Comprehensive Safe Work Method Statement for pit cover raising activities including confined space entry preparation, atmospheric testing, mechanical lifting controls, and heavy cover handling procedures

Pit Cover Raising SWMS

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Pit cover raising is a critical civil works operation involving the removal of heavy access covers from underground utility pits, drainage chambers, stormwater systems, and service trenches. This work presents significant hazards including heavy cover drop risks, confined space atmospheric hazards, manual handling injuries, and underground service damage. This Safe Work Method Statement provides comprehensive guidance for safely raising, supporting, and reinstalling pit covers while protecting workers from physical and atmospheric hazards beneath the cover.

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Overview

What this SWMS covers

Pit cover raising involves the systematic removal and reinstallation of heavy access covers from underground utility chambers, drainage pits, stormwater systems, electrical cable pits, and telecommunications trenches. These operations are essential during infrastructure maintenance, service installation, utility inspection, and underground asset upgrade projects throughout Australian urban and regional areas. Pit covers vary significantly in weight (20kg to over 200kg), material composition (cast iron, concrete, composite materials), and locking mechanisms (recessed handles, lifting hooks, or flush-mounted designs). The work requires assessment of cover type, selection of appropriate lifting equipment (manual lifting keys, vacuum lifters, mechanical hoists), and evaluation of atmospheric conditions beneath the cover before entry or work proceeds. Typical pit cover raising activities include removing covers for drainage inspection, accessing underground utilities, installing new services, conducting CCTV drain surveys, and performing maintenance on buried infrastructure. Work may occur on roadways requiring traffic management, pedestrian areas demanding public safety controls, or restricted industrial zones with specific access protocols. This SWMS addresses all phases of pit cover raising: site setup and traffic control, atmospheric testing of the confined space beneath, mechanical lifting or manual handling of the cover, work within or adjacent to the open pit, and secure reinstallation. The document provides control measures for high-risk hazards including cover drop and crush injuries, atmospheric hazards (toxic gases, oxygen deficiency), confined space entry risks, and underground service contact.

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Why this SWMS matters

Pit cover raising operations present serious injury and fatality risks that demand rigorous safety controls. Heavy covers weighing 50kg to 200kg can cause crushing injuries, fractures, or death if dropped during lifting. Workers have been killed when covers have fallen back onto them during removal, or when lifting equipment has failed causing the cover to drop. Confined space hazards beneath pit covers are particularly dangerous. Underground chambers can accumulate toxic gases (hydrogen sulfide from sewers, methane from decomposition), oxygen-deficient atmospheres, or flammable vapours. Workers have died from asphyxiation within seconds of entering untested pits. The Work Health and Safety Act 2011 and Confined Spaces Regulations require atmospheric testing before entry and continuous monitoring during work. Manual handling injuries during pit cover lifting are common, with workers experiencing back strains, shoulder injuries, and herniated discs from improper lifting techniques or attempting to lift covers that exceed safe manual handling limits. Australian WHS regulations specify that mechanical lifting aids must be used when loads exceed 15-20kg or when awkward lifting positions are required. Underground service contact presents electrocution risks (electrical cables), gas explosion hazards (gas mains), and infrastructure damage consequences. The failure to properly identify services before raising pit covers and commencing work has resulted in serious incidents, service disruptions, and costly repairs. This SWMS ensures compliance with AS 5488 for underground service location and protection protocols.

Reinforce licensing, insurance, and regulator expectations for Pit Cover Raising 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

High

Pit covers weighing between 50kg and 200kg present severe crushing and impact hazards during lifting, positioning, and reinstallation operations. Covers can slip from lifting equipment due to improper engagement, incorrect tool selection, or corroded lifting points. Workers positioned beneath or adjacent to raised covers risk catastrophic crush injuries if the cover falls. Fingers and hands can be trapped between the cover and pit frame during lowering operations. Covers may tip unexpectedly when lifted if the centre of gravity is off-balance or if lifting is attempted from one side only. Poor weather conditions (wet surfaces, high winds) increase the likelihood of cover slippage during handling.

Consequence: Crush injuries resulting in fractured limbs, amputation of fingers, spinal injuries, or fatality if the cover falls onto a worker. Historical incidents include deaths from covers falling back during removal and crushing workers who were leaning over the pit opening.

