Comprehensive SWMS for Portable Generator Operation and Temporary Power Supply

Generator Portable Safe Work Method Statement

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Portable generator operation provides essential temporary electrical power for construction sites, remote work locations, and emergency situations where permanent electrical infrastructure is unavailable. These fuel-powered machines convert mechanical energy into electrical power, supplying tools, lighting, and equipment throughout construction projects. This SWMS addresses the critical safety requirements for portable generator setup, operation, refuelling, and maintenance including carbon monoxide hazards, electrical safety, fire prevention, noise control, and fuel handling procedures in compliance with Australian WHS legislation.

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Overview

What this SWMS covers

Portable generators are internal combustion engines that convert fuel energy into electrical power, providing temporary electricity supply for construction sites, remote locations, events, and emergency backup power situations. These machines typically operate on petrol, diesel, or LPG fuel, with power outputs ranging from small 1-2 kVA units for light tools and lighting to large 20+ kVA industrial generators capable of powering entire site facilities. The fundamental operation involves a fuel-powered engine driving an alternator that produces alternating current (AC) electrical output through standard power outlets and distribution boards. Portable generators come in various configurations suited to different applications. Small recreational generators provide basic 240V AC power through standard 10-amp outlets for hand tools and lighting, typically producing 1-3 kVA and weighing 20-50kg for manual handling. Medium construction generators in the 5-10 kVA range include wheel-mounted frames for site mobility, multiple outlet configurations including 15-amp outlets, and may incorporate electrical protection devices. Large site generators exceeding 10 kVA capacity often feature trailer mounting for vehicle towing, weatherproof enclosures for outdoor operation, fuel tanks providing extended run times, and advanced electrical protection including earth leakage and overload protection. Key components of portable generator systems include the internal combustion engine with fuel tank and exhaust system, alternator producing electrical output, voltage regulator maintaining stable output voltage, circuit breakers and overload protection devices, control panel with engine start/stop controls and electrical outlets, cooling system using air or liquid cooling, and in larger units, electric start systems with battery backup. Modern generators incorporate safety features including low oil shutdown protection preventing engine damage, overload protection automatically disconnecting loads exceeding generator capacity, and in enclosed models, temperature monitoring preventing overheating. Portable generator applications span all construction phases from initial site establishment through final fit-out. Common uses include powering hand tools and power equipment where permanent electrical supply is unavailable, providing temporary lighting for work areas and site access routes, operating pumps for dewatering excavations or concrete placement, powering site facilities including amenities and office containers, supplying welding equipment and other high-power tools, and providing emergency backup power during electrical outages. The versatility and independence from grid power make generators essential construction equipment, but their operation introduces significant hazards requiring comprehensive safety management under Australian WHS regulations.

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Why this SWMS matters

Portable generator safety is critical in Australian construction, where improper operation contributes to fatalities, serious injuries, and property damage annually. Carbon monoxide poisoning from generators operated in enclosed or poorly ventilated spaces has caused multiple deaths across Australia, with victims often unaware of the colourless, odourless gas accumulating to lethal concentrations. Safe Work Australia incident data documents numerous electrocutions from faulty generator connections, contact with damaged cables, and operation in wet conditions. Fire incidents from fuel spills during refuelling, overheating due to inadequate ventilation, and electrical faults causing ignition of surrounding materials result in significant property damage and injury. Under the Work Health and Safety Act 2011 and associated regulations, persons conducting a business or undertaking have primary duties to ensure workplace health and safety including provision of safe plant and equipment. For portable generators, this encompasses requirements for competent operator training, documented pre-start inspection and maintenance procedures, implementation of controls for carbon monoxide hazards in enclosed spaces, electrical safety measures including residual current devices (RCDs) and earth leakage protection, and safe fuel handling and storage protocols. Failure to implement adequate generator safety controls can result in prohibition notices immediately halting work, significant financial penalties, and prosecution following serious incidents or fatalities. The specific hazards controlled through proper portable generator SWMS include carbon monoxide accumulation in enclosed or poorly ventilated areas causing poisoning and death, electric shock and electrocution from contact with live electrical components or faulty connections, fire and explosion from fuel spills, overheated engines, or electrical faults, noise-induced hearing loss from prolonged exposure to generator operation without adequate hearing protection, burns from contact with hot exhaust systems and engine components, and manual handling injuries during generator transport and positioning. Each of these failure modes can result in serious injury or death, making rigorous safety procedures essential for all generator operations. Additionally, generator operation must comply with Australian Standards including AS/NZS 3000 for electrical installations, AS/NZS 3760 for testing and tagging of electrical equipment, and AS 2790 for portable, mobile and transportable structures. Environmental considerations include preventing fuel and oil spills that contaminate soil and waterways, managing noise emissions to comply with local regulations and protect worker hearing, and ensuring adequate exhaust dispersion to prevent carbon monoxide accumulation. The combination of fuel hazards, electrical risks, and carbon monoxide dangers makes portable generator operation one of the highest-risk routine activities on construction sites, requiring comprehensive risk assessment, documented safe operating procedures, competent trained operators, and rigorous adherence to safety protocols to prevent serious incidents and protect worker health and safety.

