Annual inspection of amusement rides

Introduction

Amusement structures are defined as ‘plant’ under the Occupational Health and Safety Regulations (OHS Regulations). An employer or self-employed person must ensure amusement structures under their management or control are inspected to the extent necessary to ensure that any risk associated with the use of the plant is monitored.

An essential element of an effective inspection and maintenance program is having the amusement ride inspected annually by a suitably qualified engineer. Annual inspections can help monitor risks associated with the amusement ride. It can help prevent failure or malfunction that may lead to incidents that result in serious injuries or death.

This guidance is to assist employers or self-employed persons with the management or control of an amusement ride so that an annual inspection is completed to a suitable standard. A suitable standard means that the inspection is sufficiently detailed and the necessary documentation is created to demonstrate this.

The guidance is also for people engaged by the duty holder to coordinate and conduct the annual inspection, such as a suitably qualified engineer. It outlines what an annual inspection should consist of to be able to certify that the amusement ride is safe and does not pose risks to employees or other people (such as members of the public).

This guidance sets out information to assist with compliance with the Occupational Health and Safety Act 2004 (OHS Act) and OHS Regulations, referred to throughout this guidance as the OHS Framework. If used in another jurisdiction, the local regulator needs to be consulted to ensure the information in this guidance is applicable and suitable.

Terminology

An amusement structure is defined in the OHS Regulations as:

“… powered equipment operated for hire or reward that provides entertainment or amusement through movement of the equipment, or part of the equipment, or when passengers travel on, around or along the equipment.”

This document largely uses the term ‘amusement ride’. Where used, it is intended to be interchangeable with the terms ‘amusement structure’ and ‘amusement device’. The latter terms are sometimes used within the industry and in technical documents such as Australian Standards.

The guidance is intended to apply to amusement rides that are:

• mobile rides that can be dismantled and reassembled at different locations
• permanently installed, fixed rides.

Legal duties

People with responsibilities under the OHS Framework include:

• employers
• people who manage or control workplaces
• employees
• self-employed people.

Employers and self-employed persons with management or control of an amusement structure have a number of duties under the OHS Framework. This includes to:

• ensure an amusement structure is inspected to the extent necessary to ensure any risk associated with using the ride is monitored (OHS Regulations r105)
• so far as is reasonably practicable, identify all hazards associated with the installation, erection, commissioning, decommissioning, dismantling and use of the amusement structure at the workplace and associated systems of work (OHS Regulations r97)
• keep records of any inspections and maintenance carried out on an amusement structure to which Australian Standard AS 3533.1 Amusement rides and devices Part 1: Design and construction applies, other than amusement structures determined by AS 3533.1 to be class 1. These records must be kept for the period the amusement structure is in their management and control (OHS Regulations 106).

An employer must also:

• provide and maintain a working environment that is safe and without risk to health of employees, including to:
  • provide and maintain plant or systems of work that are safe and without risk to health, so far as reasonably practicable
  • make arrangements for ensuring the safety and absence of risk to health from the use, handling, storage or transport of plant
• provide information, instruction and training to any employees likely to be exposed to risk associated with the identified hazards (such as operators) and their supervisors, about:
  • the hazard identification and risk control processes
  • safety procedures associated with the use of the plant at the workplace
  • the use, fit, testing and storage of personal protective equipment (if any).
• ensure that a person involved in testing, inspection or maintenance of an amusement structure is provided with information available to the employer about how the activity can be carried out so as to ensure, so far as is reasonably practicable, the health and safety of the person
• consult with employees when identifying health and safety risks at the workplace and deciding on appropriate risk control measures. For more information about consultation, please refer to WorkSafe guidance, Consultation guide for employers.
• ensure that people other than employees are not exposed to health or safety risks from the conduct of the undertaking of the employer so far as is reasonably practicable.

Self-employed persons also have a duty to ensure that persons are not exposed to health or safety risks arising from the conduct of the undertaking of the self-employed person, so far as is reasonably practicable.

Employers and self-employed persons must comply with other OHS duties and any mandatory standards that may apply.

