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Hazards are managed depending on the level of risk they pose. The following table informs the level of risk.
Risk and Hazard Analysis
20th March 2025
Island Cliff Dairy
Hazard Analysis: Terrain, Water, and Weather-Related Risks
1. Steep and Slippery Slopes (Including Cow Lanes)
Hazards:
● Risk of vehicle slides and collisions, especially in wet conditions. ● Increased danger due to irrigation, rainfall, or recently used fixed grid irrigation.
Control Measures:
● Use quad bikes or tractors instead of utes or two-wheelers when slopes are slippery.
● Avoid no-go areas and assess conditions before proceeding. ● Choose alternative routes if traction loss is possible.
● Always maintain a run-out when traveling on slopes in case of a slide. ● Consider consequences of a slide before choosing a route.
2. Steep Drop Over Pivot Ramps
Hazards:
● High risk of losing control and going over the drop.
● Dangerous for all vehicle types and pedestrians.
Control Measures:
● Exercise extreme caution when near pivot ramps.
● Avoid the area entirely in low visibility conditions (night, fog, rain). ● If necessary to approach, use a low speed and assess ground stability first.
3. Low Visibility Conditions (Night, Fog, Rain)
Hazards:
● Increased risk of encountering unseen drops, ruts, or obstacles. ● Difficult to assess the stability of the ground.
Control Measures:
● Use headlights and additional lighting when working at night.
● Drive at low speeds and avoid unnecessary travel in dangerous areas. ● Be extra cautious in paddocks known for steep drops or ruts.
● Regularly inspect paddocks for new holes after rain and report them. 4. Uneven, Rough, Soft, or Boggy Ground
Hazards:
● High risk of losing control, collisions, or rollovers.
● Conditions can develop anywhere and at any time, particularly after rainfall. ● Pivot ruts may cause vehicles to tip or become stuck.
Control Measures:
● Regularly inspect and report new holes, bogs, or unstable areas to management. ● Adjust speed based on terrain conditions.
● Avoid areas prone to bogging, especially in heavy vehicles.
5. Water Hazards (Ponds, Drains, Waterways)
Hazards:
● High drowning risk due to soft-bottom waterways and the Waiareka Stream. ● Children under 8 are particularly at risk.
Control Measures:
● Direct supervision of children under 8 by someone over 16 at all times. ● Identify and mark high-risk water areas with warning signs.
● Avoid unnecessary travel near waterways, especially in wet conditions. 6. Flooding Hazards
Hazards:
● Floodwaters create a high risk of drowning, being swept away, or vehicle loss of control.
● Emergency situations may arise where stock rescue is considered. Control Measures:
● Avoid floodwaters unless it is more hazardous to stay in place.
● Prioritize human safety over stock welfare.
● Plan ahead to move stock to high ground before a flood.
● Use high roads if travel is necessary during flooding.
7. Fire Hazards
Risks:
● Vegetation & buildings: High fire risk due to dry conditions or electrical faults.
● Fuel storage: Diesel and petrol tanks at the dairy shed increase fire and explosion risks.
Control Measures:
● Fire extinguishers: Ensure locations are known and units are regularly checked. ● Water availability: Use high-pressure irrigation offtakes in the irrigation season and dairy shed water tanks.
● Fuel storage safety: Keep flammable materials away from ignition sources. ● Emergency procedures: Train staff in fire response and evacuation plans.
8. Heavy Machinery (Trucks & Tractors)
Risks:
● High collision risk: Large machinery with blind spots.
● Rollovers: Tractors may tip on uneven terrain.
● Visibility issues: Limited sight in poor weather or night conditions. Control Measures:
● Traffic rules: Keep left on lanes, maintain safe speeds.
● Rotating beacons: Always use if fitted.
● Clear communication: Ensure radio or hand signals are understood. ● Trained operators only: Unauthorized use is prohibited.
9. Milk Tankers (Operating Anytime)
Risks:
● High collision risk: Tankers operate at all hours.
● Limited maneuverability: Hard to stop quickly.
Control Measures:
● Traffic rules: Keep left, reduce speed, stay alert at intersections.
● Visibility aids: Use rotating beacon when moving near tanker routes. ● Scheduled movement awareness: Workers should be informed of tanker arrival times.