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Hazard identification

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

Risk register

Carbon Monoxide Poisoning from Exhaust Emissions

High

Portable generators produce carbon monoxide (CO) as a byproduct of fuel combustion, creating a lethal poisoning hazard when operated in enclosed or poorly ventilated spaces. Carbon monoxide is colourless, odourless, and tasteless, making it impossible to detect without monitoring equipment. CO binds to haemoglobin in blood more effectively than oxygen, reducing oxygen delivery to vital organs and causing symptoms progressing from headache and dizziness to unconsciousness and death. Concentration as low as 400 ppm can cause death within 2-3 hours, whilst concentrations exceeding 1600 ppm cause death within 1-2 hours. Generators operated indoors, in partially enclosed areas, in excavations or trenches, or near building air intakes can cause rapid CO accumulation to lethal levels. Cold weather increases risk as workers may operate generators in enclosed spaces seeking warmth. Even outdoor operation requires adequate clearance from buildings and work areas as exhaust can enter through doorways and ventilation openings. Multiple Australian fatalities have occurred when generators were operated in garages, sheds, partially enclosed work areas, and near building openings, often with fatal consequences occurring within 30-60 minutes of generator startup.

Consequence: Death from carbon monoxide poisoning, permanent brain damage and organ failure in survivors of severe CO exposure, unconsciousness leading to secondary injuries from falls, and poisoning of multiple workers simultaneously in enclosed spaces.

Electric Shock and Electrocution from Electrical Faults

High

Portable generators produce dangerous electrical voltage and current, creating electrocution hazards from multiple failure modes. Direct contact with energised components occurs when outlet covers are damaged, internal wiring is exposed, or workers attempt repairs whilst generator is operating. Use of damaged extension leads, power boards, or tools connected to generators results in current flowing through operators' bodies to earth. Operating generators in wet conditions or rain without weatherproof enclosures creates high-risk scenarios as moisture provides conductive paths for electricity. Backfeed through incorrect connections can energise building electrical systems unexpectedly. Generators without residual current device (RCD) protection provide no safeguard against earth leakage currents that would normally trip safety devices in building installations. Overloading generators beyond rated capacity can cause overheating of internal wiring and insulation breakdown. Amateur installation of generator-to-building connections by unqualified persons frequently creates dangerous conditions. Working on energised generator connections without proper isolation and lockout procedures leads to contact with live conductors.

Consequence: Electrocution causing cardiac arrest and death, severe electrical burns requiring extensive medical treatment and leaving permanent scarring, muscle contractions causing falls from height or into machinery, and long-term neurological damage affecting motor control and sensation.

Fire and Explosion from Fuel Handling and Spills

High

Portable generators require regular refuelling with highly flammable petrol, diesel, or LPG, creating significant fire and explosion hazards. Refuelling while generator is running or immediately after shutdown when engine and exhaust are extremely hot can ignite fuel vapours, causing flash fires and severe burn injuries. Fuel spills during filling, particularly when using makeshift funnels or overfilling tanks, create pools of flammable liquid and explosive vapour clouds. Petrol vapour is heavier than air and flows into low-lying areas, igniting from sources far from the spill point. Damaged fuel tanks and fuel lines leak continuously, creating persistent ignition hazards. Fuel storage near generators, particularly in direct sunlight or hot environments, increases fire risk and vapour pressure. Using incorrect fuel types or contaminated fuel causes engine malfunction and potential fire. Generators operated near flammable materials including timber, cardboard, chemical stores, and fuel supplies create ignition sources for surrounding combustibles. Static electricity during fuel transfer can ignite vapours, particularly when refuelling from plastic containers without proper earthing.

Consequence: Severe burn injuries from flash fires and explosions, death from being engulfed in fire, destruction of generator and surrounding equipment and materials, and major construction site fires requiring emergency response and causing project shutdown.

Noise-Induced Hearing Damage from Engine Operation

Medium

Portable generators produce high noise levels during operation, typically 65-95 decibels depending on unit size and load, with many construction generators exceeding the 85 dB threshold requiring hearing protection under Australian WHS regulations. Prolonged exposure to generator noise without adequate hearing protection causes permanent noise-induced hearing loss that is irreversible. Small generators at close range can produce 90-95 dB, equivalent to operating a chainsaw or jackhammer. Large site generators may reach 100 dB or higher at 1 metre distance. Operators working in close proximity during setup, refuelling, and monitoring experience highest exposure. Noise reflects and amplifies in enclosed or confined work areas. Multiple generators operating simultaneously create cumulative noise hazards. Workers may become acclimatised to noise, underestimating exposure risk. Communication difficulties in high-noise environments lead to safety risks when verbal warnings cannot be heard. Tinnitus, ringing or buzzing in ears, often accompanies hearing loss. Once hearing damage occurs, it cannot be reversed, affecting quality of life and employment prospects in noise-exposed industries.

Consequence: Permanent noise-induced hearing loss affecting communication and quality of life, tinnitus causing persistent ringing or buzzing in ears, reduced ability to hear warning signals and verbal communication on construction sites, and long-term disability affecting employment opportunities.