A supplier of plant who hires or leases plant must ensure that, between any hiring or leasing of the plant, it is inspected and maintained to ensure that any risk arising from its use is controlled so far as is reasonably practicable (OHS Regulations r93).

A person involved in the supply, installation or operation of amusement structures may also have other duties under the Equipment (Public Safety) Act 1994 and Equipment (Public Safety) Regulations 2017. Guidance about these duties is available on the WorkSafe website:

State of knowledge

State of knowledge refers to what a person knows or reasonably ought to know about eliminating or reducing hazards and risks in the workplace. This includes ways of controlling risks set out in the OHS Regulations, relevant compliance codes and guidance issued by WorkSafe.

The OHS Framework requires a duty holder to take a proactive approach to identifying hazards and risks in their workplace, and eliminating or reducing them so far as is reasonably practicable. Duty holders are therefore expected to understand the current available state of knowledge for controlling hazards and risks.

Duty holders should also seek out information from other available authoritative sources.

The Australian Standard series ‘AS 3533 Amusement rides and devices’ provides substantial guidance on various technical aspects associated with amusement rides. The series includes:

• AS 3533.1 Amusement rides and devices Part 1: Design and construction
• AS 3533.2 Amusement rides and devices Part 2: Operation and maintenance
• AS 3533.3 Amusement rides and devices Part 3: In-service inspection.

The series informs the technical state of knowledge for aspects of owning and operating an amusement ride.

Duty holders may refer to the AS 3533 series when determining what is “reasonably practicable” for meeting obligations under the OHS Framework. For example, AS 3533.3 provides guidance on how to conduct inspections of amusement rides which may assist duty holders meet their obligation to inspect plant to the extent necessary for monitoring associated risk.

Methodologies and principles other than those outlined in the AS 3533 series may be used, as long as the following results can be demonstrated.

• All foreseeable hazards are identified and the risks controlled so far as is reasonably practicable.
• An equivalent or higher level of safety is achieved in comparison to adhering to the AS 3533 series.

Information can also be found in sources such as relevant published safety information, alerts and bulletins, and technical and scientific literature. These include:

• material published by other Australian occupational health and safety regulators
• industry practice and publications
• industry experts such as designers or manufacturers of amusement rides, including the Original Equipment Manufacturer (OEM) of the amusement ride.

Frequency of inspections

A detailed inspection of an amusement ride should be carried out at least once every 12 months by suitably qualified persons. This is often referred to as the annual inspection.

There may be circumstances where it is necessary or appropriate for an amusement ride to have a detailed inspection by a competent person more frequently than the standard 12 months. Examples can include the following instances.

• After an amusement ride has been involved in an incident. This may include the unplanned activation of an emergency stop.
• When an amusement ride is modified or recommissioned.
• When a duty holder has purchased an amusement ride and prior to its first use, especially where there are no verifiable maintenance records for the amusement ride.
• When safety concerns are identified during a periodic inspection, assessment, or other maintenance activities.
• When an amusement ride is subjected to conditions outside of its normal operational parameters, such as overspeed or overload, and environmental conditions such as high winds.
• Where there has been a failure of a critical component.
• Where structural damage has been sustained.
• When the amusement ride has been designed to an unknown technical standard.
• If new or additional information about hazards or risks relating to the amusement ride become available, such as through alerts and bulletins.
• After receiving a request from a health and safety representative.
• Where an existing risk control measure on the amusement ride has been identified to not adequately control the risks.
• Where a competent person has determined that an inspection should occur before the next 12 months has lapsed.

While this guidance is focussed on routine, annual inspections of amusement rides, the information may also be suitable for inspections under these situations.

Engaging suitably qualified persons

Employers must, as far as is reasonably practicable, engage or employ a suitably qualified person to provide specialist advice on OHS. Where OHS risks are complex or high risk, such as those relating to amusement rides, an owner of an amusement ride needs to seek specialist expertise on a range of hazards concerning health and safety and appropriate risk control measures.

For example, a suitably qualified person should be engaged to comply with the duty to ensure an amusement ride is inspected and maintained to the extent necessary to ensure any risk associated with the ride is monitored. In this instance, a suitably qualified person may be an appropriately qualified registered engineer, such as a Registered Professional Engineer (RPE).