10. Worker Awareness & Communication
Risks:
● Unexpected movements: Other workers may be in blind spots.
● Collisions or interference: Actions of others may create hazards. Control Measures:
● Maintain low speeds: Always expect people to be around.
● Constant communication: Use radios or calls to confirm locations. ● Situational awareness: Never assume an area is clear.
11. Lone Worker Risks
Risks:
● Inability to call for help in emergencies.
● Poor reception may prevent communication.
Control Measures:
● Carry a cell phone: Always have a means of contact.
● Report location & return time: Inform someone before heading to a low-reception area.
● Use texts in poor reception areas: Texts can go through when calls fail. ● End-of-day checks: Managers must confirm all staff return safely.
12. Ladder Safety
Risks:
● Falls from unstable ladders.
● Ladders slipping or tipping.
Control Measures:
● Use alternatives: Scaffolding, cherry pickers, or telehandlers with safety cages. ● Proper ladder use: If required, always have someone holding the base.
13. Working at Heights
Risks:
● Falls from over 1.5m.
● Harness suspension trauma after a fall.
Control Measures:
● Training & equipment required: No work at height without proper training. ● Use secured lifting cages: Attach securely to tractors/telehandlers. ● Rescue plan required: Immediate action needed if a worker falls and is suspended. ● Park pivots on level ground: When conducting repairs at heights.
14. Confined Spaces (Vats & Silos)
Risks:
● Suffocation or entrapment.
● Incapacitation of spotters attempting rescue.
Control Measures:
● Only trained workers allowed.
● Lock out power sources before entry (augers, refrigeration, CIP). ● Qualified contractor requirement: No staff entry without proper certification. ● Rescue plan in place: Spotter cannot attempt rescue without training.
15. Manual Handling
Risks:
● Strains and injuries from lifting heavy objects.
Control Measures:
● Use two-person lifts: For weights over 25kg.
● Calves exception: Handle alone due to awkward shape.
16. Blind Corners & Rises
Risks:
● High collision risk due to poor visibility.
Control Measures:
● Keep left.
● Observe speed limits.
● Use lights/horns when approaching blind areas.
17. Noise Hazards
Risks:
● Hearing loss from prolonged exposure to loud equipment.
Control Measures:
● Wear hearing protection when using chainsaws, mowers, power tools, or tractors without cabs.
18. Chemical Hazards
Risks:
● Explosion, fire, corrosion, or toxic exposure.
● Pregnancy risks from certain chemicals.
Control Measures:
● Store in chemical shed at the shearing shed.
● Follow SDS guidelines.
● Keep chemicals in original containers with warning labels.
● Wear PPE (nitrile gloves, masks, safety glasses, cotton overalls, and gumboots). ● Avoid exposure to hormone treatments, anthelmintics, and herbicides when pregnant.
19. Animal Hazards
Cattle Handling in Yards
Risks:
● Crushing & kicking: High risk in confined spaces.
● Slippery/boggy surfaces: Increased risk of falls and loss of control. Control Measures:
● Follow WorkSafe guidance on cattle handling.
● Be firm but quiet when working with animals.
● Always have an escape route.
● Stay out of kicking range and remain alert.
● Expect unpredictable movements and reactions.
Bulls
Risks:
● Extremely high risk of aggression.
● Possible severe injury or fatality if charged.
Control Measures:
● Maintain escape routes.
● Never turn your back on a bull.
● Minimize time spent in close quarters.
Children on the Farm
Risks:
● High injury risk from machinery, livestock, and hazards.
● Drowning or exposure to chemicals.
Control Measures:
● Direct supervision at all times.
● Children under 12 not allowed in effluent compound or on machinery. ● Alert parents immediately if a child is found alone.
20. Public Road Hazards
Farm Entrances
Risks:
● High-speed traffic presents a high collision risk.
● Poor visibility and risk of pulling out in front of vehicles.
Control Measures:
● Follow road rules, keep left, and allow faster traffic to pass.
● Take extra care due to fast-moving traffic.
● When pulling out, account for front-end loader overhang.
Stock on Public Roads
Risks:
● High risk of vehicle collisions with stock.
Control Measures:
● Double-check stock are locked away at night.
