1
Site requirements differ, and operatives do not stay put.
One site wants a particular card scheme and a client induction, another adds task-specific requirements, a third has its own rules again. The same operative is ready for one and blocked on the next, and a spreadsheet per project stops working the first time crews are moved mid-week.
The risk: an operative turned away at the gate on the morning of a pour.
2
Cards and tickets expire on their own schedules.
Card schemes, plant and equipment tickets, working at height, confined space, asbestos awareness, first aid and face fit testing all renew on different intervals. There is no single date to watch, which is why lapses tend to be found late.
The risk: work done by someone whose ticket expired last month.
3
Equipment training is a legal duty, not a nice-to-have.
PUWER requires that people using work equipment have received adequate training, including in the risks and the precautions. That is a per-person, per-equipment record, and it is usually the one nobody can produce quickly.
The risk: no evidence of training for the plant someone was operating.
4
You are accountable for people you do not employ.
On a multi-contractor site the principal contractor is expected to be able to show that everyone on site is competent and inducted, subcontracted crews included. Collecting that by email, per subcontractor, per project, produces an answer that is out of date before it is filed.
The risk: prequalification stalling on paperwork you cannot produce.