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Plasma Cutting SWMS

Plasma cutting uses a high-temperature ionised gas jet to cut electrically conductive metals at speeds significantly faster than oxy-acetylene cutting. The process generates extreme noise levels often exceeding 100 dB(A), dense metal fume, ozone, nitrogen dioxide, and intense UV radiation. When cutting stainless steel, plasma generates chromium VI fume at concentrations that can exceed the incoming WEL of 0.005 mg/m³ within minutes of cutting. Water tables reduce fume and noise but do not eliminate airborne contaminants. This template maps controls to the binding Welding Processes Code of Practice effective 1 July 2026 under Section 26A.

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SWMS variants reference your state’s WHS legislation. Instant download after payment.

Legal Requirements

regulation

WHS Regulation 2025 Part 7.1 — Hazardous Chemicals and Part 4.3 — Noise

hrcw category

Hot work near flammable atmosphere

code of practice

Welding Processes, Managing Noise and Preventing Hearing Loss (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

Hazards

HazardConsequenceLikelihood
Noise exposure exceeding 100 dB(A) during plasma cuttingPermanent noise-induced hearing loss.Almost Certain
Metal fume and ozone inhalation from plasma arcPulmonary oedema, chronic respiratory disease.Likely
Chromium VI fume from cutting stainless steelLung cancer, nasal cancer.Likely
Intense UV radiation from plasma arcSevere arc eye, skin burns, skin cancer.Likely
Molten metal projection from cutting operationBurns, eye injuries.Likely
Electrical shock from plasma torch and workpieceElectrocution, cardiac arrest.Unlikely

Controls (Hierarchy of Controls)

Use water table plasma cutting systems to reduce fume and noise at source
Install downdraft extraction on CNC plasma tables with minimum 0.5 m/s face velocity
Provide Class 5 hearing protection for operators and bystanders within the noise zone
Fit-test P2 or powered air-purifying respirators for all plasma cutting operators
Enclose CNC plasma cutting tables with physical barriers and interlocked extraction
Conduct personal noise exposure monitoring at least annually to verify controls
Provide shade 10-14 welding helmets or face shields with UV protection for manual plasma cutting
Implement chromium VI air monitoring when cutting stainless steel to verify WEL compliance

Recent Prosecutions

Orica Australia Pty Ltd$1,200,000

Workers exposed to metal fume and dust without adequate ventilation or health monitoring, resulting in occupational lung disease.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

BI Australia Pty Ltd$400,000

Safety failures during metal fabrication operations resulting in serious worker injuries.

2025 — SafeWork NSW v BI Australia Pty Ltd [2025]

What Your SWMS Must Include

✓Noise exposure assessment and hearing protection selection for plasma cutting areas
✓Fume extraction specifications for CNC and manual plasma cutting stations
✓Material identification procedure to determine chromium VI monitoring requirements
✓UV protection requirements for operators and bystanders
✓Water table maintenance schedule and water treatment procedures

Need a compliant Plasma Cutting SWMS?

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