Thermal Burns from Hot Engine and Exhaust Components

Medium

Operating generators produce extreme heat in engine components, exhaust systems, and cooling systems, with surface temperatures exceeding 200°C on exhaust manifolds and mufflers. Accidental contact causes immediate severe burns requiring medical treatment. Refuelling immediately after shutdown when components remain dangerously hot is particularly hazardous as spilled fuel can ignite on hot surfaces. Workers reaching over hot generators to access controls or adjust loads risk burns to hands, arms, and torso. Inadequate clearance between generators and combustible materials can cause ignition. Generators positioned where workers can accidentally contact them whilst focused on other tasks create ongoing burn hazards. Children or untrained persons attracted to operating generators may touch hot components. Coolant system failures can cause boiling water or coolant to spray from radiator caps, causing scalding. Lack of guarding on exhaust systems allows direct contact with the hottest components. Burns to hands impair ability to perform work and operate equipment safely, potentially leading to secondary incidents.

Consequence: Second and third-degree burns requiring hospital treatment and skin grafts, permanent scarring and disfigurement, infection of burn wounds causing serious complications, and lost work time during lengthy recovery periods.

Manual Handling Injuries During Generator Transport and Positioning

Medium

Portable generators range from 20kg for small recreational units to 150kg or more for large construction generators, requiring careful manual handling during transport, positioning, and relocation. Awkward lifting techniques, particularly when manoeuvring generators onto trailers or into position, strain backs, shoulders, and knees. Two-person lifts require coordination and matched lifting capacity between workers. Generators have unbalanced weight distribution with heavy alternator and engine components making them difficult to control during lifting. Smooth plastic or metal fuel tanks provide poor grip points. Attempting to lift generators that exceed individual or team capacity causes acute injuries. Pushing or pulling wheeled generators over rough ground, up ramps, or across excavations creates slip and trip hazards. Rolling generators can crush feet if control is lost. Repetitive generator repositioning during extended projects causes cumulative strain injuries. Inadequate mechanical aids such as trolleys or forklift attachments lead to manual lifting beyond safe limits.

Consequence: Acute back injuries including muscle strains and disc herniation, shoulder and knee injuries from awkward lifting, crushed hands and feet from dropped generators or uncontrolled rolling, and chronic musculoskeletal disorders from repetitive heavy manual handling.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Outdoor Generator Placement with Adequate Clearance and Ventilation

Elimination

The most effective control for carbon monoxide poisoning is eliminating the hazard by positioning generators exclusively in outdoor locations with unrestricted airflow and maintaining substantial clearance from all buildings, work areas, and air intake points. This control physically separates exhaust emissions from occupied spaces, preventing carbon monoxide accumulation regardless of other factors. Generators must be positioned at least 6 metres from building openings including doors, windows, ventilation intakes, and occupied work areas. Exhaust must be directed away from buildings and work locations, utilising prevailing wind direction to disperse emissions. Operations in excavations, trenches, or partially enclosed areas must be prohibited as these configurations trap exhaust gases. This elimination-level control removes reliance on worker behaviour or engineering devices, providing inherent safety through physical separation of hazard from workers.

Implementation

1. Establish generator exclusion zones preventing placement within 6 metres of any building opening, occupied workspace, or ventilation intake that could draw exhaust into enclosed areas. 2. Survey site to identify prevailing wind directions and position generators upwind of work areas to ensure natural exhaust dispersion away from occupied locations. 3. Prohibit generator operation in excavations, trenches, sheds, partially enclosed areas, or any location without unrestricted overhead airflow to all four sides. 4. Install highly visible signage around generator placement areas warning of carbon monoxide hazard and prohibiting entry whilst generator is operating. 5. Create site-specific generator placement plans showing approved locations, exclusion zones, and exhaust dispersion directions before mobilising generators to site. 6. Brief all workers on carbon monoxide risks and symptoms, emphasising that even outdoor operation can cause poisoning if clearances are inadequate. 7. Implement daily checks confirming generators have not been repositioned closer to buildings or work areas overnight or by other trades without authorisation.

Mandatory RCD Protection and Electrical Testing for All Generator Circuits

Engineering

Installing residual current devices (RCDs) rated at 30mA or less on all generator electrical circuits provides critical protection against electrocution by automatically disconnecting power within milliseconds when earth leakage current is detected. RCDs detect imbalance between active and neutral conductors indicating current flow to earth through an alternative path such as human body, and immediately trip to prevent fatal electric shock. This engineering control protects against faults that would not be detected by generator circuit breakers including damaged cable insulation, moisture ingress into electrical equipment, and contact with live conductors. Regular testing of RCD operation ensures devices remain functional throughout generator service life. Combining RCDs with comprehensive electrical testing and tagging of all connected equipment creates robust electrical safety systems.

Implementation

1. Fit all portable generators with permanently installed RCD protection rated at 30mA maximum trip current, or use portable RCD units plugged between generator outlets and extension leads. 2. Test RCD operation daily before commencing generator use by pressing test button and verifying immediate disconnection, documenting tests in generator logbook. 3. Implement mandatory testing and tagging program for all electrical equipment used with generators per AS/NZS 3760, with 3-monthly testing intervals for construction sites. 4. Inspect all extension leads, power boards, and connected tools before use for damage to insulation, exposed conductors, or moisture contamination, removing damaged items from service. 5. Use only heavy-duty electrical leads rated for outdoor industrial use with robust insulation and weatherproof connectors, prohibiting use of domestic-grade leads and power boards. 6. Maintain dry connections by elevating plugs and sockets above ground level using stands or supports, protecting connections with weatherproof covers during rain. 7. Establish isolation and lockout procedures for all maintenance work on generators or connected electrical systems, preventing inadvertent energisation whilst personnel are working on circuits.