High

Underground pits and chambers present confined space atmospheric hazards including oxygen deficiency (less than 19.5%), toxic gas accumulation (hydrogen sulfide, carbon monoxide, methane), and flammable vapour concentrations. Sewer pits accumulate hydrogen sulfide which can cause immediate unconsciousness at concentrations above 500ppm and death within minutes. Stormwater pits may contain oxygen-depleted atmospheres due to bacterial decomposition of organic matter. Electrical cable pits can contain toxic fumes from cable insulation breakdown. Atmospheric conditions can change rapidly after opening the cover due to air mixing, temperature changes, or gas generation from disturbed materials.

Consequence: Asphyxiation and death within seconds to minutes of exposure to toxic atmospheres. Hydrogen sulfide poisoning causing immediate collapse, loss of consciousness, respiratory failure, and brain damage. Oxygen deficiency resulting in disorientation, loss of motor control, unconsciousness, and death.

Medium

Manual lifting of pit covers presents significant musculoskeletal injury risks even when covers weigh less than the maximum manual handling limits. Awkward lifting positions are common due to ground-level work, limited hand-hold access on flush-mounted covers, and the need to lean over the pit opening. Repetitive lifting during maintenance routes involving multiple pit covers causes cumulative strain injuries. Wet, muddy, or corroded covers are difficult to grip securely, requiring excessive force and increasing injury likelihood. Two-person lifting may be poorly coordinated resulting in uneven load distribution and injury to one worker.

Consequence: Lower back strain and herniated discs from improper lifting technique or excessive loads. Shoulder and rotator cuff injuries from repetitive lifting or awkward positions. Finger crush injuries when grips slip during lifting. Long-term chronic back problems from cumulative strain during repeated pit cover work.

High

Underground pits contain or provide access to buried services including electrical cables, gas mains, water pipes, telecommunications conduits, and fibre optic networks. Raising pit covers may expose workers to energised electrical cables if cable insulation is damaged or if covers are used as earth points. Work adjacent to or within pits risks service contact through dropped tools, probing activities, or excavation for pit repair. Services may not be accurately marked on plans, particularly older infrastructure, leading to unexpected contact. Electromagnetic interference from high-voltage cables can affect electronic equipment and pose health risks to workers with pacemakers.

Consequence: Electrocution and death from contact with energised electrical cables. Gas explosion and fire from gas main rupture or gas accumulation in pits. Service disruption affecting communities and businesses due to damaged telecommunications or utility infrastructure. Toxic exposure from damaged asbestos cement pipes or chemical pipelines.

High

Mechanical lifting equipment including vacuum lifters, pit cover lifting keys, magnetic lifters, and chain hoists can fail due to inadequate capacity rating, poor maintenance, incorrect operation, or unsuitable equipment selection. Vacuum lifters lose suction on wet, muddy, or corroded covers causing sudden cover drops. Lifting keys may not properly engage recessed handles if corrosion or debris blocks full engagement. Equipment rated for lighter covers may be used on heavier covers exceeding capacity limits. Attachment points on covers may be corroded or damaged, failing under load during lifting.

Consequence: Sudden cover drop causing crush injuries or death to workers beneath or adjacent to the raised cover. Equipment operator injury from recoil or kickback when equipment fails. Damage to underground services from dropped covers impacting pipes or cables within the pit.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Engineering Control

Engineering controls eliminate manual handling hazards by implementing mechanical lifting equipment for all pit covers exceeding 30kg or where awkward lifting positions are unavoidable. Vacuum lifting systems, magnetic lifters, pit cover lifting keys, and portable gantries provide safe lifting capacity while removing worker exposure to heavy loads.

Implementation

1. Select vacuum lifting equipment rated for pit cover weight plus 50% safety margin (e.g., 90kg lifter for 60kg cover) 2. Verify cover surface is suitable for vacuum lifting (clean, relatively flat, non-porous material) 3. Use pit cover lifting keys with secure engagement mechanisms for recessed handle covers 4. Deploy magnetic lifters only on ferrous metal covers with manufacturer confirmation of capacity 5. Position portable gantry frames over pit opening with stabilising outriggers on firm ground 6. Attach chain hoists or electric winches to gantry with load rating displayed and verified 7. Test lifting equipment on first cover before proceeding with operation to verify secure engagement 8. Maintain exclusion zone beneath and around raised covers preventing worker entry during lifting

Engineering Control

Atmospheric testing before removing pit covers identifies life-threatening gas hazards, oxygen deficiency, and flammable atmospheres that may be present in the confined space beneath. Testing must be conducted with calibrated gas detection equipment by trained personnel before any worker approaches the open pit.

