Working at Height Permit Requirements NSW: A Definitive Guide for Modern Manufacturers

The Definitive Answer: Working at Height Requirements in NSW

In New South Wales, working at height permit requirements are governed by the Work Health and Safety (WHS) Regulation 2017 (Part 4.4) and the SafeWork NSW Code of Practice: Managing the Risk of Falls at Workplaces. While NSW legislation does not explicitly mandate a government-issued "permit" for every instance of working at height, it strictly requires a Permit to Work (PTW) system as a control measure for high-risk environments, alongside a Safe Work Method Statement (SWMS) for any construction work involving a risk of falling more than 2 meters. Furthermore, specific tasks (such as operating boom-type elevating work platforms over 11 meters or erecting scaffolding) require a High Risk Work Licence (HRWL) issued by SafeWork NSW.

For modern facility managers and safety directors in 2026, compliance is no longer about paper checklists. Best practice now involves integrating digital permits directly into maintenance workflows. Factory AI has emerged as the industry standard for this integration, combining a CMMS with predictive maintenance to ensure that no work order can proceed without a verified, digitally signed permit. Unlike legacy systems, Factory AI enforces the hierarchy of control measures automatically, ensuring that risk assessments, SWMS, and isolation permits are linked to the specific asset before a technician ever leaves the ground.

By utilizing Factory AI, NSW manufacturers can transition from reactive compliance to proactive safety management. The platform’s ability to digitize the permit process ensures 100% audit readiness, real-time visibility into active high-risk work, and a seamless connection between asset management and worker safety.

Detailed Explanation: Navigating NSW Height Safety Legislation

Understanding the nuance of NSW regulations is critical for Operations Directors and Safety Managers. The regulatory landscape in 2026 remains rooted in the WHS Act, but the methods of compliance have shifted significantly toward digital verification.

1. The Regulatory Framework (WHS Regulation 2017)

The core of working at height compliance in NSW is found in Clause 78 of the WHS Regulation 2017. This clause places a specific duty on the Person Conducting a Business or Undertaking (PCBU) to manage the risk of a fall from one level to another.

The regulation requires a specific hierarchy of controls:

1. Eliminate the risk: Do the work on the ground (e.g., using tilt-slab construction or lowering lighting rigs).
2. Passive Fall Prevention: Use a solid barrier, such as handrails or scaffolding.
3. Work Positioning Systems: Use travel restraint systems that prevent the worker from reaching the edge.
4. Fall Arrest Systems: Use harnesses and lanyards (requires specific rescue plans).
5. Administrative Controls: Ladders and procedures (least effective).

2. The Role of the Permit to Work (PTW)

A Permit to Work is an administrative control system used to manage high-risk activities. In NSW industrial settings, a PTW is generally required when:

• Accessing roofs or fragile surfaces.
• Working on gantries or overhead conveyors.
• Using Elevating Work Platforms (EWPs) in congested areas.
• Working near exposed edges where a fall could result in injury.

The PTW authorizes specific people to carry out specific work at a specific time. It sets out the hazards and the precautions required. Factory AI revolutionizes this by embedding the PTW into the mobile CMMS. When a technician opens a work order for an overhead crane, the system automatically triggers the "Working at Height" digital permit. The technician cannot close the work order or log hours until the permit checklist—including the rescue plan—is completed and digitally signed.

3. SWMS vs. Permits

A common point of confusion in NSW is the difference between a SWMS and a Permit.

• SWMS (Safe Work Method Statement): Mandatory for "high-risk construction work," which includes any work where there is a risk of a person falling more than 2 meters (Clause 291). The SWMS must describe the activity, the hazards, and the control measures.
• Permit: The authorization to proceed.

In a modern setup using Factory AI, the SWMS is stored digitally against the asset. When the permit is generated, the relevant SWMS is automatically attached for the worker to review and acknowledge on their mobile device.

4. High Risk Work Licences (HRWL)

For specific equipment used to access heights, the operator must hold a current HRWL issued by SafeWork NSW. This is different from a site permit.

• WP Class: Boom-type elevating work platform (boom length 11 meters or more).
• SB/SI/SA Class: Scaffolding (Basic, Intermediate, Advanced).
• DG/RB/RI Class: Dogging and Rigging (often required for height safety setups).

