Air Compressor Safe Work Method Statement

Air compressor operation does not typically require formal licensing in Australia, but operators must be trained and deemed competent by their employer to safely operate the specific equipment. General construction induction training (White Card) is mandatory for all construction site workers. Additionally, operators should receive specific training covering air compressor principles, pressure hazards, pre-operation inspections, safe operating procedures, compressed air hazards, emergency shutdown procedures, and basic maintenance requirements including moisture drainage. Training should be documented with competency assessment confirming the operator understands pressure equipment risks and can safely perform all operating tasks. For large industrial compressors or high-pressure systems, additional training from equipment manufacturers may be required. Operators of petrol or diesel compressors should understand engine operation, refuelling safety, and carbon monoxide hazards. Employers must ensure operators are adequately trained before assigning compressor operation duties, and should provide refresher training annually or when new equipment is introduced. Training records should be maintained documenting operator qualifications and competency assessment results for verification during safety audits and incident investigations.

Pressure relief valves should be tested monthly through manual activation to verify they operate freely and discharge air properly. This test involves briefly lifting the relief valve lever while compressor is pressurised, confirming the valve opens easily, releases air audibly, and reseats completely when lever is released with no residual leakage. Any relief valve that fails to operate freely, shows corrosion or damage, or fails to reseat properly must be replaced immediately before further compressor use. In addition to monthly operational testing, pressure relief valves should be removed and inspected internally during annual comprehensive equipment inspections, verifying spring condition, seat condition, and proper set pressure calibration. Most manufacturers recommend complete relief valve replacement every five years regardless of apparent condition, as internal spring fatigue and seat deterioration can occur without external visible signs. Any impact damage to relief valve, exposure to chemicals or corrosive environments, or evidence of tampering requires immediate valve replacement. Replacement relief valves must be identical specification to original equipment, with proper pressure rating matching compressor maximum working pressure. Installation must ensure proper orientation and secure mounting. Critical to safety is ensuring relief valves are never adjusted, plugged, blocked, or removed during compressor operation, as the relief valve is the final protection against catastrophic tank over-pressurisation and rupture. Document all relief valve testing and replacement in equipment maintenance logbooks.

Air injection injuries occur when compressed air penetrates skin and enters body tissues or bloodstream, causing serious internal damage that may not be immediately apparent. Symptoms include severe pain at injection site, swelling that develops rapidly and may spread along limbs, skin discolouration or bruising, numbness or tingling in affected area, crackling sensation under skin (crepitus) from air in tissues, difficulty breathing if air enters chest cavity, and confusion or loss of consciousness if air embolism affects the brain. Symptoms may be subtle initially but worsen over hours following exposure. First aid for suspected air injection requires immediate emergency medical response by calling 000, as these injuries require surgical intervention and hyperbaric oxygen treatment. Position the casualty in recovery position if conscious, or commence CPR if unconscious and not breathing. Do not attempt to express air from tissues by squeezing or massaging, as this can force air further into tissues or bloodstream. Keep casualty warm and calm, reassuring them that help is coming. Monitor breathing and consciousness level continuously until ambulance arrives. Provide paramedics with information about compressed air pressure, injury location, and time of incident. Even if symptoms seem minor, all compressed air injection incidents require emergency medical assessment, as internal damage including air embolism can be life-threatening without immediate treatment. Prevention through safe work practices is critical, as air injection injuries can result in permanent disability, amputation, or death even with proper medical intervention.