For more information, refer to how WorkSafe applies the law in relation to Employing or engaging suitably qualified persons to provide health and safety advice.

The person engaged needs to do the following things.

• Ensure they are only undertaking inspections within their area of expertise, and that they are qualified and competent for the part of the amusement ride being inspected. For example, a mechanical engineer should not be tasked with checking the electrical or electronic components of the amusement ride
• Practise according to legal and statutory requirements.
• Practise according to the contemporary state of knowledge.
• Inform their employer or client if a task requires specific qualifications, expertise, or experience outside of their own.

Depending on the complexity of the amusement ride itself, it may be necessary to engage multiple, suitably qualified people with different areas of expertise to conduct a complete inspection of the amusement ride.

It is common for one of the competent persons to coordinate the overall inspection with a number of other experts or specialists. This is to ensure all relevant areas and components of the amusement ride have been appropriately inspected, and there are no gaps in the inspection. For example:

• A mechanical engineer may arrange for an electrical engineer and a structural engineer to review aspects of the amusement ride while the mechanical engineer focuses on mechanical components and the production of an inspection report.
• The structural engineer may arrange, or get the owner to arrange, for a Non-Destructive Testing (NDT) specialist to perform NDT and provide a report on stipulated components. The structural engineer will read the report to inform themselves of the condition of the components and refer to the report in their own report.

Employing or engaging a suitably qualified person to provide OHS advice does not discharge the duty holder from their legal responsibilities to ensure health and safety under the OHS Framework. These duties cannot be delegated.

Scope of an annual inspection

An annual inspection of an amusement ride should include the following elements.

• Review the operational history since the last annual inspection.
• Reviewing the logbook and ensure it is up to date.
• Check that maintenance and inspections have been carried out according to the instructions of the manufacturer or a suitably qualified person, and have been recorded. This should include the completion of relevant periodic inspections such as daily and weekly inspections.
• Review alterations and modifications made to the amusement ride since the last annual inspection including mechanical, structural, electrical, and software changes.
• Ensure that any required tests, such as non-destructive testing (NDT) or examinations, have been conducted and the records of these maintained.
• Carry out a detailed physical inspection of all applicable aspects of the amusement ride. This should include all mechanical, structural and electrical critical components.

The elements that need to form part of an inspection will vary between amusement rides. Consulting the operator and maintenance manuals for the specific amusement ride can provide guidance on which key elements need to be included in the inspection.

The inspection of the amusement ride should be carried out in its various configurations and modes of operation. This includes (where applicable):

• packed for transport
• partly erected
• fully assembled
• when operating.

This may mean the inspection takes place over a period of time and is not finalised until all relevant aspects of the inspection are completed.

Logbook and manuals

A logbook is a collection of documents and records associated with the amusement ride. A logbook is not a substitute for the operator and maintenance manuals for the amusement ride.

The employer or self-employed person with the management or control of an amusement ride needs to ensure its manuals are readily available, along with the logbook. These should be referenced when inspecting the amusement ride. This is because they contain critical information that can inform the inspection process. The manuals provide a guide for what inspection action needs to be taken and can assist in documenting this.

If the amusement ride is without an operator or maintenance manual, then one needs to be obtained from the manufacturer of the amusement ride. If this is not possible, the duty holder needs to engage a suitably qualified person to assist with developing one.

Guide to completing an inspection report

The person leading the annual inspection needs to prepare a sufficiently detailed report to demonstrate that a proper and satisfactory inspection of the amusement ride has been carried out. The information provided should assist the reader or owner of the amusement ride who commissioned the report to determine the following matters.

• The people who have inspected the amusement ride hold suitable qualifications or have appropriate expertise.
• The amusement ride is in a safe and suitable condition for continued use.
• Whether any necessary remedial or maintenance work has been carried out to ensure continued safe operation prior to the next scheduled inspection.

Completing an annual inspection report should not be by ‘exception’, that is, only if something unexpected or abnormal has been identified.

