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Workshop risk assessment template (PDF & Excel) – pre-filled

Pre-filled risk assessment for workshops in trades, industry and maintenance with 23 typical hazards – from machines and electrical work to welding, noise and dust, ladders and cranes – with measures, legal bases under German law and inspection intervals.

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Workshops in trades, industry and maintenance bring many hazards together: machines and power tools, welding and grinding, noise, vibration, dust, metalworking fluids and solvents, lifting equipment and ladders. Here, the risk assessment (Gefährdungsbeurteilung) under Sections 5 and 6 of the Occupational Safety and Health Act (ArbSchG) is supplemented by the Industrial Safety Ordinance (BetrSichV), the Hazardous Substances Ordinance (GefStoffV) and the Noise and Vibration Ordinance (LärmVibrationsArbSchV).

The template uses the same structure as our general risk assessment template and comes pre-filled with 23 typical hazards and common measures – each with its legal basis. You add the rating, owners and deadlines yourself; a second overview lists the periodic inspections and instructions in the workshop, with automatic due dates in Excel.

What the template contains

  • Landscape PDF with 23 pre-filled hazards from machines and electrical work to welding, noise and dust, cranes and ladders
  • Same structure as the general risk assessment: hazard factor, risk rating, STOP measures, deadlines, effectiveness
  • Excel spreadsheet with drop-down lists and automatic risk calculation
  • Overview of 12 periodic inspections and instructions – in the PDF and as an Excel sheet that calculates the next due date

How to use the template

  1. 1

    Adapt the template

    Delete rows that do not apply and add your machines, processes and hazardous substances – such as CNC machines, painting or work at customer sites. Individual machines and hazardous substances also need their own operating instructions.

  2. 2

    Check and rate on site

    Walk through the workshop, look at safety devices, extraction systems and inspection labels and talk to employees. Have noise, vibration and hazardous substances assessed competently, for example using manufacturer data or measurements.

  3. 3

    Follow up measures and inspections

    Enter owners and deadlines, check effectiveness after implementation and keep the dates for equipment tests, crane and vehicle lift inspections, extraction systems and instructions up to date in the second sheet.

Risk assessments in AMS GoIndustry templates, AI suggestions for typical workshop hazards, photos of the current situation and measures with deadlines in the action plan – with a history of every change.

Legal basis

  • Sections 5 and 6 ArbSchG: risk assessment and documentation
  • Sections 3, 6, 10 and 12 BetrSichV: work equipment, safety devices, maintenance, instruction
  • Sections 6, 7 and 14 GefStoffV with TRGS 401, 528 and 553: hazardous substances, skin contact, welding fumes, wood dust
  • LärmVibrationsArbSchV and the Ordinance on Occupational Health Care (ArbMedVV): action values for noise and vibration, occupational health care
  • DGUV Regulation 3 and DGUV Regulation 52: electrical installations and equipment, cranes

Frequently asked questions

Is one risk assessment enough for the whole workshop?

For similar working conditions, yes (Section 5 (2) ArbSchG). Machines with special hazards, welding stations, work with hazardous substances and maintenance work on installations, however, need their own rows or a separate assessment. For hazardous substances, the assessment must be carried out before work starts (Section 6 GefStoffV).

Which occupational health care do workshop employees need?

That depends on the risk assessment. Common triggers are noise (offered above 80 dB(A), mandatory from 85 dB(A)), hand-arm vibration (offered above 2.5 m/s², mandatory from 5 m/s²), welding fumes (offered, mandatory if 3 mg/m³ is exceeded) and wet work, for example with water-mixed metalworking fluids (ArbMedVV Annex).

May apprentices work on machines?

Yes, if this is necessary for the training objective and a competent person supervises them (Section 22 (2) of the Youth Employment Protection Act, JArbSchG). Young people receive instruction before starting work and then at least every six months (Section 29 JArbSchG).

You may use and adapt the template freely in your own company and for your own clients. It reflects the regulations named as they stand.

Never search a spreadsheet for a deadline again

In AMS Go, what this template covers lives in one system with reminders, history and records at the push of a button – mobile and with AI support.

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