Implementation

1. Conduct initial atmospheric testing before removing cover using remote testing probes where possible 2. Test for oxygen concentration (must be 19.5% to 23.5%), flammable gases (must be less than 5% LEL), and toxic gases (H2S, CO, CO2 within safe limits per AS 2865) 3. Insert gas detector probe through cover ventilation holes or small gaps before full cover removal 4. Re-test atmosphere immediately after cover removal from multiple depths within the pit (top, middle, bottom) 5. Implement continuous atmospheric monitoring if work requires personnel near or within the pit opening 6. Use calibrated multi-gas detectors serviced and bump-tested according to manufacturer requirements 7. Record all atmospheric test results on permit documentation before work proceeds 8. Ventilate pit using forced air ventilation systems if initial tests reveal unsafe atmospheres, then re-test before entry

Administrative Control

Formal confined space entry procedures and permit systems ensure systematic hazard assessment, atmospheric testing, rescue planning, and emergency preparedness before workers enter or work within pit openings. Confined Space Entry Permits authorise work only after all safety controls are verified and documented.

Implementation

1. Classify pit as confined space requiring entry permit if work involves worker entry below chest level into pit 2. Complete Confined Space Entry Permit identifying hazards, controls, atmospheric test results, and rescue plan 3. Assign trained confined space standby person who maintains visual contact with entrant and does not perform other tasks 4. Provide rescue equipment (tripod, winch, harness) positioned at pit opening before entry commences 5. Establish communication system between entrant and standby person (radio, hand signals, tag line) 6. Brief all personnel on emergency rescue procedures and limitations (standby person must not enter without additional rescue team) 7. Post permit and emergency contact numbers at work location visible to all workers 8. Conduct pre-entry toolbox meeting covering atmospheric testing, rescue procedures, and emergency signals

Engineering Control

Traffic management controls and physical barriers prevent vehicle strikes to workers, protect the public from open pit hazards, and secure the work area from unauthorised entry. Controls are particularly critical for roadway and footpath pits where traffic and pedestrian activity continues during work.

Implementation

1. Establish traffic management plan following AS 1742.3 for roadway work including advance warning signs, speed restrictions, and traffic control personnel 2. Deploy physical barriers (fencing, delineators, cones) creating minimum 2-metre exclusion zone around open pit on all sides 3. Use high-visibility reflective barriers and lighting for night work ensuring pit opening is clearly identified 4. Position traffic control personnel (if required by Traffic Management Plan) with clear visibility and communication equipment 5. Cover open pits with temporary covers or grating if work is paused preventing accidental falls by public or workers 6. Install edge protection guardrails around large pits (greater than 1.5m dimension) if work duration exceeds 30 minutes 7. Display warning signage identifying open pit hazards, confined space risks, and authorised personnel only restrictions 8. Assign spotter to monitor approaching vehicles and alert workers when vehicles approach within 10 metres of work zone

Elimination Control

Underground service location eliminates electrocution and service damage risks by identifying and marking all buried utilities before pit cover raising and associated work commences. Service location provides critical information about electrical cables, gas mains, water pipes, and telecommunications conduits within or adjacent to pits.

Implementation

1. Contact Dial Before You Dig (1100) minimum 2 business days before work requesting service plans for work location 2. Review service plans identifying predicted locations of electrical, gas, water, telecommunications, and other services 3. Engage qualified service locator using electromagnetic (cable) and ground penetrating radar (GPR) detection equipment to verify actual service locations 4. Mark identified services on ground surface using temporary paint, flags, or stakes with service type and depth indicated 5. Request service authority attendance for isolation or supervision if work occurs within 1 metre of high-risk services (HV electrical, gas) 6. Photograph marked services and service plans for work documentation and future reference 7. Brief all workers on identified services, no-go zones, and service contact emergency procedures during pre-start meeting 8. Maintain service location marks throughout work duration, re-marking if weather or traffic degrades visibility

Administrative Control

Two-person lifting teams with coordinated communication and technique reduce manual handling injury risks for lighter covers (under 40kg) where mechanical lifting is not deployed. Coordination ensures even load distribution and prevents sudden movements that cause strain injuries.

