerlines are identified, exclusion zones are marked, and operators understand minimum approach distances
✓Review geotechnical reports and trial pit records to understand soil conditions and groundwater levels at planned pile locations
✓Inspect all lifting equipment including excavator attachments, crane hooks, slings, and shackles for damage, wear, or deformation
✓Verify service location information is current by checking dial-before-you-dig responses are less than 30 days old and site markings remain visible
✓Conduct toolbox meeting reviewing pile locations, drilling sequence, hazard controls, and emergency procedures with all drilling crew members

During work

✓Monitor drilling rig stability continuously, observing inclinometer readings and responding immediately to any stability alarms
✓Check outrigger settlement every 30 minutes during drilling operations, installing additional timber mats if ground deterioration is observed
✓Observe borehole wall condition as drilling progresses, noting any water ingress, caving, or soil instability requiring casing installation
✓Verify exclusion zones around drilling equipment are maintained, preventing unauthorised access to areas with rotating components or suspended loads
✓Monitor weather conditions including wind speed and rainfall, suspending operations if winds exceed manufacturer-specified limits (typically 40 km/h)
✓Inspect drill tooling connections and wear at regular intervals, replacing worn bits or damaged augers before failure occurs
✓Check groundwater levels in boreholes during drilling, ensuring water levels remain above external water table to prevent piping and base heave
✓Communicate continuously between rig operators, crane operators, and ground crew using two-way radios or hand signals to coordinate activities

After work

✓Inspect completed boreholes for verticality and diameter using survey equipment before reinforcement installation proceeds
✓Check drilling rig for damage or defects requiring maintenance, documenting issues in equipment logbooks for corrective action
✓Clean and store drilling tools in designated areas, preventing corrosion and damage that could compromise future operations
✓Document all pile installations including depths achieved, soil conditions encountered, installation times, and any difficulties experienced
✓Review daily operations to identify near-misses or improvement opportunities, conducting debrief sessions with drilling crews

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Site Establishment and Service Verification

Establish drilling work area by installing protective barriers, marking pile locations with survey equipment, and verifying underground service locations through physical exposure. Review geotechnical reports and dial-before-you-dig responses to understand subsurface conditions and service locations at each pile position. Conduct trial excavations using vacuum excavation equipment at planned pile locations to physically confirm service locations and depths, adjusting pile positions if services are found within minimum clearance distances. Install highly visible service markers and exclusion zone boundaries to alert all personnel to underground hazards. Prepare level working platforms at each pile location by removing vegetation and topsoil, placing and compacting engineered fill to create minimum 3-metre diameter hardstand areas, and proof rolling to verify adequate bearing capacity for drilling rig outrigger loads. Install drainage to prevent water accumulation that could undermine platform stability. Document all site establishment activities including service locations, platform preparation methods, and proof rolling results in project records accessible to drilling crews and supervisors.

Safety considerations

Service strikes during trial excavations can cause electrocution, gas releases, or flooding. Ensure vacuum excavation operators are trained in emergency shutdown procedures and all personnel understand service identification protocols. Unstable working platforms cause rig tip-overs—verify platform bearing capacity before positioning drilling equipment.

Drilling Rig Setup and Stability Verification

Position drilling rig on prepared working platform by slowly approaching pile location under spotter guidance, ensuring accurate alignment of drill centerline with surveyed pile position. Deploy outriggers fully and verify each outrigger pad is bearing on solid ground with timber mats installed where required to distribute loads. Use rig-mounted inclinometers and levels to verify rig is within manufacturer-specified levelness tolerances (typically ±1 degree in both axes). Conduct stability system checks by activating inclinometers and load moment indicators, verifying alarm functions operate correctly and automatic shutdown systems engage at configured thresholds. Raise mast to vertical position under controlled conditions, monitoring stability indicators continuously and ensuring no overhead powerlines are within minimum approach distances. Install safety barriers around drilling rig maintaining minimum 5-metre exclusion zones to prevent unauthorised access during operations. Position emergency stop controls within easy reach of operators and ground personnel. Conduct final pre-operation checks including hydraulic system pressures, engine oil levels, coolant temperatures, and communication system function before commencing drilling operations. Document rig setup activities including platform verification, outrigger positions, levelness measurements, and stability system checks in daily work records.