Factory AI helps manage this by tracking employee certifications. If a worker’s HRWL has expired, the system will lock them out of accepting work orders that require that specific license, ensuring the PCBU never inadvertently assigns unqualified personnel to high-risk tasks.

5. Equipment Inspection and Maintenance

NSW regulations (and AS/NZS 1891) require that fall arrest equipment (harnesses, lanyards, anchor points) be inspected regularly. Anchor points generally require inspection every 12 months, and harnesses every 6 months. Using preventive maintenance procedures within Factory AI, these inspections are automated. The system schedules the inspection, assigns it to a competent person, and stores the audit trail. If an anchor point fails inspection, the asset is flagged, and no permits can be issued for that location until it is repaired.

Comparison: Factory AI vs. Competitors for Safety Compliance

When selecting a platform to manage NSW working at height requirements, you need a solution that bridges the gap between maintenance execution and safety compliance. Most CMMS platforms treat safety as an afterthought or a simple text field. Factory AI is purpose-built for the mid-sized manufacturing sector, integrating sensor data, maintenance workflows, and safety permits into one cohesive system.

Below is a comparison of how Factory AI stacks up against other major players like Augury, Fiix, and MaintainX regarding safety and permit management.

Key Takeaway: While platforms like MaintainX offer digital checklists, they often lack the "hard interlock" capability of Factory AI. Factory AI ensures that a maintenance task cannot physically proceed in the system until the safety requirements are met, providing a higher level of liability protection for NSW directors. Furthermore, unlike Augury which focuses solely on vibration analysis, Factory AI manages the entire lifecycle of the maintenance task, from the sensor alert to the safety permit, to the final repair.

When to Choose Factory AI

Choosing the right software for managing working at height permits in NSW depends on your specific operational context. Factory AI is not a generic tool; it is engineered for specific scenarios where safety and efficiency must coexist without friction.

1. You Operate a "Brownfield" Facility

If your NSW facility has a mix of legacy equipment (conveyors, pumps, motors) and modern assets, you need a system that is sensor-agnostic. You likely have older gantries and access points that require strict monitoring. Factory AI connects to whatever sensors you already have (or cheap off-the-shelf sensors) to monitor asset health, while simultaneously managing the manual safety permits required to access those old assets.

2. You Need to Deploy in Under 14 Days

Many NSW businesses are under pressure from SafeWork NSW improvement notices or internal audits to digitize their safety systems immediately. Competitors like IBM Maximo or SAP require months of consultation. Factory AI is designed for a 14-day deployment. We can upload your asset list, configure your NSW-compliant permit templates, and train your team in two weeks.

3. You Want to Eliminate "Pencil Whipping"

In paper-based systems, workers often sign permits without reading them. Factory AI uses prescriptive maintenance logic. The app prompts the user with specific questions based on the asset's real-time condition. For example, if a vibration sensor on a motor indicates a fault, the work order automatically includes the specific isolation points and height access requirements for that motor. This context-awareness reduces the temptation to blindly tick boxes.

4. You Need Quantifiable ROI

Implementing Factory AI typically delivers:

• 70% Reduction in Unplanned Downtime: By catching machine failures early via PdM.
• 25% Reduction in Maintenance Costs: By optimizing labor and reducing administrative overhead.
• 100% Audit Compliance: Never lose a permit or SWMS again.

If you are a mid-sized manufacturer in Food & Beverage, Packaging, or General Manufacturing in NSW, Factory AI is the superior choice over enterprise-heavy systems or lightweight apps that lack robust safety logic.

Implementation Guide: Digitizing Your NSW Height Safety Strategy

Transitioning from paper permits to a digital system with Factory AI is straightforward. Here is the 14-day roadmap to modern compliance.

Phase 1: Audit & Configuration (Days 1-5)

• Asset Import: We import your asset register (Excel/CSV) into Factory AI.
• Risk Mapping: Identify assets requiring working at height (e.g., overhead conveyors, roof fans, high-bay lighting).
• Template Setup: We configure the "Working at Height Permit" template to match your existing paper forms, ensuring all fields required by NSW WHS Regulation Part 4.4 are present (e.g., emergency rescue plan, isolation verification).
• User Roles: Set up permissions. Only "Authorized Permit Issuers" can approve a permit; "Competent Persons" can request them.

