Galvanised Steel Welding SWMS
Welding and cutting galvanised steel generates zinc oxide fume that causes metal fume fever, a flu-like illness characterised by chills, fever, nausea, and muscle pain that typically resolves within 48 hours but can recur with each exposure. Older galvanised coatings may also contain lead, cadmium, or chromate primers that generate highly toxic fume requiring specific respiratory protection beyond standard welding RPE. The fume generation rate from galvanised steel welding is significantly higher than from uncoated steel, and standard workshop ventilation is often inadequate to control exposure. This template maps controls to the binding Welding Processes and Hazardous Chemicals Codes of Practice effective 1 July 2026 under Section 26A.
SWMS variants reference your state's WHS legislation. Instant download after payment.
Legal Requirements
WHS Regulation 2025 Part 7.1 — Hazardous Chemicals
Hot work with toxic fume generation
Welding Processes, Managing Risks of Hazardous Chemicals (binding 1 July 2026 under Section 26A)
Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.
Hazards
| Hazard | Consequence | Likelihood |
|---|---|---|
| Zinc oxide fume inhalation causing metal fume fever | Flu-like illness, recurrent episodes with repeated exposure | Almost Certain |
| Lead fume from older galvanised coatings containing lead | Lead poisoning, neurological damage, kidney damage | Possible |
| Cadmium fume from cadmium-plated or older galvanised components | Acute cadmium poisoning, lung damage, kidney failure, death | Unlikely |
| Manganese fume from the base steel and welding consumable | Manganism, neurological damage | Likely |
| Standard welding hazards amplified by dense fume production | Reduced visibility, increased fume inhalation | Likely |
| Chromate primer fume if galvanised surface has been painted | Chromium VI exposure, lung cancer | Possible |
Controls (Hierarchy of Controls)
Recent Prosecutions
Workers exposed to metal fume and hazardous substances without adequate ventilation or health monitoring.
2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]
Apprentice injured during welding operations with inadequate training, supervision, and safety controls.
2022 — SafeWork NSW v KML Auto Parts Pty Ltd [2022]
What Your SWMS Must Include
Related SWMS
SWMS templates for this work
🔥Welding SWMS
MIG, TIG, stick, and oxy welding on structural steel, pipework, and fabrication on site and in workshops.
🔥Galvanised Steel Welding SWMS
This SWMS covers galvanised steel welding activities, addressing the specific hazards, risk controls and safe …
🏗️Structural Steel SWMS
Structural steel erection, bolting, welding, and decking on commercial and industrial construction.
Need a compliant Galvanised Steel Welding SWMS?
Our WHS consultants build coating-specific SWMS that address zinc oxide fume, lead testing, and health surveillance for your galvanised steel welding operations.
Contact Us