Safety considerations

Rig tip-over during mast raising causes fatal crushing injuries. Never raise mast when wind speeds exceed manufacturer limits (typically 40 km/h) or when ground conditions are questionable. Powerline contact during mast raising causes electrocution—verify minimum approach distances before any vertical movements. Ensure all personnel remain outside exclusion zones during mast raising operations.

Drilling Operation and Borehole Advancement

Commence drilling operations by engaging drill motor and lowering auger or drill bit into ground at controlled penetration rates appropriate for soil conditions encountered. Monitor drilling parameters including penetration rate, torque, and hydraulic pressures to identify changes in soil stratigraphy or obstructions requiring adjusted drilling methods. Extract drilling spoil at regular intervals, inspecting material to verify soil conditions match geotechnical expectations and identifying any unexpected materials such as buried debris, contaminated soils, or groundwater inflows. Install temporary casing progressively as drilling advances through unstable soil conditions, maintaining minimum 2-metre penetration of casing below current drill depth to prevent base heave or piping. Monitor groundwater levels in borehole continuously, maintaining water level at or above external groundwater table by adding water as necessary. Adjust drilling method if obstructions such as boulders, concrete rubble, or timber piles are encountered, using appropriate tooling including rock augers, core barrels, or chisel bits. Communicate with supervisor immediately if significant deviations from expected soil conditions occur or if drilling cannot achieve specified depth within reasonable time. Monitor rig stability continuously throughout drilling operations, observing inclinometer readings and responding immediately if stability alarms activate by stopping operations and investigating cause. Check outrigger settlement every 30 minutes, installing additional timber mats if ground deterioration is observed. Suspend drilling operations during adverse weather including high winds, heavy rain, or lightning activity as specified in project weather shutdown procedures.

Safety considerations

Borehole collapse during drilling can bury workers in unstable soil—never allow personnel to approach or enter boreholes even during brief stoppages. Install casing in unstable ground before collapse occurs. Service strikes cause electrocution, gas releases, or flooding—reduce penetration rates and maintain heightened awareness when drilling within 3 metres of identified services. Rig tip-over from unstable ground or excessive loading causes fatal crushing injuries—monitor stability systems continuously and respond immediately to alarms.

Reinforcement Cage Installation

Upon reaching specified pile depth and verifying borehole stability, prepare for reinforcement cage installation by inspecting cage for fabrication defects, verifying cage diameter provides specified concrete cover (typically 75mm minimum), and confirming cage length matches pile depth requirements. Position mechanical handling equipment including excavator with cage handling attachment or mobile crane adjacent to borehole, maintaining minimum approach distances from excavation edges to prevent ground collapse under equipment loading. Attach lifting gear to reinforcement cage using multiple connection points distributed along cage length to prevent bending or deformation during lifting. Conduct pre-lift checks including lift weight verification, equipment capacity confirmation, and exclusion zone establishment preventing unauthorised personnel from approaching suspended loads. Lift cage vertically and maneuver into position above borehole under coordination between excavator/crane operator and ground personnel using established hand signals or two-way radio communications. Lower reinforcement cage into borehole at controlled rates preventing impacts with borehole walls that could damage cage or destabilise bore sides. Install cage spacers or centralizers at specified intervals to maintain concrete cover on all sides. Verify cage achieves specified depth by measuring cage top elevation relative to survey benchmarks, adjusting cage position if necessary before securing cage against flotation during concrete placement. Prohibit personnel from entering boreholes to adjust cage positions—use mechanical handling equipment for all adjustments. Document cage installation including cage identification numbers, installation depths, and any difficulties encountered during installation process.

