How We Work
Clear pathway from assessment to compliance.
Fixed-price site assessments. Accurate project scoping. No guesswork
Site Assessment Details
Most compliance projects are poorly scoped because facilities don't know what they don't know.
Our approach starts with understanding your actual position, then addresses gaps systematically.
Price: $8,800* Inc GST (Fixed Investment)
*Travel expenses calculated separately based on site location
Why It Matters:
You'll know exactly your current compliance position, what gaps exist and why they matter, accurate timeline and investment required to address them, and priority sequence for addressing issues.
What's Included:
Pre-Assessment Documentation Review: We review existing documentation before arriving on-site - previous assessments, equipment lists, P&IDs, operating procedures. This ensures we maximise on-site time.
Full Facility Walkthrough: Complete facility inspection with your operations team. We examine dust generation points, collection systems, ignition sources, housekeeping practices, and operational realities.
Equipment Inventory & Suitability Evaluation: Documentation of equipment in potentially hazardous areas. Assessment of equipment suitability for classified zones. Identification of equipment requiring verification or replacement.
Gap Identification Against AS/NZS IEC 60079 & NFPA 660: Clear documentation of where current state differs from standard requirements. Explanation of why each gap matters and its relative priority.
Detailed Written Report: Detailed report delivered within one week of site visit. Prioritised recommendations with clear rationale. Accurate scoping for any required projects.
Post-Report Consultation: Discussion of findings and recommendations. Clarification of any questions. Strategic planning for addressing priorities.
Timeline: Typically 2-3 days on-site + 1 week report delivery
Typical Outcome: 70% of site assessments proceed to core projects because the assessment creates confidence in scope and investment.
Core Services
Hazardous Area Classification (HAC)
What It Is:
A systematic engineering study that identifies where explosive atmospheres may occur at your facility and defines the protective measures required for electrical equipment in those areas. HAC creates the fundamental safety framework for sites handling flammable gases, vapours, liquids, or combustible dusts.
When You Need It:
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New facility design or brownfield modifications
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After process changes affecting hazardous materials
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When audits reveal undocumented or outdated classifications
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Before installing electrical equipment in potentially hazardous areas
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To satisfy regulatory compliance requirements under AS/NZS 60079.10 series
What's Involved:
We conduct a site evaluation including process analysis, material property assessment, ventilation studies, and release scenario modelling. This results in detailed hazardous area drawings showing zone classifications, extent of zones, and equipment selection requirements. All work references current Standards and your specific operational context.
Typical Timeline:
4-8 weeks from site assessment to final documentation, depending on facility complexity, number of process areas, and stakeholder consultation requirements.
Estimation Approach:
Every facility is different. Variables like site size, process complexity, number of hazardous materials, existing documentation quality, and access requirements significantly impact project scope. A site assessment lets us understand your specific situation and provide accurate, fixed-price quotations rather than estimates that might prove inadequate.
Outcome:
Compliant hazardous area classification documentation including zone classification drawings, basis of classification report, equipment selection schedules, and maintenance recommendations. You'll understand exactly where hazards exist and what's required to work safely in those areas.
Dust Hazard Analysis (DHA)
What It Is
Another type of engineering study that identifies combustible dust hazards at your facility and defines the protective measures required to prevent dust explosions. DHAs evaluate where combustible dust accumulations may occur, assess ignition sources, and determine appropriate risk mitigation strategies.
When You Need It
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Facilities handling combustible dusts (grain, wood, metal, chemical powders)
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After incidents involving dust fires or explosions
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When audits reveal uncontrolled dust accumulation
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Before installing equipment in dust environments
What's Involved
We conduct site evaluation including dust sampling and testing, process analysis, accumulation assessment, ignition source identification, and explosion risk evaluation. This results in detailed hazardous area classifications for dust zones, housekeeping procedures, ignition control measures, and equipment selection requirements specific to combustible dust environments.
Typical Timeline
4-10 weeks from site assessment to final documentation, depending on facility size, dust testing requirements, number of process areas, and complexity of mitigation measures.
Estimation Approach
Combustible dust facilities vary enormously. Factors like dust types, process complexity, facility size, existing housekeeping practices, and whether dust testing is required significantly impact project scope. Site assessments let us understand your specific dust hazards, evaluate current controls, and identify what testing or analysis is needed for accurate, fixed-price quotations.
Outcome
A dust hazard analysis including dust explosion risk analysis, housekeeping and ignition control recommendations, equipment selection requirements, and ongoing management procedures. You'll understand your dust explosion risks and exactly what's required to manage them safely.
