SAE AMS2700G

For example:

1. A large machine is installed.
2. Pipework is added.
3. Electrical equipment is installed.
4. Maintenance access is considered afterward.
5. A narrow platform is added around the equipment.

This approach can create difficult access arrangements.

A better process is:

Equipment Layout → Maintenance Requirements → Access Route → Platform → Stairs/Ladder → Edge Protection

This allows access requirements to influence the design from the beginning.

AS 1657:2018 AND INDUSTRIAL MAINTENANCE

Maintenance personnel often work in areas that normal operators rarely visit.

This can include:

– Roof spaces
– Elevated platforms
– Machinery platforms
– Pipe racks
– Processing equipment
– Plant rooms
– Service areas

These locations may be more challenging than normal working areas.

A properly designed fixed access system can make maintenance activities more predictable and reduce unnecessary exposure to fall hazards.

COMMON ACCESS DESIGN PROBLEMS

PROBLEM 1: ACCESS ADDED TOO LATE

When access is treated as an afterthought, available space may be insufficient.

PROBLEM 2: EQUIPMENT BLOCKS THE ROUTE

Pipes, cables, ducts or machinery can reduce available clearance.

PROBLEM 3: INCONSISTENT STAIR DIMENSIONS

Variations can make movement less predictable.

PROBLEM 4: POOR TRANSITION BETWEEN LADDER AND PLATFORM

The point where a worker leaves a ladder and enters a platform requires careful design.

PROBLEM 5: MISSING OR INADEQUATE EDGE PROTECTION

Open platform edges can create fall hazards.

PROBLEM 6: POOR SURFACE CONDITION

Corrosion, contamination or deterioration can affect the usability of a walkway.

PROBLEM 7: INSUFFICIENT MAINTENANCE SPACE

Workers may be able to reach equipment but cannot safely perform the required maintenance task.

DESIGNING AN AS 1657:2018 ACCESS SYSTEM

A practical design process can follow these steps.

STEP 1 — IDENTIFY THE TASK

Determine why workers need access.

Is the purpose:

– Inspection?
– Operation?
– Cleaning?
– Maintenance?
– Repair?
– Emergency access?

STEP 2 — DETERMINE FREQUENCY

Frequent access may require a different solution from occasional access.

STEP 3 — MAP THE ROUTE

Identify the complete path from the normal working area to the destination.

STEP 4 — SELECT THE ACCESS TYPE

Consider whether the location requires:

– Stairways
– Ladders
– Platforms
– Walkways
– Landings

STEP 5 — ADD EDGE PROTECTION

Consider handrails, guardrails and other relevant protective features.

STEP 6 — CHECK CLEARANCES

Review the relationship between the access system and surrounding equipment.

STEP 7 — REVIEW THE FINISHED INSTALLATION

The final system should be assessed as a complete access arrangement rather than as individual components.

INSPECTION OF EXISTING FIXED ACCESS SYSTEMS

Existing access systems should not be ignored simply because they were installed many years ago.

Regular inspection can identify:

– Corrosion
– Cracked welds
– Loose fasteners
– Damaged grating
– Bent components
– Missing handrails
– Damaged ladders
– Deteriorated surfaces
– Structural movement
– Unauthorised modifications

The inspection should consider both the physical condition and the current use of the access system.

A system that was suitable ten years ago may no longer be appropriate after equipment or building modifications.

WHAT SHOULD BE CHECKED DURING AN ACCESS INSPECTION?

A practical inspection can consider several areas.

STRUCTURE

Check for:

– Corrosion
– Cracking
– Deformation
– Damaged connections
– Loose components

WALKING SURFACE

Check for:

– Damage
– Excessive wear
– Slippery contamination
– Missing sections
– Deterioration

STAIRWAYS

Check:

– Step condition
– Consistency
– Handrails
– Guardrails
– Landings

LADDERS

Check:

– Rungs
– Side members
– Connections
– Access points
– Surrounding clearance

PLATFORMS

Check:

– Platform condition
– Edge protection
– Access openings
– Structural support
– Working clearance

AS 1657:2018 FOR NEW CONSTRUCTION PROJECTS

For a new industrial facility, access should be considered during the engineering and architectural design stages.