Strict Shutdown, Cooling, and Spill Prevention Refuelling Procedures

Administrative

Implementing comprehensive refuelling procedures that mandate generator shutdown, adequate cooling time, use of appropriate fuel transfer equipment, and spill containment measures prevents fire and explosion incidents during fuel handling operations. These administrative controls establish systematic steps eliminating common refuelling errors including adding fuel to hot or running generators, overfilling tanks, and creating fuel spills that ignite on hot surfaces. Procedures must account for different fuel types and storage configurations, specify required equipment including funnels and spill containment, and clearly define responsibilities for refuelling operations. Documentation of refuelling creates accountability and allows supervisors to verify procedures are being followed consistently.

Implementation

1. Establish mandatory refuelling procedure requiring complete generator shutdown and minimum 10-minute cooling period before fuel cap is removed, allowing engine and exhaust to cool below ignition temperature. 2. Prohibit smoking, open flames, and spark-producing activities within 6 metres of refuelling operations, with clearly visible signage warning of flammable fuel hazard. 3. Require use of appropriate funnels and fuel transfer equipment preventing spills, with spill containment materials including absorbent pads and fire extinguisher immediately available during all refuelling. 4. Implement fuel level monitoring to schedule refuelling during planned breaks rather than emergency refuelling under time pressure when safety shortcuts are more likely. 5. Designate refuelling areas on level ground away from ignition sources, with spill containment provisions including impermeable surfaces or drip trays catching any spilled fuel. 6. Use only approved fuel containers with proper labelling, spouts, and flame arresters, prohibiting makeshift containers or fuel storage in damaged receptacles. 7. Document each refuelling operation in generator logbook including fuel quantity, time, operator name, and confirmation cooling period was observed, creating accountability for procedure compliance.

Hearing Protection and Generator Noise Management Program

Administrative

Protecting workers from noise-induced hearing loss requires comprehensive noise management including identification of high-noise areas around operating generators, provision of appropriate hearing protection, enforcement of hearing protection use, and selection of quieter generator models where practicable. Administrative controls establish noise exposure limits, define hearing protection requirements, and create systems ensuring consistent protection for all workers exposed to generator noise. Noise monitoring identifies specific exposure levels allowing appropriate selection of hearing protection class. Regular audiometric testing detects early signs of hearing damage allowing intervention before permanent loss occurs. Signage and training ensure workers understand noise hazards and hearing protection requirements.

Implementation

1. Conduct noise monitoring using calibrated sound level meters to measure actual noise levels at various distances from operating generators under different load conditions. 2. Establish hearing protection zones extending to distance where noise reduces below 85 dB, typically 7-10 metres from larger generators, marking zones with clear signage. 3. Provide Class 4 or 5 hearing protection (earplugs or earmuffs per AS/NZS 1270) to all workers, with selection allowing workers to choose style they find most comfortable to encourage consistent use. 4. Implement mandatory hearing protection use for anyone entering marked noise zones or working within 5 metres of operating generators regardless of exposure duration. 5. Include hearing conservation training in site induction explaining noise hazards, hearing protection requirements, proper fitting of earplugs and earmuffs, and symptoms of hearing damage. 6. Consider generator selection criteria favouring quieter models with noise suppression features including insulated enclosures and enhanced muffling systems where this reduces exposure. 7. Arrange generator placement to maximise distance from primary work areas and utilise acoustic barriers or enclosures where extended operation near occupied areas is unavoidable.

Thermal Hazard Guarding and Burn Prevention Measures

Engineering

Installing physical guards and barriers around hot engine components, exhaust systems, and cooling system pressure caps prevents accidental contact with surfaces hot enough to cause severe burns. Engineering controls include mesh guards around exhaust manifolds and mufflers, insulation on exposed pipes, protective covers over engine components, and warning labels identifying hot surfaces. These physical barriers remain effective regardless of worker behaviour or attention, providing constant protection throughout generator operation and cool-down periods. Guards must allow adequate airflow for cooling whilst preventing accidental contact from any angle of approach to the generator.

Implementation

1. Fit guards and heat shields around all exhaust components including manifolds, exhaust pipes, and mufflers, using mesh or perforated guards allowing heat dissipation whilst preventing direct contact. 2. Install insulation wrapping on exposed exhaust pipes where guards cannot be fitted, reducing surface temperatures to levels that minimise burn severity from brief contact. 3. Fit protective covers or guards around engine components including cylinder heads, cooling systems, and turbochargers on larger units, preventing access to hot surfaces. 4. Apply highly visible warning labels on generator covers and near hot components warning of burn hazard and showing maximum surface temperatures. 5. Paint hot components in bright colours distinct from surrounding equipment to provide visual warning of hazardous areas, making hot surfaces readily identifiable. 6. Position generators with exhaust systems facing away from normal approach paths and work areas, reducing likelihood of contact during routine generator access. 7. Establish cool-down period requirements posted on generators specifying minimum time after shutdown before maintenance or refuelling, typically 15-20 minutes depending on unit size and operating duration.