Implementation

1. Assess cover weight before lifting; if weight exceeds 40kg or if awkward lifting position required, use mechanical lifting equipment instead 2. Assign lifting leader who provides verbal commands for all lifting movements (lift, move, lower) 3. Position both workers on same side of pit cover ensuring symmetrical lifting stance with even load distribution 4. Use proper lifting technique: squat position, straight back, core engaged, power from legs not back 5. Lift cover using controlled movement on leader's count (on three: one, two, three, lift) 6. Move cover short distance only (maximum 2 metres) before resting and repositioning grip if required 7. Place cover on level ground or cover stand, never lean against walls or vehicles where it may fall 8. Communicate continuously during lifting; if either worker experiences difficulty, immediately lower cover and reassess method

PPE

Personal protective equipment provides the final layer of defence against pit cover raising hazards including crush injuries, atmospheric exposure, and environmental conditions. PPE must be selected based on specific hazards identified during risk assessment for each pit location.

Implementation

1. Wear steel cap safety boots (AS/NZS 2210.3) with ankle support protecting feet from dropped covers and crush hazards 2. Use heavy-duty work gloves with grip enhancement and impact protection on back of hand for cover handling 3. Don high-visibility vest (Class D, AS/NZS 4602.1) with reflective striping for roadway and footpath work locations 4. Wear safety glasses (AS/NZS 1337) with side shields protecting from debris and splash when working near open pits 5. Use respiratory protection (AS/NZS 1716) if atmospheric testing reveals concentrations near exposure limits or if ventilation is inadequate 6. Don full-body harness with dorsal D-ring connection if confined space entry is required, connected to retrieval system before entry 7. Apply sun protection (sunscreen SPF 50+, broad-brim hat, long sleeves) for outdoor work during high UV periods 8. Wear hearing protection (AS/NZS 1270) if mechanical equipment (saws, breakers, generators) exceeds 85dB during work

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Personal protective equipment

Requirement: AS/NZS 2210.3 compliant with 200-joule impact resistance

When: Required for all pit cover raising operations to protect feet from dropped or rolling covers and crush hazards during lifting and positioning activities

Requirement: Heavy-duty gloves with reinforced palms and impact padding on back of hand

When: Required during all cover handling activities protecting hands from crush injuries, cuts from sharp cover edges, and improving grip on wet or corroded surfaces

Requirement: Class D day/night vest per AS/NZS 4602.1 with 360-degree reflective striping

When: Required for all roadway and footpath work ensuring worker visibility to traffic and public, particularly critical during dawn, dusk, and night operations

Requirement: AS/NZS 1337 medium impact rating with side protection

When: Required when working near open pits to protect eyes from debris displaced by lifting operations, splash from pit contents, and airborne particles from adjacent traffic

Requirement: AS/NZS 1891.1 compliant harness with dorsal D-ring and shock-absorbing lanyard

When: Required when confined space entry below chest level is necessary, harness must be connected to retrieval system (tripod, winch) before entry commences

Requirement: AS/NZS 1716 P2 particulate respirator or SCBA for toxic atmospheres

When: Required if atmospheric testing reveals gas concentrations approaching exposure limits, during forced ventilation of contaminated pits, or if dust generation during pit work

Inspections & checks

Before work starts

✓Inspect pit cover lifting equipment (vacuum lifters, lifting keys, chains, hooks) for damage, wear, corrosion, and current inspection tags
✓Verify gas detection equipment is calibrated, bump-tested, and alarm functions operate correctly before atmospheric testing
✓Review site-specific Traffic Management Plan ensuring all signage, barriers, delineators, and traffic control equipment is available
✓Confirm underground service location has been completed with Dial Before You Dig contacted and service locator reports received
✓Check weather forecast for high winds (over 40km/h), heavy rain, or temperature extremes that may impact safe pit cover work
✓Inspect pit cover and surrounding frame for visible damage, corrosion, unusual venting of gases, or signs of recent disturbance
✓Verify emergency rescue equipment (retrieval system, harnesses, first aid kit, fire extinguisher) is available and inspected if confined space entry planned
✓Confirm all workers have completed confined space entry training, atmospheric testing training, and are medically cleared for confined space work