Safety considerations

Suspended reinforcement cages weighing up to 2,000 kilograms can crush workers if dropped—maintain minimum 5-metre exclusion zones around lifting operations. Cages can become stuck in boreholes, creating lifting equipment overload that causes crane tip-over or component failure—never exceed equipment rated capacity attempting to free stuck cages. Manual handling of heavy cages causes back injuries and crush injuries—use mechanical handling equipment for all cage movements.

Concrete Placement and Casing Extraction

Prepare for concrete placement by installing tremie pipe to borehole base, ensuring tremie inlet remains embedded in concrete throughout placement to prevent segregation and contamination. Verify concrete supply is available and mix design meets project specifications including strength requirements, slump specifications, and any special admixtures for underwater placement. Confirm concrete delivery schedule provides continuous supply preventing cold joints in piles. Commence concrete placement by pumping concrete through tremie pipe at controlled rates while slowly raising tremie to maintain embedment in rising concrete level. Monitor concrete level rise using weighted tape or electronic sensors, comparing actual rise to theoretical volume calculations to verify borehole diameter remains consistent and no voids or collapses have occurred. Extract temporary casing progressively during concrete placement using controlled pull rates of 1-2 metres per 1 cubic metre of concrete placed, preventing void formation beneath casing or soil contamination of concrete. Continue concrete placement until pile extends minimum 200mm above specified cut-off level to allow for trimming of contaminated concrete from pile top. Install pile identification markers including pile number and installation date before concrete sets. Conduct concrete testing including slump tests on delivered concrete and collection of concrete cylinders for compressive strength testing in accordance with AS 1379. Document all concrete placement activities including volumes placed, concrete test results, installation times, and any difficulties encountered during placement. Allow concrete to cure for minimum 48 hours before conducting pile integrity testing or pile load testing as specified in project requirements.

Safety considerations

Concrete pump line failures can spray high-pressure concrete causing serious impact injuries—inspect all pump lines and connections before commencing concrete placement, and maintain exclusion zones around pump operations. Rapid casing extraction can cause soil collapse into fresh concrete, reducing pile capacity and potentially requiring pile replacement—extract casing at controlled rates with continuous monitoring. Fresh concrete in boreholes presents asphyxiation hazards from carbon dioxide accumulation—prohibit personnel from approaching borehole openings during concrete placement and curing periods.

Rig Demobilisation and Site Restoration

After completing all piles in work area, prepare drilling rig for demobilisation by conducting thorough cleaning to remove drilling spoil and concrete residues, lowering mast to horizontal transport position, and retracting outriggers. Inspect rig for damage or defects requiring maintenance before next deployment, documenting issues in equipment service records and arranging repairs as necessary. Load drill tools, casing sections, and accessories onto transport vehicles using mechanical handling equipment, securing loads in accordance with transport regulations. Remove all safety barriers, service markers, and temporary installations from site, restoring work area to specified condition. Dispose of drilling spoil and waste concrete in accordance with waste management plans and environmental approvals, with contaminated soils handled through licensed waste facilities if contamination was encountered. Conduct final site inspection to verify all drilling operations are complete, all equipment and materials are removed, and site is left in safe condition for subsequent trades. Complete project documentation including pile installation records, concrete test results, daily work logs, and any incident reports or non-conformances requiring corrective action. Submit final documentation to project managers and supervisors within specified timeframes, ensuring all records are complete and accurate for project quality assurance and regulatory compliance purposes. Conduct project debrief with drilling crews to identify lessons learned and improvement opportunities for future drilling operations.

Safety considerations

Mast lowering during demobilisation presents powerline contact risks—verify powerline clearances before lowering mast and use spotters where approach distances are limited. Equipment loading on transport vehicles can cause crushing injuries—use mechanical handling equipment for all heavy lifts and ensure personnel remain clear during loading operations. Contaminated drilling spoil may contain hazardous substances—conduct testing if contamination is suspected and handle through appropriate waste facilities to prevent environmental harm.

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Frequently asked questions

What licenses and qualifications are required for drilling rig operators in Australia?