Mechanical Handling Aids and Team Lifting Procedures

Engineering

Providing mechanical handling aids including trolleys, forklift attachments, and lifting frames eliminates manual lifting of heavy generators, preventing back injuries and crush incidents. Where mechanical aids are impractical, implementing structured team lifting procedures with clear communication, coordinated movement, and appropriate numbers of workers matched to load weight distributes forces and reduces individual strain. This control recognises that generators frequently exceed safe manual handling limits for individuals, requiring engineered solutions or carefully controlled manual handling to prevent injury.

Implementation

1. Provide wheeled trolleys or carts sized for generators used on project, with brakes to secure units during transport over slopes or uneven ground. 2. Equip forklifts and telehandlers with generator lifting attachments or use pallet-mounted generators allowing mechanical handling for positioning and relocation. 3. Establish generator weight classifications and specify handling method for each class: under 25kg single person, 25-50kg two-person team lift, over 50kg mechanical handling mandatory. 4. Train workers in team lifting techniques including assessment of load weight, selection of adequate team size, coordinated lift commands, and safe lowering procedures. 5. Require verbal communication protocol for team lifts with designated leader calling preparation, lift, movement, and lowering commands ensuring synchronized action. 6. Use mechanical ramps or vehicle tailgate loaders for loading generators onto trailers or vehicles, eliminating lifting to height. 7. Position generators on sturdy platforms or pallets at working height where they will remain stationary for extended periods, reducing manual handling required for daily access to controls and refuelling.

Download complete control procedures

Personal protective equipment

Hearing Protection

Requirement: Class 4 or 5 earplugs or earmuffs per AS/NZS 1270

When: Mandatory when working within 10 metres of operating generators or in areas where noise exceeds 85 decibels. Must be properly fitted and worn for entire duration of noise exposure.

Safety Glasses with Side Shields

Requirement: Impact-rated to AS/NZS 1337 with side protection

When: Required during generator setup, refuelling, maintenance, and troubleshooting to protect against fuel splash, debris, and particulates from engine operation.

Electrical Safety Gloves

Requirement: Insulating gloves rated for voltage being worked on per AS/NZS 2225

When: Required for any work on energised electrical connections or circuits, or when connecting/disconnecting loads to operating generators. Must be tested and certified.

Steel Toe Cap Safety Boots

Requirement: Certified to AS/NZS 2210.3 with steel toe caps and slip-resistant soles

When: Mandatory at all times when working with or around generators to protect feet from crushing injuries if generators are dropped or rolled, and from electrical hazards.

High-Visibility Clothing

Requirement: Class D Day/Night compliant with AS/NZS 4602.1

When: Required on all construction sites to ensure operators are visible to mobile plant operators and other workers, particularly important when generators are positioned near vehicle routes.

Chemical-Resistant Gloves

Requirement: Suitable for fuel handling per AS/NZS 2161.10

When: Required during all refuelling operations to protect hands from fuel contact and provide grip on fuel containers. Must allow adequate dexterity for safe fuel transfer.

Heat-Resistant Gloves

Requirement: Rated for temperatures up to 200°C per AS 2161.2

When: Required when working on or near hot generator components during troubleshooting or emergency shutdown procedures where contact with hot surfaces is unavoidable.

Inspections & checks

Before work starts

  • ✓Verify adequate fuel level for planned operation duration and inspect fuel tank for leaks, damage, or deterioration
  • ✓Check engine oil level using dipstick and inspect for oil leaks from engine, oil filter, or drain plug
  • ✓Inspect air filter for blockage or contamination and clean or replace if required for proper engine operation
  • ✓Test generator operation by starting engine and verifying normal startup, stable running, and proper shutdown
  • ✓Verify RCD protection devices are installed and test operation by pressing test button to confirm proper function
  • ✓Inspect all electrical outlets and connections for damage, moisture, or exposed conductors
  • ✓Check exhaust system for leaks, damage, or disconnection that could direct exhaust into work areas
  • ✓Verify generator placement maintains minimum 6 metre clearance from buildings, work areas, and ventilation intakes

During work

  • ✓Monitor generator running condition including engine sound, vibration, and exhaust smoke colour indicating normal operation
  • ✓Check for fuel leaks, oil leaks, or coolant leaks developing during operation requiring immediate shutdown
  • ✓Verify electrical load remains within generator rated capacity and circuit breakers have not tripped indicating overload
  • ✓Monitor generator exhaust dispersion ensuring prevailing wind has not changed to direct exhaust toward occupied areas
  • ✓Listen for abnormal engine sounds including knocking, excessive vibration, or labouring indicating developing problems
  • ✓Verify generator has not been repositioned or moved closer to buildings or work areas creating carbon monoxide hazard
  • ✓Check operating temperature remains normal with adequate cooling airflow and no signs of overheating

After work

  • ✓Shut down generator following proper shutdown procedure and allow adequate cooling period before refuelling
  • ✓Inspect generator for any damage, leaks, or defects that developed during operation period
  • ✓Check fuel level and refuel if required for next shift following proper refuelling procedures
  • ✓Verify all connected electrical equipment has been disconnected before shutdown to prevent startup surge damage
  • ✓Document generator running hours, fuel consumed, and any issues encountered in equipment logbook
  • ✓Clean any fuel spills or oil leaks before leaving generator to prevent contamination and slip hazards
  • ✓Secure generator against unauthorised use and theft using locks or by removing fuel/battery where appropriate