● Use warning signs, rotating beacons, and sufficient staff when moving stock. ● Notify the council before shifting stock.
● Ensure stock are well-fed and hydrated to reduce breakout risk. ● Maintain good fence power.
21. Electrical Hazards
Overhead & Underground Cables
Risks:
● High electrocution risk from overhead power lines.
● Risk of striking underground cables when digging.
Control Measures:
● Remain at least 4m clear of overhead wires.
● Look up and live – check wire height before operating telehandlers or excavators.
● Consult management before digging.
● Use Network Waitaki resources for underground cable locations. Electric Fences
Risks:
● Mild electrocution risk to workers and visitors.
Control Measures:
● Warn visitors not to touch fences.
22. Water Hazards
High-Pressure Water Systems & Irrigation Infrastructure
Risks:
● Medium risk of injury from high-pressure water.
● Associated electrical risks.
Control Measures:
● Isolate electricity and pressure before performing maintenance. ● Ensure proper PPE is used when working with irrigation systems.
Water Blasters
Risks:
● High electrocution risk.
● High-pressure injury hazard.
Control Measures:
● Keep water away from electric pumps.
● Never spray people.
Automated Irrigation Systems
Risks:
● Low risk of injury, but equipment may start unexpectedly. Control Measures:
● Do not park or leave equipment on pivot tracks or in the path of traveling irrigators.
Overground Pipework (K-Line Hoses)
Risks:
● High risk of falling off two-wheelers due to obstacles.
Control Measures:
● Ride slowly and keep a constant lookout.
Water Troughs
Risks:
● Medium risk – located in paddocks and may be hit by vehicles. Control Measures:
● Learn the location of all troughs.
● Drive slowly in paddocks.
23. Fire Safety
Fire Extinguishers
Risks:
● Medium risk – high-pressure gas cylinders may be dangerous if mishandled. Control Measures:
● Handle with care.
● Ensure regular maintenance (every 5 years as per law).
24. General Farm Hazards
Tape Gates
Risks:
● Low risk – elastic cords can snap back, causing injury.
Control Measures:
● Release carefully and avoid standing directly in front.
Offal Disposal & Dead Animals
Risks:
● Pathogen exposure risk.
Control Measures:
● Remain in tractor cabin when handling carcasses.
● Hose down bucket after use.
● Wear PPE when handling decomposing material. Firearms
Risks:
● High shooting risk if mishandled.
Control Measures:
● Follow the seven rules of firearm safety.
● Only licensed, trained individuals may operate firearms. ● Bolt guns only used by trained operators.
25. Environmental Hazards
Weather (Sun, Rain, Snow, Visibility, Wind, Storms) Risks:
● High risk of exposure-related health issues.
Control Measures:
● Wear appropriate clothing for conditions.
● Use sunblock and eye protection in high UV conditions. Bale Stacks
Risks:
● High risk of falling bales causing severe injury. Control Measures:
● Do not climb on bale stacks.
● Avoid working near unstable stacks.
Silos
Risks:
● High suffocation and fall risk.
Control Measures:
● Do not enter full silos.
● Use a buddy system when entering.
● Only climb silos with harnesses and proper training.
26. Machinery-Specific Hazards
Augers
Risks:
● High risk of entanglement.
Control Measures:
● Never reach into a running auger.
● Turn the tractor off before servicing.
● Do not wear loose clothing.
27. Equipment Hazards & Safety Controls
Angle Grinder
Risks:
● High-speed disc shattering, leading to severe injuries. ● Kickback from improper handling.
● Flying sparks and debris causing burns or eye injuries. ● Electric shock risk if used with damaged cords.
Control Measures:
● Always use the guard—never remove it.
● Wear safety glasses, face shield, gloves, and ear protection. ● Secure the workpiece to prevent movement.
● Use both hands and maintain a firm grip.
● Do not use a damaged or worn-out disc.
Bench Grinder
Risks:
● Eye injuries from sparks and debris.
● Wheel shattering if cracked or improperly installed. ● Hand injuries from getting pulled into the wheel.
Control Measures:
● Wear protective glasses and face shield.
● Keep tool rests adjusted close (1-2mm) to the wheel. ● Use light pressure to avoid overheating the wheel.