A summary document signed or initialled by the inspecting engineer may accompany the report as a summary record, or certificate, of the inspection. An inspection certificate should not be issued if there are outstanding items to be addressed that could impact the safe operation of the amusement ride. A single page certificate may not provide sufficient evidence to demonstrate that the risks associated with the use of the amusement ride are being monitored.  WorkSafe may not recognise the completion of an annual inspection of the amusement ride if the duty holder fails to produce a sufficiently detailed inspection report.

Scope of annual inspection

The OHS Regulations require an employer or self-employed person to ensure the amusement structure is inspected to the extent necessary to ensure that any risk associated with the use of the plant is monitored. The inspection of the amusement ride usually consists of assessment of the mechanical, structural, and electrical components.

The following considerations can inform the scope of these inspections.

• Recommendations from relevant published technical standards (for example, the Australian Standard series AS 3533).
• Information on the inspection and maintenance program as specified or recommended by the designer and manufacturer of the amusement ride, or by a suitably qualified person.
• Parts of the amusement ride that a suitably qualified person, designer or manufacturer has identified as being prone to higher rates of failure or wear
• Any published safety information, alerts and bulletins, including from:
  • other safety organisations and regulators
  • designers or manufacturers of amusement rides.
• The age and history of the amusement ride, including:
  • total hours of operation
  • the type of loading the amusement ride has undergone
  • any time spent in transit where components are exposed to vibrational loads or other impact stressors (this may impact the integrity of the components)
  • any time spent in storage (poor storage condition may contribute to corrosion)
  • environmental conditions in which the amusement ride operates, such as in wet, coastal, humid or very hot environments.
• Information and findings from incidents, locally or globally.

This is not an exhaustive list of elements that should inform the scope of the annual inspection.

Inspection activities should be sufficiently flexible to allow for additional examinations and reviews to be undertaken. For example, if something unexpected is identified, particularly in relation to a critical component, additional disassembly and tests need to be carried out to properly understand the extent of the findings.

The sections below are not an exhaustive list on what mechanical, structural, and electrical inspection of an amusement ride should consist of. An inspection may include more or less than this depending on the complexity and condition of the amusement ride.

Mechanical and Structural

The condition and integrity of the following mechanical and structural critical components need to be inspected.

Mechanical

• Patron restraint systems, including the seating
• Physical guarding of danger areas or points
• Slew bearings and axle shafts
• Wheels, rollers and bearings
• Suspension systems, such as ropes and chains
• Drive/transmission and braking systems, such as gear boxes
• Controls

Structural

• Load bearing components
• Fasteners and connections
• Frames
• Suspension systems, such as ropes and chains
• Stabilisation systems, such as jacking and anchor points
• Fences and barriers

When inspecting and reporting on the mechanical and structural components, consider the following things.

• Components such as motors and gearboxes are inspected to ensure wear is consistent with the amusement ride’s use since last inspection.
• List of inspection and maintenance requirements tasks performed, including:
  • reviewing and interpreting any NDT results, if applicable
  • explaining why any tasks were not completed.

If only some common components were examined or tested during the inspection, clearly record which components were inspected and which were not, along with the system of work to manage this (such as additional monitoring). The documentation and the system of work should include a plan for when these parts need to be subject to routine inspection.

Electrical

Other considerations

Duration of an annual inspection

The time it takes to inspect an amusement ride will depend on many factors, such as:

• the complexity of the amusement ride’s design and components
• the age of the amusement ride
• the issues identified during the inspection.

It can take many hours to physically inspect a single amusement ride to the extent necessary to monitor and manage the risks associated with its use. Large or complex rides should be expected to take longer. Producing the detailed inspection report will take additional time, beyond that of the physical inspection.

Requirement to keep records of inspections

The OHS Regulations require an employer or self-employed person to keep a record of any inspection and maintenance, including repairs, carried out on an amusement structure to which AS 3533.1 Amusement rides and devices Part 1: Design and construction applies.

These records must be maintained for the period that the duty holder has management or control of the plant.

This record keeping requirement does not apply if the amusement structure is determined by AS 3533.1 to be Class 1. It is expected that records of all maintenance and inspections of the amusement ride are readily accessible and available for review on request. This includes annual inspection records, and any supporting documents associated with the inspection.

Records do not need to be a physical copy.