During work

✓Monitor atmospheric conditions continuously using calibrated gas detection if workers are positioned near or within open pit
✓Observe lifting equipment operation for signs of slippage, loss of suction, or insecure engagement during cover raising and lowering
✓Check exclusion zone barriers remain in position and unauthorised persons have not entered work area throughout operation
✓Monitor traffic flow and vehicle behaviour near work zone; reposition barriers or request additional traffic control if vehicles approach too close
✓Assess worker technique during manual handling; intervene immediately if improper lifting positions or excessive strain observed
✓Verify standby person maintains visual contact with confined space entrant and is not distracted by other tasks during entry operations
✓Observe weather conditions for sudden changes (approaching storms, high winds) requiring work suspension and pit cover reinstallation
✓Monitor communication systems between confined space entrant and standby person ensuring reliable contact is maintained throughout work

After work

✓Confirm pit cover is fully reinstalled, correctly seated in frame, and secure before removing barriers and departing site
✓Remove all tools, equipment, and materials from pit ensuring no items left in underground chamber before cover replacement
✓Complete Confined Space Entry Permit documentation recording atmospheric test results, work conducted, and any incidents or near-misses
✓Clean and store lifting equipment; report any damage or issues observed during use for repair before next deployment
✓Dismantle traffic management in reverse order (removal of signs last) ensuring ongoing traffic and worker safety during pack-up
✓Conduct debrief with crew discussing hazards encountered, control effectiveness, and improvements for future pit cover operations
✓Document work completed including pit location, cover condition, services observed, and recommendations for future work
✓Report any unsafe pit conditions (damaged covers, corroded frames, unidentified services) to asset owner and site supervisor

Step-by-step work procedure

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

Field ready

Site Assessment and Service Location Verification

Conduct comprehensive site assessment identifying pit location, cover type and weight, surrounding hazards (traffic, public access, terrain), and weather conditions. Verify underground service location has been completed with Dial Before You Dig contacted minimum 2 business days prior and service locator reports reviewed. Identify all services within 3 metres of pit including electrical cables, gas mains, water pipes, and telecommunications. Mark service locations on ground using temporary paint or flags. Review site-specific hazards including overhead power lines, underground services, traffic requirements, and confined space entry likelihood. Photograph site conditions and marked services for documentation. Obtain any required permits (road opening, traffic management, confined space entry) before equipment setup begins. Conduct toolbox meeting briefing all workers on site hazards, work sequence, emergency procedures, and individual responsibilities.

Safety considerations

Ensure Dial Before You Dig has been contacted and service plans reviewed before any work commences. Identify overhead and underground services as first priority. Assess weather forecast for conditions that may prevent safe work.

Traffic Management and Exclusion Zone Setup

Implement traffic management controls following approved Traffic Management Plan and AS 1742.3 standards for roadway and footpath work. Position advance warning signs at required distances alerting traffic to upcoming work zone. Deploy physical barriers including fencing, delineators, and cones establishing minimum 2-metre exclusion zone on all sides of pit location. Install high-visibility tape or barriers preventing public access to work area. For roadway work, position traffic control personnel (if required) with communication equipment and clear visibility of approaching traffic. Ensure all barriers are stable and will not be displaced by vehicle wake or wind. Place emergency equipment (first aid kit, fire extinguisher, spill kit) within exclusion zone for immediate access. For night work, position adequate lighting illuminating work area and making barriers visible to approaching traffic. Assign spotter if working in active traffic area to alert crew of approaching vehicles.

Safety considerations

Never commence pit cover work without adequate traffic management and exclusion zones in place. Ensure barriers are highly visible and physically prevent public entry to open pit area. Verify traffic control personnel have clear visibility and communication.

Initial Atmospheric Testing Before Cover Removal

Conduct initial atmospheric testing before removing pit cover to identify life-threatening atmospheres that may be present in confined space beneath. Use calibrated multi-gas detector that has been bump-tested and verified operational. If cover has ventilation holes or gaps, insert detector probe through opening to sample atmosphere before full cover removal. Test for oxygen concentration (must be 19.5% to 23.5%), flammable gases (must be less than 5% LEL), hydrogen sulfide (must be less than 10ppm), carbon monoxide (must be less than 50ppm), and carbon dioxide (should be less than 5,000ppm). Record all test results on Confined Space Entry Permit or work documentation. If unsafe atmosphere detected, do not remove cover; implement forced ventilation and retest. If atmosphere is safe, proceed with cover removal but maintain gas detector available for immediate retesting after cover is opened. Position gas detector where alarms are audible to all workers during subsequent operations.