● Ensure guards and safety shields are in place. Drills (Handheld & Drill Press)
Risks:
● Hand injuries from slipping.
● Flying debris causing eye injuries.
● Entanglement with loose clothing.
● Kickback when drilling through tough material.
Control Measures:
● Wear safety glasses and gloves.
● Secure workpieces with clamps.
● Avoid loose clothing, jewelry, or gloves near rotating parts. ● Keep hands away from the drill bit.
Circular Saw
Risks:
● Severe cuts or amputations.
● Kickback causing loss of control.
● High noise exposure.
Control Measures:
● Wear safety glasses, gloves, and ear protection. ● Always use the blade guard.
● Keep fingers clear of the cutting path.
● Use a push stick for small pieces.
Electric Fence Unit
Risks:
● Electrocution hazard if improperly handled.
● Shock risk from damaged wires or improper grounding. Control Measures:
● Turn off power before maintenance.
● Use insulated gloves when handling live wires. ● Ensure proper grounding.
Air Compressor
Risks:
● Explosion risk if over-pressurized.
● Hearing damage from prolonged exposure.
● High-pressure air can cause serious injuries. Control Measures:
● Wear hearing protection.
● Drain moisture regularly to prevent corrosion. ● Never point air hoses at people.
Chemicals
Risks:
● Toxic exposure through skin or inhalation.
● Fire/explosion hazard.
Control Measures:
● Wear chemical-resistant gloves, goggles, and a mask. ● Store chemicals in labeled containers.
● Ensure proper ventilation.
Water Blaster
Risks:
● High-pressure water can penetrate the skin. ● Electrocution risk near electrical equipment.
Control Measures:
● Never spray towards people.
● Use waterproof gloves and boots.
● Keep water away from electrical outlets.
Welders (Arc & Gas)
Risks:
● Severe burns from sparks and heat.
● Eye damage from welding arc (flash burn). ● Gas explosion risk (for gas welding).
Control Measures:
● Always wear welding helmet and gloves.
● Ensure proper ventilation for fumes.
● Store gas cylinders upright and secured.
● Check gas fittings for leaks before use.
Hand Tools
Risks:
● Lacerations or impact injuries from misuse.
● Puncture wounds from sharp tools.
Control Measures:
● Keep tools in good condition.
● Use the right tool for the job.
● Store tools properly to prevent tripping hazards.
Chainsaws
Risks:
● Severe lacerations or amputations.
● Kickback leading to loss of control.
● Hearing damage.
Control Measures:
● Only trained and authorized staff may use chainsaws. ● Never use a chainsaw alone.
● Wear full PPE (helmet, chaps, gloves, glasses, ear protection). ● Ensure escape routes are clear.
● Always maintain a firm grip with both hands.
Fencing Equipment (Including Strainers)
Risks:
● Hand injuries from tensioned wire.
● Impact injuries from snapping wire.
Control Measures:
● Wear heavy-duty gloves.
● Use proper technique to tension wire safely.
Line Trimmer
Risks:
● Flying debris causing eye injuries.
● Lacerations from contact with blade.
Control Measures:
● Wear safety glasses and face shield.
● Do not remove guards.
● Avoid using near bystanders.
Generator
Risks:
● Electrocution risk in wet conditions.
● Carbon monoxide poisoning in enclosed spaces.
Control Measures:
● Only operate in dry conditions.
● Use a circuit breaker.
● Place generators outdoors with proper ventilation.
28. Falls – High Injury Risk
Risks:
● Falls from height (silos, vats, ladders).
● Slippery surfaces (feed pad, shed steps, middle pit).
● Injury from falling onto hard surfaces.
Control Measures:
● Use handrails and provided steps—never climb onto vats or silos. ● Keep surfaces clean—hose down algae growth monthly. ● Wear appropriate footwear with good grip.
29. Crushing Danger – High Injury Risk
Risks:
● High risk under platform and on the bridge.
● Serious injuries from backing gates, vet crush, and animals. Control Measures:
● Pull the red emergency cord before working under the platform. ● Communicate with others before entering hazardous areas. ● Always have an escape route when working with animals. ● Remain clear of backing gates—expect them to move at any time. ● Check the condition of ropes on backing gates regularly.
