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Hydraulic Systems Risk Assessment

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Generate Risk Assessments in 4 Easy Steps: Complete the assessment details below, then add risks from our pre-populated library or create custom ones. Add your logo and signatures, save your document, then share it with staff and workers to collect electronic signatures—ensuring everyone has read and understood the risk assessment. Export to PDF anytime!

Assessment Details

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Risk Assessments

How to add risks: Use Add from Library for pre-written templates, or Add Custom to write your own.

Choose what goes in the document: Every risk is included by default — untick the box on any you don't want in the document.

Edit a risk: Click anywhere on the row to expand it and edit the details — ticked or unticked, both can be edited.

Step 1 must be completed before you can manage and edit the risks. Fill in the assessment details on Step 1 and click Next Step to unlock.

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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 hydraulic systems risk assessment template is designed for manufacturing operatives, maintenance engineers and plant technicians who need a quick, compliant way to assess the hazards of working on hydraulic equipment in factories and production lines. Whether you’re performing routine maintenance on hydraulic presses, troubleshooting a hydraulic lift, or cleaning a hydraulic tank, this hydraulic system risk assessment example provides pre‑filled hazards and control measures you can customise.

The template covers all key risks associated with hydraulic systems, including high‑pressure fluid release, unexpected start‑up, slip hazards from fluid leaks, chemical exposure to hydraulic fluid, noise, vibration, manual handling of heavy components and confined‑space entry for tank cleaning. It also references relevant legislation such as the Provision and Use of Work Equipment Regulations 1998 (PUWER) (HSE PUWER guidance), the Control of Substances Hazardous to Health Regulations 2002 (COSHH) (HSE COSHH essentials) and the Pressure Systems Safety Regulations 2000 (PSSR) (HSE PSSR guidance).

Use this template for:

  • Risk planning during scheduled maintenance shutdowns – identify hydraulic hazards before work starts.
  • Worker briefings and permit‑to‑work preparation – provide clear, actionable control measures.
  • Compliance documentation – demonstrate adherence to PUWER, COSHH and PSSR requirements.

Each hazard includes suggested control measures covering isolation and lock‑off procedures, safe drainage, personal protective equipment, safe working speeds, noise and vibration control and environmental spill containment. The risk matrix uses a standard 5×5 likelihood‑severity scoring, with controlled severity always 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 plant conditions, then download as a PDF for records or share with your team.

Compliant with: PUWER 1998, COSHH 2002, Pressure Systems Safety Regulations 2000.

Sample PDF Document Image:

Risks covered in this Working on Hydraulic Systems risk assessment

This Working on Hydraulic Systems risk assessment template covers 13 assessed hazards, each scored before and after control measures on a 5×5 HSE risk matrix.

HazardInitial riskControlled risk
Unexpected machine start‑up during maintenance2510
High‑pressure fluid release2010
Confined‑space entry for hydraulic tank cleaning2010
Failure of pressure relief valve leading to over‑pressure2010
Pinch points from moving pistons and cylinders168
Working at height to access overhead hydraulic equipment155
Electrical hazards from hydraulic pump motors155
Hydraulic fluid leak – slip and fire hazard124
Overheating of hydraulic fluid124
Thermal burns from hot hydraulic fluid during servicing124
Noise exposure from hydraulic pumps93
Hand‑arm vibration from hydraulic tools93
Chemical exposure to hydraulic fluid (COSHH)93

Frequently asked questions

Are these risk assessment templates really free to download?

Yes — completely free. Over 1500 free UK risk assessment templates, free to use forever, no signup required for guests, 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 1500 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 1500 pre-written templates you can customise to your specific workplace.

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

No — guests can generate and download risk assessments for free without signing up. Register a free account if you want to save documents to your dashboard, edit them later, or 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.