A coordinated design process may involve:

Structural Design

↓

Equipment Layout

↓

Maintenance Planning

↓

Access Design

↓

Stairways and Ladders

↓

Platforms and Walkways

↓

Guardrails and Handrails

↓

Inspection and Commissioning

This approach can reduce expensive modifications later.

AS 1657:2018 FOR EXISTING FACILITIES

Existing facilities can present a different challenge.

Older access systems may have been installed under previous requirements or modified multiple times.

A practical assessment can begin with:

– What access systems exist?
– What equipment do they serve?
– How frequently are they used?
– Have they been modified?
– Are there visible defects?
– Are access routes obstructed?
– Have surrounding conditions changed?
– Is the current arrangement still suitable?

This can help identify areas that require detailed engineering review.

WHY COMPLIANCE SHOULD NOT BE TREATED AS A CHECKBOX

A common approach to standards is:

Compliant / Non-Compliant

However, access safety requires more context.

A technically compliant component can still be affected by:

– Poor maintenance
– Environmental contamination
– Equipment changes
– Obstructions
– Corrosion
– Unauthorised modifications

Therefore, effective access management should combine:

Design + Installation + Inspection + Maintenance + Change Management

AS 1657:2018 QUICK REVIEW CHECKLIST

ACCESS ROUTE

– Is there a clear route to the work area?
– Is the route suitable for its intended frequency of use?
– Are there unnecessary obstacles?

PLATFORMS

– Is the platform suitable for the intended task?
– Is the walking surface maintained?
– Is appropriate edge protection provided?

WALKWAYS

– Is the route clear?
– Is the surface suitable for the environment?
– Are changes in level properly addressed?

STAIRWAYS

– Are steps consistent?
– Are handrails and guardrails in good condition?
– Are landings appropriate?

LADDERS

– Are ladders structurally sound?
– Are rungs and connections secure?
– Is the transition to the destination safe?

MAINTENANCE

– Is corrosion controlled?
– Are damaged components repaired?
– Are modifications recorded?
– Are inspections documented?

FREQUENTLY ASKED QUESTIONS

What is AS 1657:2018?

AS 1657:2018 is an Australian Standard covering fixed platforms, walkways, stairways and ladders that provide access to and within workplaces.

Why is AS 1657 important?

It provides a recognised framework for designing and constructing fixed access systems intended to support safer movement and work in industrial environments.

Does AS 1657 apply to ladders?

Yes. Fixed ladders are one of the access systems covered by the standard.

Does AS 1657 cover platforms?

Yes. Fixed platforms used for workplace access and related activities are included within its scope.

Does AS 1657 cover handrails and guardrails?

Handrails and guardrails form important parts of the access systems addressed by the standard.

Can AS 1657 be used for existing access systems?

The standard is commonly considered when assessing fixed workplace access systems, but the applicable requirements for an existing installation can depend on the project, jurisdiction, legislation and circumstances.

Is AS 1657 only for factories?

No. Fixed workplace access systems can be found across many industries, including manufacturing, mining, energy, utilities, processing plants and other industrial environments.

FINAL THOUGHTS

AS 1657:2018 is fundamentally about providing practical and safe fixed access to workplaces.

The most effective access system is not necessarily the one with the largest platform or the most complicated design.

It is the system that allows workers to reach their destination, perform the required task and return safely.

Good access design should therefore consider the entire journey:

Where does the worker start?

How do they get there?

What obstacles exist along the route?

What work needs to be performed?

How do they safely leave the area?

For industrial facilities, incorporating these questions into the design, inspection and maintenance process can help create more reliable fixed access systems.

AS 1657:2018 should be considered as part of a broader workplace safety and engineering process, together with applicable legislation, building requirements, structural considerations and site-specific risk assessments.

Safe access begins with good design — and continues with regular inspection and maintenance.