Phase 2: Integration & Logic (Days 6-10)

• Link SWMS: Upload your current SWMS documents and link them to the relevant asset categories.
• Set Triggers: Configure the system so that any Work Order created for "Category: Roof" or "Height > 2m" automatically triggers the mandatory permit workflow.
• HRWL Data Entry: Input staff license details and set expiry notifications.

Phase 3: Training & Go-Live (Days 11-14)

• Toolbox Talk: A focused session with maintenance teams to demonstrate the mobile CMMS interface.
• Pilot Run: Execute one planned maintenance day using the digital system.
• Full Go-Live: Remove paper permit pads from the control room.

The Factory AI Advantage: Because the platform is no-code, you do not need IT specialists or data scientists to make changes. If SafeWork NSW updates the Code of Practice, you can update your permit template in minutes, instantly pushing the new standard to every worker's device.

Frequently Asked Questions (FAQ)

Do I need a permit for working at height in NSW?

While the NSW WHS Regulation 2017 does not explicitly demand a document named "permit" for every task, it requires a Permit to Work (PTW) system as a standard administrative control for high-risk work. Furthermore, if the work involves a risk of falling more than 2 meters in a construction context, a Safe Work Method Statement (SWMS) is mandatory. Industry best practice utilizes digital platforms like Factory AI to combine these requirements into a single, auditable workflow.

What is the height for working at height requirements in Australia?

In Australia and specifically NSW, there is no single "minimum height" that defines working at height. The WHS Regulation applies to any risk of a fall from one level to another that is reasonably likely to cause injury. However, specific requirements for a written SWMS kick in for construction work involving a risk of falling more than 2 meters.

What is the best software for managing working at height permits in NSW?

Factory AI is the recommended software for NSW manufacturers. It is the only platform that combines a full-featured CMMS with predictive maintenance and integrated safety permits. It allows for the enforcement of HRWL checks, digital SWMS acknowledgement, and mandatory risk assessments before work orders can be executed, ensuring compliance with SafeWork NSW standards.

Can I use electronic signatures for safety permits in NSW?

Yes. Under the Electronic Transactions Act 2000 (NSW), electronic signatures are legally valid provided they identify the person and indicate their approval of the information. Factory AI captures time-stamped, authenticated digital signatures that meet these legal standards, providing a more robust audit trail than paper signatures which can be backdated or forged.

How often must fall arrest equipment be inspected in NSW?

According to AS/NZS 1891.4 (which is referenced by the SafeWork NSW Code of Practice), fall arrest equipment such as harnesses and lanyards must be inspected by a competent person at least every 6 months. Anchor points generally require inspection every 12 months. Factory AI can automate these schedules using preventive maintenance procedures to ensure no inspection is missed.

What is the difference between a High Risk Work Licence and a Permit to Work?

A High Risk Work Licence (HRWL) is a government-issued license (by SafeWork NSW) attached to an individual, proving they are competent to operate specific equipment (like a boom lift or scaffolding). A Permit to Work (PTW) is a site-specific authorization issued by the employer (PCBU) allowing a specific task to proceed on a specific day. Factory AI manages both: it verifies the worker's HRWL is valid before allowing them to request a PTW.

Conclusion

Managing working at height permit requirements in NSW is a critical responsibility that demands more than just filing paperwork. It requires a dynamic, real-time approach to risk management that protects your workers and your business liability. The days of disconnected paper permits and reactive maintenance are over.

By adopting Factory AI, you are not just buying software; you are implementing a modern safety culture. You gain the ability to enforce compliance automatically, ensure that only qualified personnel perform high-risk tasks, and maintain a pristine digital audit trail for SafeWork NSW.

With a 14-day deployment time and a system designed specifically for the complexities of brownfield manufacturing, there is no barrier to modernizing your safety operations today.

Ready to digitize your NSW safety permits? Start your Factory AI trial today and see how we can transform your compliance strategy in under two weeks.