Safety considerations

Never open pit cover without conducting atmospheric testing first. Use calibrated equipment only. If unsafe atmosphere detected, ventilate pit using forced air ventilation and retest before proceeding. Maintain gas detection available throughout operation.

Pit Cover Lifting and Removal

Select appropriate lifting method based on cover weight, type, and available equipment. For covers exceeding 40kg or requiring awkward lifting positions, deploy mechanical lifting equipment (vacuum lifter, pit key, magnetic lifter, or portable gantry with hoist). Position lifting equipment directly over cover centre of gravity ensuring stable footing for equipment and operators. For vacuum lifters, clean cover surface of debris and moisture, position suction pad, and activate vacuum confirming gauge indicates adequate suction before lifting. For lifting keys, engage key fully into recessed handle ensuring secure engagement before applying lifting force. Establish exclusion zone preventing worker presence beneath or adjacent to raised cover during lifting. Lift cover slowly and smoothly watching for equipment slippage or unexpected movement. Once cover is clear of frame, move horizontally away from pit opening and lower to ground on stable surface. Never lean cover against walls, vehicles, or structures where it may fall. If manual handling is used (covers under 30kg only), use two-person team with coordinated lifting commands, proper lifting technique (squat position, straight back), and short carry distance (maximum 2 metres) to cover stand.

Safety considerations

Use mechanical lifting equipment for covers over 40kg or awkward lifting positions. Maintain exclusion zone beneath raised covers. Ensure secure engagement of lifting equipment before raising load. Two-person coordination essential for manual lifts with clear communication.

Post-Opening Atmospheric Testing and Pit Inspection

Immediately after removing pit cover, conduct comprehensive atmospheric testing from multiple depths within pit chamber. Lower gas detector probe to top, middle, and bottom levels within pit sampling atmosphere at each depth and recording results. Atmospheres can stratify with heavier toxic gases accumulating at bottom and oxygen deficiency at top levels. Test results must confirm safe atmosphere (oxygen 19.5-23.5%, flammable gases less than 5% LEL, toxic gases below exposure limits per AS 2865) at all depths before any worker approaches pit opening. Visually inspect pit interior from safe position identifying standing water, debris, damaged services, structural deterioration, or unexpected hazards. Use flashlight or mirror to inspect areas not visible from surface. Look for indications of gas generation (bubbling water, unusual odours), active water flow, or recent disturbance. If confined space entry will be required, complete Confined Space Entry Permit, establish rescue equipment, assign standby person, and brief on emergency procedures before entry. If work can be completed without entry (external access to services), position workers to minimise leaning over pit opening and maintain secure footing.

Safety considerations

Retest atmosphere immediately after opening pit as conditions may change when fresh air mixes with pit atmosphere. Test at multiple depths as gases stratify. Complete confined space entry procedures if workers will enter below chest level. Assign standby person who maintains visual contact with entrant.

Work Execution Within or Adjacent to Pit

Execute planned work using safe work practices appropriate for pit work environment and identified hazards. If confined space entry is required, entrant dons full-body harness connected to retrieval system (tripod and winch) positioned over pit opening before entry. Standby person maintains continuous visual contact with entrant and monitoring of gas detection equipment. Establish communication system (radio or hand signals) between entrant and standby. Lower required tools and equipment into pit using tool bags or rope; never throw tools into pit. Conduct work efficiently minimising time within confined space. If atmospheric monitoring indicates changing conditions (decreasing oxygen, increasing toxic gases), immediately evacuate pit and reassess ventilation requirements. For work adjacent to pit without entry, workers maintain secure footing, use appropriate tools for reaching into pit without overextending, and wear fall protection if working near edge of large pits. Protect services identified during pre-work location; use service plans and marked locations to avoid contact. Implement additional atmospheric testing every 30 minutes or if work activities change (disturbance of sediments, cutting operations, welding).