Step-by-step work procedure

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

Field ready
1

Select Appropriate Generator Location with Adequate Clearances

Before mobilising generator to site, survey work area to identify appropriate placement location meeting all safety clearance requirements. Select outdoor location on level, stable ground that will support generator weight without sinking or becoming unstable during extended operation. Verify minimum 6 metre clearance in all directions from buildings, work areas, site amenities, fuel storage, and any ventilation intakes or openings that could draw exhaust into occupied spaces. Consider prevailing wind direction to ensure exhaust disperses away from work areas. Avoid locations in excavations, trenches, or partially enclosed areas where carbon monoxide could accumulate. Ensure location provides adequate access for refuelling, maintenance, and emergency shutdown whilst maintaining separation from high-traffic areas. Position generator where electrical distribution leads can reach work areas without creating trip hazards or requiring excessive extension lead lengths. Mark approved generator location with barriers or marking paint before generator placement.

Safety considerations

Carbon monoxide poisoning is the leading cause of generator-related fatalities. Even outdoor operation can cause poisoning if clearances are inadequate or exhaust is directed toward occupied areas. Never operate generators in sheds, partially enclosed areas, or locations without unrestricted airflow. Verify wind direction before startup as changing winds can redirect exhaust toward work areas.

2

Conduct Comprehensive Pre-Start Generator Inspection

Before initial startup, perform detailed inspection of all generator components following manufacturer checklist and site-specific inspection procedures. Begin by checking engine oil level using dipstick, ensuring oil is at correct level and appearance indicates no contamination. Inspect fuel tank and verify adequate fuel for planned operation period, checking tank, fuel cap, and fuel lines for leaks or damage. Examine air filter and clean or replace if dirty or blocked. Inspect exhaust system for leaks, damage, or loose connections. Check electrical outlets and connection points for damage, moisture, or exposed conductors. Verify RCD protection devices are installed and functional by pressing test button. Inspect structural components including frame, wheels, handles for cracks or damage. For electric start models, check battery connections and charge level. Inspect cooling system and verify coolant level is adequate. Document inspection completion on checklist and tag out any generator showing defects until repairs are completed.

Safety considerations

Operating generators with low oil levels can cause catastrophic engine failure and potential fire. Fuel leaks create serious fire hazards particularly when engine heat could ignite leaking fuel. Damaged electrical components can cause electrocution. Never operate generator with known defects or missing safety guards.

3

Start Generator and Verify Normal Operation

Following manufacturer starting procedure, prepare generator for operation by ensuring fuel tap is open, choke is set appropriately for ambient temperature, and all connected loads are switched off to prevent startup surge. For electric start models, turn key to start position and allow starter motor to crank engine. For manual pull-start models, pull starter cord smoothly with controlled motion until engine fires. Once engine starts, allow to warm up for 2-3 minutes at no-load condition before connecting electrical loads. Observe engine operation during warm-up, listening for unusual sounds and checking exhaust smoke colour indicates normal combustion. Verify generator is producing correct output voltage using built-in voltmeter or multimeter, typically 230-240V AC for single phase Australian standard. Test RCD by pressing test button and verifying immediate shutdown, then restart generator. Confirm low oil shutdown protection is functional by reviewing manufacturer specification. Monitor generator for first 5-10 minutes of operation to ensure stable running and no developing problems before leaving generator to run unattended.

Safety considerations

Connecting high loads immediately at startup can damage generator alternator. Always warm up generator under no-load conditions before applying loads. Abnormal exhaust smoke colours (blue, black, or white) indicate engine problems requiring investigation before continued operation. Ensure RCD protection is functional before connecting any electrical loads to prevent electrocution if faults develop.

4

Connect Electrical Loads Within Generator Rated Capacity

Calculate total electrical load of all tools and equipment to be connected to generator, ensuring combined load does not exceed generator rated output capacity typically marked on unit in kVA or kW. Account for surge current required at motor startup by applying 2-3 times running current for tools with electric motors. Connect loads beginning with largest motor loads first, allowing each to reach full running speed before connecting additional equipment. Use only heavy-duty industrial-grade extension leads rated for outdoor use with proper weatherproof connectors. Route electrical leads away from traffic routes, machinery paths, and tripping hazards, elevating leads across pathways where necessary. Protect connections from moisture using weatherproof covers or elevated connection points. Verify RCD devices trip correctly when test button is pressed after loads are connected. Monitor generator output voltage and frequency during load connection to ensure voltage remains stable within acceptable range (230V ±10%). If circuit breaker trips or voltage drops significantly, reduce connected load by disconnecting equipment until generator operates within capacity.

Safety considerations

Overloading generators causes voltage drop, overheating, and potential electrical fires from overloaded wiring. Calculate loads accurately and maintain margin between actual load and generator capacity. Using damaged extension leads or connections creates electrocution hazards. Verify all electrical equipment has been tested and tagged per AS/NZS 3760 before connection to generators.

5

Monitor Generator Operation and Environmental Conditions

Throughout generator operation period, conduct regular monitoring inspections to verify continued safe operation and identify developing problems before failures occur. Monitor intervals should be hourly as minimum, with more frequent checks during critical operations or in adverse conditions. During each check, observe engine operation including smooth running without excessive vibration or unusual sounds. Verify fuel level and check for any fuel leaks developing during operation. Inspect for oil leaks and check oil level if extended operation period. Monitor generator temperature to ensure adequate cooling and no overheating. Observe exhaust colour and verify exhaust is dispersing away from work areas. Check electrical connections remain secure and RCDs have not tripped. Verify generator has not been moved or clearances compromised by material storage or other activities. Monitor weather conditions particularly wind direction changes that could redirect exhaust toward occupied areas. Document monitoring checks including time, observations, and any issues identified in generator logbook.