30. Animal Hazards – High Risk
Risks:
● Kicking, crushing, or pushing injuries.
● Particularly hazardous when administering drugs.
Control Measures:
● Be firm but quiet when handling animals.
● Follow Worksafe guidance and always have an escape route.
31. Chemical Hazards – High Risk
Risks:
● Mixing alkali and acid can create deadly mustard gas.
● Carcinogenic properties and severe burns from chemicals. ● Toxic refrigerant leak from the cooling system.
● Explosion and fire risks from stored hazardous substances. Control Measures:
● Refer to Material Safety Data Sheets (MSDS) for first aid information. ● Never mix chemicals without proper knowledge.
● If refrigerant leak is detected, call management immediately. ● Store spray cans away from heat sources.
32. Hot Water Hazards
Risks:
● Severe burns from pipes and hot cylinders.
● Risk of gumboots filling with hot water.
Control Measures:
● Secure cylinders to prevent earthquake hazards.
● Wear PPE—long sleeves, milking aprons, safety glasses, gloves. 33. Pressurised Water & Air Systems
Risks:
● Injury from plant wash air purge.
● Injury from pressurised teat spray and drafting systems. Control Measures:
● Do not remove hoses or fittings unless pressure is confirmed released. 34. Confined Spaces – High Risk
Risks:
● Asphyxiation, burns, and chemical exposure in confined spaces. ● High risk of suffocation in milk vats and silos.
Control Measures:
● Never enter a confined space without a buddy system. ● If vat entry is necessary, call Fonterra Assets team.
35. Electrical Hazards – High Risk
Risks:
● Electrocution risk in plant room and buried cables.
● Risk of electrical shock in wet areas.
● Extension cord at vet crush is particularly high risk.
Control Measures:
● Use Residual Current Devices (RCDs) when plugging in equipment. ● Do not open protective covers of electrical equipment. ● Keep electrical outlets dry—be mindful when using hoses.
36. Drugs & Needles – High Risk
Risks:
● Toxic exposure and injury from accidental needle sticks. Control Measures:
● Dispose of used needles in the sharps bin.
● Only remove needle cover when ready to use.
37. Automated Equipment
Risks:
● Drafting gates and irrigators may operate at any time. Control Measures:
● Remain clear of automated equipment during operation. 38. High Pressure Hoses & Equipment
Risks:
● Tripping hazards from hoses on the floor.
Control Measures:
● Store hoses against walls.
● Turn off taps when not in use.
39. Dust Hazards
Risks:
● Eye and respiratory irritation from dust.
Control Measures:
● Use dust masks and protective eyewear when needed. 40. Zoological Disease (Cryptosporidium, Leptospirosis, etc.) Risks:
● Risk of infection from animal fluids.
Control Measures:
● Use PPE and practice good hygiene.
● Avoid direct contact with animal fluids.
41. Effluent Ponds – High Drowning Risk
Risks:
● High risk of drowning if falling in.
● Children are at particular risk.
Control Measures:
● Two people must be present if working near the pond. ● Keep gates closed and supervise children.
42. Grain Mill & Silos
Risks:
● Crushing risk from grain mill.
● High fall and asphyxiation risk from silos.
Control Measures:
● Keep hands clear of the grain mill.
● Do not climb or enter silos on stands.
● Ground silos can be entered, but never alone.
● Remove ladders when silos are not in use to prevent climbing.
43. Grain Augers
Risks:
● Risk of entanglement with auger screw.
Control Measures:
● Only operate augers with guards in place.
● Disable augers before entering a silo.
44. Backing Gates – Medium Crushing Risk
Risks:
● The operator cannot see the gates when pushing the button. Control Measures:
● Remain clear of gates and always expect movement. ● Regularly inspect ropes and replace if worn.
45. Yards – High Risk of Injury from Animals
Risks:
● Crushing and kicking hazards in the yards.
Control Measures:
● Always have an escape route.
46. Vet Crush – High Kicking Risk
Risks:
● Severe injury if caught in kicking range.
Control Measures:
● Minimise time in the danger zone.
47. Occupational Overuse Syndrome (Repetitive Strain Injury) Risks:
● Injuries from repetitive milking or farm work.
Control Measures:
● Rotate tasks, swap hands, and take breaks when necessary.
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