Drilling rig operators must hold high-risk work licenses appropriate for the equipment class being operated. For most drilling rigs, this requires a CN (crane) license or DG (dogging) license depending on whether the rig incorporates lifting capabilities. Operators should also complete manufacturer-specific training for the rig model being operated, as control systems and safety features vary significantly between manufacturers. Many employers require operators to hold Certificate III in Drilling Operations (AUR30620) or equivalent qualifications demonstrating competence in drilling techniques, geotechnical interpretation, and equipment maintenance. Additionally, operators working near powerlines must complete powerline awareness training, and those involved in confined space entry for borehole inspection require confined space entry training and current medical clearances. Supervisors overseeing drilling operations should hold relevant civil construction qualifications and demonstrate experience in geotechnical construction methods. Verifying operator qualifications before commencing work is a fundamental requirement under WHS legislation and most client prequalification systems.

How do I determine if temporary casing is required for borehole stability during drilling?

The requirement for temporary casing depends on soil conditions encountered during drilling, with unstable soils including sands, silts, fills, and highly fractured rock generally requiring casing support. Engage a competent person (typically a geotechnical engineer) to review soil conditions and specify casing requirements based on geotechnical investigation results and observed drilling behavior. Indicators that casing is required include borehole walls caving or sloughing during drilling, groundwater entering the borehole and causing sand boils or piping, drilling in loose granular soils below the water table, or drilling in areas with previous filling or disturbed ground. As a general rule, any borehole deeper than 3 metres in granular soils below the water table should be cased, as should boreholes in loose fill materials regardless of depth. Install casing progressively as drilling advances, maintaining minimum 2-metre penetration below current drill depth. Casing also provides worker protection if borehole entry becomes necessary for problem-solving, though confined space entry should be avoided wherever possible. Document decisions regarding casing use in drilling records, including the competent person's assessment and justification for casing or non-casing approaches. Remember that while casing installation adds time and cost to drilling operations, the consequence of borehole collapse can be fatal to workers and requires expensive pile remediation.

What are the specific requirements for working near overhead powerlines during piling operations?

Work near overhead powerlines is regulated by AS/NZS 4836 Safe Approach Distances to Electrical Apparatus, which specifies minimum separation distances based on voltage levels. For drilling rigs, the total approach distance includes the maximum vertical height of the rig plus mast in the raised position. Low-voltage lines (up to 1,000V) require minimum 3-metre clearance, high-voltage lines (1kV to 132kV) require 6 metres, and transmission lines (above 132kV) require 8 metres or more. Before commencing work near powerlines, contact the electricity network operator to determine voltage levels and request powerline de-energisation if clearances cannot be maintained. If de-energisation is not possible, implement multiple controls including appointing trained spotters with direct communication to rig operators, installing highly visible height markers at exclusion zone boundaries, and providing operators with arc-rated personal protective equipment. Some jurisdictions require formal permits or approvals for work within certain distances of powerlines—check with local electrical safety regulators for specific requirements. Never rely solely on operator vigilance—the high consequence of powerline contact demands engineering and administrative controls that prevent contact even if operators lose situational awareness. Document all powerline assessments, de-energisation arrangements, and spotter appointments in project records to demonstrate compliance with electrical safety requirements.

What testing and verification is required after pile installation to confirm pile integrity and capacity?

Pile testing requirements vary depending on project specifications, with typical requirements including pile integrity testing (PIT) using low-strain dynamic testing to detect defects such as necking, voids, or discontinuities in concrete piles. PIT testing involves striking the pile top with an instrumented hammer and analyzing reflected stress waves to identify impedance changes that indicate defects. For critical piles or projects requiring capacity verification, static load testing may be specified where hydraulic jacks apply loads up to 1.5-2.0 times design load while measuring pile settlement. Dynamic load testing using high-strain methods can provide capacity estimates at lower cost than static testing, though results require correlation with static tests for validation. Thermal integrity profiling (TIP) provides detailed information about concrete quality and cage positioning by installing thermal sensors in ducts cast into reinforcement cages. All testing should be conducted by specialist pile testing contractors using calibrated equipment, with results interpreted by geotechnical engineers competent in foundation testing analysis. Testing typically occurs 7-28 days after pile installation to allow concrete to gain adequate strength, though some dynamic methods can be applied earlier. Document all testing results in project quality records, addressing any defects or non-conformances through remedial measures such as additional piling, pile grouting, or design modifications. Note that testing requirements are specified by structural engineers based on project importance, ground conditions, and design methodology—always confirm testing scope during project planning stages to ensure budget and program allowances are adequate.