Safety considerations

Confined space entrant must wear harness connected to retrieval system before entry. Standby person maintains visual contact and does not enter pit if emergency occurs without rescue team. Continuous atmospheric monitoring required during entry. Evacuate immediately if atmosphere deteriorates.

Pit Cover Reinstallation and Securing

After completing work within or adjacent to pit, remove all tools, equipment, and materials from pit chamber ensuring nothing is left inside before cover replacement. Inspect pit frame and cover seating surface removing debris, sediment, or materials that would prevent proper cover seating. For heavy covers requiring mechanical lifting, position lifting equipment over cover on ground, engage lifting mechanism (vacuum, lifting key, chain), and verify secure engagement. Lift cover vertically, move horizontally to position directly over pit frame, and lower slowly ensuring alignment with frame before final seating. Guide cover into position using hands on sides (never underneath cover) watching fingers to prevent crush injuries between cover and frame. For circular covers, rotate to align with locking features or to position manufacturer markings correctly. Verify cover is fully seated with no gaps between cover and frame that could cause tripping hazards or allow objects to fall into pit. For locking covers, engage locking mechanisms per manufacturer requirements. Test cover stability by applying moderate force confirming it will not lift or shift under foot traffic or vehicle loads. Remove lifting equipment and conduct final visual inspection confirming secure installation before permitting traffic or public access over cover.

Safety considerations

Remove all tools and equipment from pit before cover reinstallation. Guide cover into position using hands on sides only, never place hands beneath cover. Verify cover is fully seated and stable before removing barriers and permitting traffic over pit. Test locking mechanisms engage correctly.

Site Restoration and Post-Work Inspection

Dismantle traffic management controls and exclusion zones in reverse sequence from installation ensuring ongoing safety of workers and traffic during removal. Remove barriers and delineators last after all equipment has been removed from work zone. Inspect site for tools, materials, or debris left behind; remove all items to vehicles for transport. Verify pit cover remains securely seated after equipment removal and barrier dismantling. Clean work area of any spilled materials, debris, or markings that are not required to remain. Photograph final site condition documenting completed work and pit cover reinstallation. Complete all required documentation including Confined Space Entry Permits, atmospheric test records, work completion reports, and incident/near-miss reports if applicable. Conduct crew debrief discussing work execution, control effectiveness, hazards encountered, and recommendations for future operations. Report any site hazards identified during work including damaged pit covers, corroded frames, unidentified underground services, or structural concerns to asset owner and site supervisor. Clean and store all equipment checking for damage and reporting any equipment issues observed during operations. File documentation per company and regulatory requirements for confined space work records retention.

Safety considerations

Remove traffic management in reverse order maintaining worker safety during dismantling. Verify pit cover is secure and stable in final inspection. Document any hazards or concerns observed during work for future reference and asset owner notification.

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Frequently asked questions

What atmospheric testing is required before raising pit covers and when must testing be conducted?

Atmospheric testing must be conducted before removing any pit cover where confined space hazards may exist. Testing must measure oxygen concentration (must be 19.5% to 23.5%), flammable gases (must be less than 5% LEL), hydrogen sulfide (less than 10ppm), carbon monoxide (less than 50ppm), and carbon dioxide per AS 2865 requirements. Initial testing should be conducted through cover ventilation holes or gaps before full cover removal if possible. Comprehensive testing at multiple depths (top, middle, bottom) within the pit must be performed immediately after cover removal as atmospheres can change when fresh air mixes. Continuous monitoring is required if workers will enter the pit or work adjacent to the opening. Testing must be conducted using calibrated multi-gas detection equipment that has been bump-tested before use. Retesting is required every 30 minutes during extended work operations or if work activities change (disturbance of sediments, cutting, welding). If unsafe atmospheres are detected, forced ventilation must be implemented and atmosphere retested before work proceeds. All test results must be documented on Confined Space Entry Permits or work records.

When must mechanical lifting equipment be used instead of manual handling for pit covers?

