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End-of-Line Product Testing (Pressure and Electrical) Risk Assessment

Free Risk Assessment template · Category: ManufacturingView all Risk Assessment templates
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Risk Assessments

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Risk Assessment Matrix

Risk Assessment Matrix

Likelihood

  • 5 = Certain
  • 4 = Likely
  • 3 = Possible
  • 2 = Unlikely
  • 1 = Remote

Severity

  • 5 = Fatality
  • 4 = Major Injury
  • 3 = Lost Time Injury
  • 2 = Minor injury
  • 1 = Trivial Injury

Risk Rating [L x S]

1-5 = Low
6-12 = Medium
13-25 = High

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Risk Assessment Description:

This free end-of-line product testing risk assessment template is designed for manufacturing operatives, machine operators and maintenance staff who carry out final pressure and electrical testing of products before release. Whether you’re performing pressure leak checks on hydraulic assemblies, verifying burst‑pressure ratings, conducting insulation resistance tests, or performing high‑voltage functional checks, this end‑of‑line product testing risk assessment example provides pre‑filled hazards and control measures you can customise.

The template covers key risks such as over‑pressurisation of test rigs, accidental release of pressurised fluids, failure of pressure relief devices, unexpected energisation of equipment, arc‑flash exposure, inadequate earthing, damaged test leads, manual handling of heavy test fixtures, noise from pressure releases and slip hazards from fluid spills. Additional manufacturing‑specific hazards include inadequate guarding on moving test‑rig components, overheating of electrical test equipment during prolonged use, and exposure to cleaning solvents used for de‑contamination. It also includes manufacturing safety assessment keywords like pressure testing hazards, electrical testing hazards, factory testing procedures and compliance documentation.

Use this template for:

  • Pre‑test planning – identify hazards and allocate safe systems of work before testing begins.
  • Operator briefings – provide clear, actionable controls to the test crew.
  • Compliance records – demonstrate adherence to the Pressure Systems Safety Regulations 2000, PUWER 1998 and Electrical Safety at Work Regulations 1992.

Each hazard includes suggested control measures covering isolation procedures, lock‑out/tag‑out, regular equipment inspection, PPE, safe discharge methods and emergency response. The risk matrix uses a standard 5×5 likelihood‑severity scoring, with controlled severity matching the initial severity as required by HSE guidance.

Fully editable and shareable – customise hazards, add site‑specific risks, adjust control measures to match your conditions, and download as a PDF for records or share with your team.

Compliant with: Pressure Systems Safety Regulations 2000 (PSSR) – HSE, Provision and Use of Work Equipment Regulations 1998 (PUWER) – HSE, Electrical Safety at Work Regulations 1992 – HSE.

Sample PDF Document Image:

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Risks covered in this End-of-Line Product Testing (Pressure and Electrical) risk assessment

This End-of-Line Product Testing (Pressure and Electrical) risk assessment template covers 15 assessed hazards, each scored before and after control measures on a 5×5 HSE risk matrix.

HazardInitial riskControlled risk
Over‑pressurisation of test equipment leading to rupture2010
Unexpected energisation of electrical test equipment2010
Damaged test leads or connectors168
Failure of pressure relief valve during test155
Arc‑flash exposure during high‑voltage functional testing155
Overheating of electrical test equipment during prolonged use155
Release of hazardous pressurised fluid causing burns128
Inadequate earthing/grounding of test rigs124
Inadequate guarding on moving test‑rig components124
Failure of safety interlock devices on test rigs124
Manual handling of heavy test rigs and pressure vessels93
Slips, trips and falls due to fluid spills93
Exposure to cleaning solvents used for de‑contamination of test rigs63
Exposure to high‑frequency electromagnetic fields (EMF) from electrical testing equipment63
Noise exposure from pressure release events42

Frequently asked questions

Are these risk assessment templates really free to download?

Yes - completely free. Over 1900 free UK risk assessment templates, free to use forever, no paywall. Customise to your workplace and download as a professional HSE-compliant PDF in minutes.

Can I download risk assessment templates in PDF or Word format?

Risk assessments download as a professional, HSE-compliant PDF - ready to print and file as-is. Word (.docx) export is not available for risk assessments, but you can fully customise every hazard, control measure, persons-at-risk entry and rating online before you download.

Are the risk assessment templates HSE-compliant?

Yes. Every template aligns with HSE guidance and the HSE 5-Step Risk Assessment process. They cover the requirements of the Management of Health and Safety at Work Regulations 1999, COSHH 2002, Manual Handling Operations Regulations 1992, Work at Height Regulations 2005, and other relevant UK regulations.

What industries do the risk assessment templates cover?

Over 1900 templates across every UK industry - painting, electrical, HVAC, plumbing, carpentry, concrete, solar panel installation, asbestos, scaffolding, working at height, manual handling, fall protection, hot works, confined space entry, lifting operations, kitchen fitting, plumbing, drywall, tiling, plastering, and many more.

What's the difference between a risk assessment form and a risk assessment template?

A risk assessment form is the blank document; a risk assessment template is a pre-filled form ready to customise. Our generator gives you both - a free interactive form you fill in plus over 1900 pre-written templates you can customise to your specific workplace.

Do I need to create an account to use the risk assessment templates?

You can build and preview a risk assessment without an account. To download the PDF you'll need a free account - it takes less than a minute, costs nothing, and also lets you save documents to your dashboard, edit them later, and share them for digital signatures.

Can I customise the risk assessment templates to my workplace?

Yes - fully. Edit hazards, control measures, persons at risk, likelihood and severity ratings, PPE requirements, and review schedules. Each template is a starting point you tailor to your specific operation.

How many risks can I add to a single risk assessment?

The number of risks (hazards) you can include in one assessment depends on your plan: guests get unlimited risks, Free accounts unlimited risks, Standard unlimited risks, Pro unlimited risks, and Enterprise unlimited risks per assessment. You can add and preview every risk in a template, then tick the ones to include up to your plan limit - upgrade any time for more. See our pricing page for the full plan comparison.

Are these risk assessment templates valid for UK construction work?

Yes. Our construction-specific risk assessment templates align with HSE construction guidance, the Construction (Design and Management) Regulations 2015 (CDM 2015), and the Work at Height Regulations 2005. Templates cover scaffolding, working at height, concrete pouring, excavation, roofing, electrical installation, and more.

How often should I update my risk assessment?

Whenever there is reason to believe the assessment is no longer valid - after workplace changes, near-misses, accidents, new equipment, new substances, or new processes. HSE guidance recommends an annual formal review at minimum.

What is the HSE 5-step risk assessment process?

Step 1: Identify the hazards. Step 2: Decide who might be harmed and how. Step 3: Evaluate the risks and decide on precautions. Step 4: Record findings and implement them. Step 5: Review the assessment and update if necessary. Our interactive generator walks you through all 5 steps.

Can I use these risk assessment templates for self-employed work?

Yes. Self-employed workers are required to assess risks to themselves and anyone affected by their work. Our templates are suitable for sole traders, contractors, and small businesses.

Do you have RIDDOR-aligned risk assessment templates?

Yes. Several templates cover RIDDOR (Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 2013) requirements - including accident reporting and investigation risk assessments. All RA templates support incident logging and review.