Overview

Drilling and piling encompasses a range of foundation construction techniques including bored piling where drilling equipment excavates cylindrical shafts into which reinforcement cages and concrete are placed; driven piling where hydraulic or diesel hammers drive prefabricated piles into the ground; continuous flight auger (CFA) piling that uses hollow-stem augers to drill and simultaneously place concrete; and micropiling for restricted access locations or underpinning applications. Projects requiring drilling and piling operations range from small residential developments with a handful of piles to major infrastructure projects involving hundreds of large-diameter foundation elements extending 30 metres or more below ground level. The drilling and piling sector employs specialised operators, riggers, concreters, steel fixers, geotechnical engineers, and supervisors who must work cohesively to achieve safe and successful foundation installation. Work typically occurs in challenging environments including confined urban sites adjacent to existing structures, remote locations with limited access, waterfront areas requiring marine piling techniques, and contaminated land requiring specialised handling procedures. The scale of equipment involved—with drilling rigs often exceeding 20 tonnes and operating heights of 15-25 metres—creates significant hazards that demand rigorous planning and control. Drilling and piling operations interact with numerous subsurface hazards including underground services that may be energised, pressurised, or contain hazardous substances; variable soil and groundwater conditions that can cause bore collapse or equipment entrapment; and contaminated ground that may release toxic gases or expose workers to carcinogenic substances. Surface hazards include mobile plant movements, suspended loads from cranes and pile frames, noise and vibration affecting surrounding structures, and manual handling of heavy reinforcement cages and piling materials. Weather conditions significantly impact operations, with high winds preventing safe operation of tall pile frames, rain affecting bore stability, and extreme heat creating additional risks for operators working on exposed plant. The technical complexity of drilling and piling requires strict adherence to engineering specifications while simultaneously managing safety risks. Pile installation must achieve specified depths, diameters, verticality tolerances, and concrete strengths, all while preventing subsurface and surface hazards from causing incidents. This dual focus on production and safety, combined with the irreversible nature of foundation work (piles cannot be easily removed or relocated if incorrectly installed), creates substantial pressure on work crews. Comprehensive SWMS provide the framework for managing these competing demands, ensuring that safety considerations are integrated into every phase of drilling and piling operations from site establishment through to pile testing and demobilisation.

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Risk Rating

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After ControlsLow

Key Controls

• Pre-start briefing covering hazards
• PPE: hard hats, eye protection, gloves
• Emergency plan communicated to crew

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Drilling and Piling Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Drilling Rig Tip-Over and Instability

Contact with Overhead Powerlines

Borehole Collapse and Worker Burial

Entanglement in Rotating Drilling Components

Underground Service Strikes During Drilling

Manual Handling of Reinforcement Cages and Drilling Components

Control measures

Geotechnical Investigation and Ground Preparation

Powerline Proximity Assessment and Exclusion Zones

Rig Stability Monitoring and Operating Limits

Temporary Casing Installation for Borehole Stability

Drilling Shutdown Procedures and Isolation

Service Location and Positive Identification Protocol

Mechanical Handling Equipment and Lifting Procedures

Personal protective equipment

Hard Hat with Chin Strap

Steel Toe-Capped Safety Boots

High-Visibility Clothing Class D/N

Heavy-Duty Work Gloves

Hearing Protection

Safety Glasses with Side Shields

Arc-Rated Face Shield and Clothing

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Site Establishment and Service Verification

Drilling Rig Setup and Stability Verification

Drilling Operation and Borehole Advancement

Reinforcement Cage Installation

Concrete Placement and Casing Extraction

Rig Demobilisation and Site Restoration

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Drilling and Piling SWMS Sample

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