Mechanical lifting equipment must be used for all pit covers exceeding 40kg, where awkward lifting positions are required (such as ground-level lifting without good hand-holds), or where repetitive lifting during the workday creates cumulative strain risks. Australian WHS regulations and manual handling codes of practice specify that mechanical aids must be provided when loads exceed safe manual handling limits or where risk of injury exists despite proper technique. Vacuum lifters are preferred for smooth concrete or metal covers as they provide controlled lifting without workers needing to bend or grip awkward edges. Pit cover lifting keys or magnetic lifters are used for covers with recessed handles or ferrous metal construction. Portable gantries with chain hoists or electric winches provide lifting capacity for very heavy covers (over 100kg) or where other equipment is unsuitable. All mechanical lifting equipment must be rated for the cover weight plus a safety margin (typically 50% over cover weight) and must be inspected before use. Even for lighter covers (under 40kg), mechanical lifting is recommended where ergonomic assessment indicates manual handling risk remains unacceptable.

What are the confined space entry requirements when working in or around open pits?

Confined space entry requirements apply when work involves a worker entering into a pit below chest level or when the worker's head enters the pit opening. A Confined Space Entry Permit must be completed identifying hazards, atmospheric test results, controls, and rescue arrangements before entry. The permit must be authorised by a competent person who verifies all controls are in place. A trained standby person must be assigned who maintains continuous visual contact with the entrant and does not perform other tasks during entry. The standby person must not enter the pit to perform rescue without additional rescue team support. Rescue equipment including tripod, winch, and retrieval harness must be set up before entry with the entrant connected to the retrieval system via full-body harness. Atmospheric monitoring must be continuous during entry operations with immediate evacuation if conditions deteriorate. Communication systems (radio or hand signals) must be established between entrant and standby person. Emergency procedures must be briefed including rescue plan, emergency services notification, and first aid arrangements. Workers must hold confined space entry training certification and medical clearance for confined space work. The permit remains valid only while work conditions remain unchanged; any variation requires permit reassessment and reauthorisation.

How should traffic management be implemented for pit cover work on roadways and footpaths?

Traffic management for roadway and footpath pit cover work must follow AS 1742.3 standards and site-specific Traffic Management Plans authorised by road authorities. Advance warning signs must be positioned at prescribed distances upstream of work location alerting traffic to the upcoming work zone and any required speed reductions. Physical barriers including fencing, delineators, and cones must establish a minimum 2-metre exclusion zone on all sides of the pit location preventing vehicle encroachment into the work area. For roadway work, traffic control personnel may be required to manage traffic flow depending on road classification, traffic volume, and work duration. High-visibility vests (Class D day/night) must be worn by all workers in traffic areas. For night work, adequate lighting must illuminate the work area and make barriers clearly visible to approaching traffic using reflective materials and active lighting (flashing lights, illuminated signs). Open pits must never be left unattended without temporary covers or barriers preventing accidental vehicle or pedestrian entry. If work extends over multiple days, pit covers must be reinstalled at end of each workday or heavy-duty temporary covers with load rating adequate for traffic must be installed. A spotter should be assigned to monitor approaching traffic and alert workers when vehicles approach within 10 metres of the work zone, particularly in higher-speed environments.

What should workers do if atmospheric testing reveals unsafe atmospheres beneath a pit cover?

If atmospheric testing reveals unsafe atmospheres (oxygen below 19.5% or above 23.5%, flammable gases at or above 5% LEL, toxic gases exceeding exposure limits), work must not proceed and the pit cover must remain in place or be immediately reinstalled if already removed. Forced ventilation must be implemented using blowers or fans positioned to introduce fresh air into the pit chamber and displace contaminated atmosphere. Ventilation equipment must provide adequate air exchange rates (typically 6 to 10 air changes per minute) and must operate for sufficient duration (minimum 15 minutes, often longer for deep pits). After ventilation, atmospheric testing must be repeated at multiple depths to verify safe atmosphere throughout the pit chamber. If ventilation does not achieve safe atmosphere, the pit must be classified as requiring specialist confined space entry procedures with supplied air respiratory protection (SCBA or airline respirators), continuous monitoring, and enhanced rescue arrangements. Do not attempt to proceed with work using respiratory protection alone without proper confined space entry controls. The presence of toxic atmospheres (particularly hydrogen sulfide or high methane) may indicate ongoing contamination sources requiring investigation before work proceeds. Emergency services (000) must be contacted if workers show symptoms of gas exposure (dizziness, nausea, difficulty breathing, loss of consciousness) before, during, or after atmospheric testing. Report unsafe atmospheres to pit owner and site supervisor as the condition may require specialist remediation before future access.