Using compressed air to blow dust from clothing or skin presents multiple serious hazards that have resulted in fatalities and severe injuries. Firstly, compressed air above 30 PSI can penetrate skin through existing cuts, abrasions, or even skin pores, causing air injection into tissues and potentially fatal air embolism when air enters the bloodstream and travels to vital organs including heart, brain, and lungs. Even pressures as low as 15 PSI have caused serious injection injuries. Secondly, directing compressed air at body creates risk of air entering body through eyes, ears, mouth, or other orifices, causing severe internal injuries. Air forced into the intestines through the rectum has caused fatal injuries when workers sat on open air hoses or were subjected to compressed air as horseplay. Thirdly, when compressed air is used to blow dust from clothing or work areas where silica dust is present, it creates dense airborne dust clouds in the breathing zone, causing severe exposure to respirable crystalline silica well above safe exposure limits. This is particularly dangerous on sites where concrete cutting, grinding, or drilling has generated silica dust. The practice essentially concentrates days worth of dust exposure into seconds of intense inhalation. Additionally, compressed air blown across skin can force particles and contamination into the skin, causing infections or embedding foreign material. Safe alternatives for cleaning include using HEPA-filtered vacuum systems to remove dust from clothing and work areas, wet cleaning methods, and designated change rooms where workers remove dusty clothing and shower before leaving sites. Personal hygiene measures should never involve compressed air directed at the body under any circumstances.

Petrol and diesel air compressors should not be operated in enclosed buildings, basements, building cores, or poorly ventilated indoor spaces due to carbon monoxide poisoning hazards from exhaust emissions. Carbon monoxide is a colourless, odourless toxic gas that causes poisoning when inhaled, with symptoms including headache, dizziness, nausea, confusion, and at high concentrations, loss of consciousness and death. If compressor operation in areas with limited natural ventilation is absolutely unavoidable, mechanical exhaust extraction must be installed to remove combustion gases and maintain safe air quality. Extraction systems should provide at least 12 air changes per hour in the space where the compressor operates, with exhaust ducting connected directly to compressor outlet and vented to outside atmosphere away from air intakes, doorways, and work areas. Atmospheric monitoring using calibrated carbon monoxide detectors with alarms set at 30 ppm (parts per million) exposure limit must be implemented, with continuous monitoring during compressor operation. Work must cease immediately if CO levels exceed alarm threshold, with all personnel evacuating to fresh air. Where possible, position compressor outside buildings with air hoses running through doorways or temporary openings to deliver compressed air to indoor work locations, eliminating exhaust emissions from indoor spaces entirely. For work requiring portable compressed air in buildings, electric compressors should be used preferentially as they produce no exhaust emissions. Project planning should identify compressed air requirements early, allowing permanent or temporary electrical installation to support electric compressor use rather than relying on fuel-powered units in enclosed spaces. Signs prohibiting entry to areas where fuel compressors operate should be displayed, restricting access to essential personnel equipped with CO monitors. Training all workers on carbon monoxide poisoning symptoms and emergency response including immediate fresh air and medical attention is essential for preventing fatalities.

Safe transport and positioning of portable air compressors requires proper manual handling techniques, appropriate mechanical aids, and securing during vehicle transport to prevent load shift and equipment damage. Small portable compressors under 30 kilograms may be carried short distances by one person using proper lifting technique including squatting with straight back, secure grip on equipment frame or handle, and maintaining load close to body whilst lifting. Larger compressors require two-person team lifting or mechanical aids including hand trolleys, pallet jacks, or forklift handling. Many portable compressors include wheels and tow handles allowing manual movement, but uneven construction site terrain may require assistance navigating obstacles. When using vehicles to transport compressors between locations, secure equipment using tie-down straps or chains preventing movement during transit, as unsecured loads can shift during braking or turning, causing vehicle instability and equipment damage. For utility vehicles and utes, position compressor against front of tray and secure with multiple attachment points. Drain fuel from petrol or diesel compressors before vehicle transport if practical to reduce fire risk from fuel spillage during transport. When positioning compressor at work location, select stable level surface that supports equipment weight without sinking, provides adequate clearance for air circulation around compressor, positions exhaust away from enclosed spaces and work areas, and allows operator access to controls, drain valve, and pressure gauge. Avoid positioning near excavations, traffic routes, or areas where mobile plant operates to prevent accidental contact. Route power cables and air hoses to avoid creating trip hazards across walkways. For extended work at single location, consider bollards or barriers protecting compressor from vehicle contact. Never drag compressors by air hoses or power cables as this damages critical components. Inspect compressor after any move for damage from impacts, dropped loads, or rough handling before placing back in service.