Safety considerations

Generator failures often show warning signs including unusual sounds, vibration, exhaust smoke changes, or temperature increases before catastrophic failure. Regular monitoring allows shutdown and investigation before serious damage or safety incidents occur. Changed wind direction can redirect exhaust containing carbon monoxide toward work areas that were previously safe.

6

Shutdown Generator and Conduct Refuelling Operations Safely

When generator requires refuelling or at completion of work shift, conduct proper shutdown procedure to prevent equipment damage and ensure refuelling safety. First disconnect all electrical loads or switch off connected tools to eliminate load on generator. Allow generator to run under no-load condition for 2-3 minutes to cool alternator windings. Stop engine using stop switch or turning fuel valve to off position. Once engine has stopped, wait minimum 10 minutes for engine and exhaust components to cool below fuel ignition temperature before removing fuel cap or beginning refuelling operations. Position fire extinguisher within easy reach and have spill containment materials available. Remove fuel cap slowly allowing any fuel vapour pressure to release. Using proper funnel and transfer equipment, slowly fill fuel tank whilst avoiding spills and taking care not to overfill. Wipe up any fuel spills immediately using absorbent materials and dispose of contaminated absorbents properly. Replace fuel cap securely and ensure no fuel residue remains on generator surfaces before next startup.

Safety considerations

Refuelling hot generators or whilst running has caused numerous flash fires and severe burn injuries. Fuel vapour ignition on hot exhaust surfaces can occur within seconds of fuel contact. Always ensure adequate cooling period before opening fuel system. Never smoke or create ignition sources during refuelling. Have fire extinguisher immediately available for refuelling operations.

7

Post-Operation Inspection and Maintenance Documentation

At completion of each work shift or after extended operation periods, conduct post-operation inspection to identify any problems developed during use and prepare generator for next operation. Check general condition including any new damage to frame, covers, or controls. Inspect for fuel leaks, oil leaks, or coolant leaks that may have developed. Verify exhaust system remains secure without damage or deterioration. Check electrical outlets and connections for any heat damage, moisture ingress, or damage from connection/disconnection cycles. Review engine oil appearance for contamination or excessive consumption. Inspect air filter and clean if required. Test battery charge for electric start models and place on charge if needed. Document total running hours, fuel consumption, observations, and any issues encountered in generator maintenance logbook. Schedule maintenance activities per manufacturer recommendations based on accumulated running hours. Report any defects or developing problems to supervisor for scheduling repairs before next use. Clean generator exterior removing dirt, concrete dust, or other contamination that could block cooling air or cause corrosion.

Safety considerations

Accumulated damage and deterioration often goes unnoticed without systematic post-operation inspection. Regular maintenance prevents catastrophic failures that can cause serious safety incidents. Documentation of running hours and maintenance creates audit trail demonstrating due diligence in equipment management and supports warranty claims if defects develop.

8

Secure Generator Against Unauthorised Use and Theft

When generators are left unattended overnight or during non-work periods, implement security measures to prevent unauthorised operation, tampering, and theft. For sites with high theft risk, remove portable generators to secure compound or locked storage container. Where generators must remain in operational position, use heavy-duty chains and locks securing generator to fixed structures or ground anchors. Remove ignition keys for electric start models and store separately from generator. For manual start models, remove spark plug lead connection preventing engine starting. Consider removing fuel from tank and storing separately both to prevent theft and to eliminate fire hazard overnight. Position generators within view of security cameras where site surveillance is available. Mark generators with highly visible company identification using paint or permanent labels assisting recovery if theft occurs. Implement site access controls preventing unauthorised persons entering generator areas. Install security lighting around generator locations deterring tampering. Document generator location, security measures applied, and responsible person at end of each shift. Conduct first-person check of generator security before leaving site.

Safety considerations

Unauthorised operation by untrained persons causes numerous incidents including carbon monoxide poisoning when generators are moved into enclosed areas, electrocution from amateur electrical connections, and fire from improper refuelling. Theft of generators creates project delays and cost impacts. Effective security measures protect both safety and assets.

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Frequently asked questions

What size generator do I need for my construction site?

Generator sizing requires calculating total electrical load of all tools and equipment that will operate simultaneously. List all equipment with their power ratings in watts or kilowatts, typically found on equipment nameplates. Add together running wattage of all items. For equipment with electric motors (saws, drills, compressors), multiply running wattage by 2-3 to account for surge current at motor startup, using the highest surge value. Total this combined load and add 20-30% safety margin to prevent continuous operation at maximum capacity. Convert total watts to kilowatt (divide by 1000) or kilovolt-ampere (kVA) to match generator ratings. For example, if total calculated load is 6000 watts with surge, select generator rated 7.5-8 kVA minimum. Larger is better than undersized. Consider whether all equipment actually runs simultaneously - staged operation allows smaller generator. Consult electrical contractors or generator suppliers for complex load calculations involving multiple large motors or three-phase equipment.