Verification Dossier
What is it:
A list of technical documentation proving that equipment installed in hazardous areas meets the requirements of your HAC study and Australian Standards. Verification dossiers demonstrate compliance through detailed equipment specifications, installation validation, and maintenance requirements.
When You Need It
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After installing equipment in hazardous areas
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During compliance audits or regulatory inspections
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Before operational commissioning
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To demonstrate due diligence to insurers
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When acquiring facilities with inadequate existing documentation
What's Involved
We review your HAC documentation, inspect installed equipment, verify certification markings and specifications, assess installation methods, document cable gland selections, and create comprehensive equipment schedules. All findings are compiled into a dossier that proves compliance with AS/NZS 60079.14 installation requirements.
Typical Timeline
3-5 weeks from site inspection to completed dossier, depending on the number of installed equipment items and documentation complexity.
Estimation Approach
The scope depends heavily on site size, number of equipment items requiring verification, quality of existing documentation, and installation complexity. Site assessments allow us to count equipment, assess documentation gaps, and understand access constraints, providing the foundation for accurate fixed-price quotes.
Outcome
Complete verification dossier including equipment schedules, certification records, installation compliance verification, photographic evidence, and maintenance recommendations. You'll have documented proof that your hazardous area installations meet Australian Standards requirements.
Technical Person with Executive Function
What It Is
An independent competent person appointed to verify that equipment and installations in hazardous areas comply with Australian Standards. The TPEF provides independent oversight and sign-off on equipment selection, installation methods, and maintenance procedures, acting as the technical authority for hazardous area compliance.
When You Need It
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During design and installation of equipment in classified areas
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When modifications affect hazardous area installations
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To satisfy AS/NZS 60079.14 competent person requirements
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For commissioning sign-off before operation
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When internal expertise isn't available or conflicts of interest exist
What's Involved
I act as your independent TPEF throughout the project lifecycle, reviewing equipment specifications against HAC requirements, assessing installation designs and methods, conducting site inspections during and after installation, verifying documentation, and providing formal sign-off that work complies with Australian Standards. This includes ongoing consultation as issues arise during installation.
Typical Timeline
Engagement duration varies based on project length—from 2-3 weeks for simple installations to 3-6 months for complex facility projects. TPEF involvement is typically intermittent across the project rather than continuous.
Estimation Approach
TPEF scope depends on project complexity, number of equipment items, installation duration, required site visits, and level of design review needed. Site assessments reveal the scale of work requiring oversight, existing documentation quality, and project timelines, allowing accurate estimation of involvement level and fixed pricing.
Outcome
Independent verification that your hazardous area installations meet Australian Standards, including reviewed documentation, site inspection reports, non-conformance identification and resolution, and formal TPEF sign-off. You'll have the confidence and documented proof that work has been independently verified by a competent person.
Client Stories
Real Challenges, Real Solutions.
Every business faces unique explosion risk challenges. Here, we showcase how real businesses like yours have navigated these complex issues.
From tackling compliance concerns to reassessing hazardous areas, these stories show the diverse ways we've helped clients make informed decisions and implement effective solutions.
CopRice - Feed Production
CopRice is a subsidiary of Ricegrowers Limited.
SunRice’s proud history dates back to the establishment of a single rice mill in the Riverina region of New South Wales in 1950. Today SunRice has operations – including processing, packing and value added food plant
Solution Provided
Proactively enhanced their dust explosion measures, turning requirements from Risk Mitigation Underwriters into a Safety Improvement program.
Challenge
In animal feed production, grain dust is a constant companion - and a potential hazard.
Operators face unique challenges in managing combustible dusts from various grains and ingredients.
CSIRO - Research
As Australia's national science agency, CSIRO are solving the greatest challenges through innovative science and technology.
Solution Provided
Optimised their Research Operations by reassessing the Hazardous Area Classification report, and providing them with a classification that reflected their operation and building systems designs. The report aligned with their commitment to both safety and efficient research practices
Challenge
Research Facilities often deal with a range of materials, each with it's own safety consideration.
Laboratories require flexible yet safe systems to accommodate changing research needs.
Allied Pinnacle - Flour
One of Australia's largest supplies to the bakery, food service and food manufacturing sectors
Solution Provided
Successfully aligned their operations and documentation with current safety requirements. Setting new benchmarks for their Engineering team for safety in plant operations
Challenge
From Flour to Sugar, food manufacturing involves a multitude of fine particles that can pose dust explosion risks.
Production & Operation staff are always having to balance efficiency, product quality and safety requirements.