How far away from buildings must generators be positioned to prevent carbon monoxide poisoning?

Australian safety guidelines and manufacturer recommendations require minimum 6 metre clearance between generator exhaust and any building opening including doors, windows, ventilation intakes, or occupied workspace. This distance allows exhaust dispersion and prevents carbon monoxide entering enclosed areas where it can accumulate to lethal concentrations. Position generators outdoors only, never in garages, sheds, or partially enclosed areas even with doors open. Direct exhaust away from buildings using prevailing wind to carry emissions away from occupied areas. If work requires generator operation closer than 6 metres to buildings, implement additional controls including carbon monoxide monitoring, forced ventilation, or relocate generator using longer electrical leads. Excavations, trenches, and low-lying areas trap carbon monoxide and must be avoided even if technically outdoors. Remember carbon monoxide is colourless and odourless - you cannot detect dangerous levels without monitoring equipment. When in doubt, position generator further away. Multiple Australian fatalities have occurred when generators were operated too close to buildings or in partially enclosed locations.

Do I need RCD protection when using portable generators?

Yes, RCD (Residual Current Device) protection is mandatory when using portable generators on Australian construction sites under WHS regulations and AS/NZS 3012 electrical standard. Generators lack the earthing systems present in building electrical installations, increasing electrocution risk from insulation faults or damaged equipment. RCDs rated at 30mA or less must be installed either as integral protection on generator outlets or as portable RCD units plugged between generator and extension leads. The RCD detects current leakage indicating fault path through person's body and immediately disconnects power preventing fatal electric shock. Test RCD function daily before use by pressing test button and verifying immediate disconnection - if RCD doesn't trip, do not use until replaced. Remember RCDs only protect against earth leakage; they don't protect against overload or contact between active and neutral. Use RCDs in combination with proper extension lead inspection, connection protection from moisture, and tested/tagged equipment. Some industries and clients require additional protection including isolation transformers - verify site-specific electrical safety requirements.

What is the correct procedure for refuelling portable generators safely?

Safe refuelling requires complete generator shutdown followed by adequate cooling period before opening fuel system. Stop engine and wait minimum 10 minutes allowing exhaust and engine components to cool below fuel ignition temperature (petrol ignites at approximately 280°C, well below exhaust temperatures during operation). Position approved 9kg fire extinguisher within easy reach before starting refuelling. Ensure no smoking, open flames, or spark-producing activities within 6 metres. Remove fuel cap slowly allowing vapour pressure to release. Use proper funnel or fuel transfer equipment preventing spills. Fill tank slowly avoiding overfilling which causes spillage when cap is replaced. Stop when fuel reaches bottom of filler neck, allowing expansion space. Immediately wipe up any spilled fuel using absorbent materials before starting generator. Replace cap securely and move absorbent materials well away from generator before startup. Use only approved fuel containers with proper spouts and labels. Never use makeshift containers or store fuel in direct sunlight. Refuel in well-ventilated outdoor areas on level ground with spill containment. Never add fuel whilst generator is running or hot - this causes majority of generator fire incidents.

What symptoms indicate carbon monoxide poisoning from generator exhaust?

Carbon monoxide poisoning symptoms progress from mild to severe as exposure continues. Early symptoms include headache, dizziness, nausea, fatigue, and shortness of breath - often mistaken for flu or fatigue. These symptoms occur within 1-2 hours of exposure to moderate CO concentrations. As exposure continues or concentration increases, symptoms worsen to include confusion, vomiting, chest pain, visual disturbances, and difficulty coordinating movements. Severe exposure causes loss of consciousness, convulsions, and death from oxygen deprivation to vital organs, particularly brain and heart. Carbon monoxide is colourless, odourless, and tasteless - you cannot detect it without monitoring equipment. If multiple people develop headaches or flu-like symptoms simultaneously, suspect carbon monoxide exposure. Immediate action is crucial: evacuate area immediately to fresh air, shut down generator if safe to do so, call 000 for ambulance, and do not re-enter area until it has been verified safe by emergency services. Anyone who has lost consciousness or has severe symptoms requires immediate emergency medical treatment. Long-term exposure to lower concentrations causes cumulative damage. Never ignore symptoms or convince yourself they are due to other causes when generators are operating nearby.

How do I connect a generator to building electrical systems safely?

Connecting generators to building electrical systems requires proper transfer switch installation by licensed electrician in accordance with AS/NZS 3000 wiring rules. Never connect generator directly to building power points or switchboards using makeshift connections - this creates serious hazards including backfeed that can electrocute utility workers, inappropriate voltage/frequency, lack of earthing, and bypass of safety devices. Legal installation requires automatic transfer switch that isolates building from utility grid before generator connection, preventing backfeed. Switch must interlock to prevent simultaneous connection of utility and generator power. Circuit must include appropriate overcurrent protection, earthing per AS/NZS 3000, and verification generator capacity matches building loads. Only licensed electricians may perform generator-to-building connections, and installations require electrical inspection and compliance certification. For temporary construction site power, run extension leads directly from generator to individual tools rather than attempting building connections. If permanent or frequent generator operation is required, engage electrical contractor to design and install compliant transfer switch system. Amateur generator connections have caused electrocutions, fires, and equipment damage. When using generators at residential properties during outages, run appliances directly from generator using extension leads rather than attempting connection to home wiring.

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