Galvanised Steel Welding SWMS
Welding and cutting galvanised, zinc-coated, and zinc-alloy steel. Metal fume fever prevention, zinc oxide controls, emergency response.
SWMS variants reference your stateβs WHS legislation. Instant download after payment.
Welding, cutting, grinding or brazing galvanised steel releases zinc oxide fume that can rapidly cause metal fume fever β a flu-like illness with fever, chills, muscle aches and respiratory irritation typically presenting 4 to 12 hours after exposure. The hot work decomposes the zinc coating well before the underlying steel reaches melting point, generating ultrafine particulate that easily bypasses standard nuisance dust masks. In addition to zinc oxide, galvanised coatings frequently contain trace lead, cadmium and aluminium, each of which carries its own toxicological profile and exposure standard under the Workplace Exposure Standards for Airborne Contaminants.
Under the model Work Health and Safety Act 2011 and WHS Regulation 2025 Part 4.1 (Hazardous Chemicals) and Part 3.1 (General Workplace Management β Airborne Contaminants), a Person Conducting a Business or Undertaking (PCBU) must ensure no worker is exposed above the Workplace Exposure Standard (WES) for zinc oxide, currently 2 mg/mΒ³ (inhalable) as a TWA. Regulation 49 requires the PCBU to ensure exposure is monitored where there is uncertainty, and Regulation 50 mandates health monitoring where there is a significant risk of exposure to a hazardous chemical with adverse health effects.
A Safe Work Method Statement is the principal documented control demonstrating how zinc fume risks are eliminated or minimised so far as is reasonably practicable, in line with the Safe Work Australia Welding Processes Code of Practice 2021 and AS/NZS 1715:2009 respiratory protection guidance. Although galvanised steel welding is not in itself a High Risk Construction Work category under Regulation 291, regulators including SafeWork NSW and WorkSafe Victoria treat metal fume fever as a notifiable serious illness, and a SWMS is a critical due-diligence record for officers under section 27 of the WHS Act.
Hazards identified
8 hazards covered, sorted by priority.
Fever, chills, nausea, respiratory inflammation 4β12 hours post-exposure; repeated episodes linked to chronic respiratory effects
Cumulative neurotoxicity, kidney damage, reproductive harm; exceedance of WES for lead (0.05 mg/mΒ³) and cadmium (0.01 mg/mΒ³)
Rapid accumulation of zinc oxide fume to many multiples of the WES; oxygen displacement; loss of consciousness
Filter penetration by ultrafine fume <0.3 ΞΌm; assigned protection factor insufficient for measured exposure
Flash fire, burns, secondary ignition of nearby combustibles; toxic smoke from burning oils
Arc-eye (photokeratitis), skin burns, long-term skin cancer risk; flash exposure to bystanders
Delayed reporting, repeated unrecognised exposure, progression to chemical pneumonitis
Ingestion exposure, take-home contamination of family members, breach of Reg 49 control hierarchy
Control measures
Hierarchy-of-controls order: elimination β substitution β isolation β engineering β administrative β PPE.
- 1Eliminate where reasonably practicable by specifying ungalvanised stock for items welded in-shop, or by removing the zinc coating mechanically (grinding with HEPA-extracted tool) for a minimum 50 mm either side of the weld line before striking an arc
- 2Provide on-tool Local Exhaust Ventilation (LEV) β fume extraction torch (MIG-on-gun) or movable capture hood positioned within 300 mm of the arc, with capture velocity β₯0.5 m/s verified by smoke tube or anemometer at the start of each shift
- 3Conduct atmospheric monitoring in accordance with AS 3640:2009 for the first three shifts of any new galvanised welding task, with results compared against the zinc oxide WES of 2 mg/mΒ³ (inhalable, 8-hour TWA) and the short-term excursion limit of 10 mg/mΒ³
- 4Issue Powered Air Purifying Respirators (PAPR) with P3 particulate filters (minimum APF 50) for all galvanised welding; disposable P2 half-face respirators are NOT acceptable for routine galvanised work
- 5Implement health monitoring under WHS Regulation 50 for workers welding galvanised material more than 4 hours per week, including baseline and periodic urinary zinc and, where coatings contain lead, blood lead per Schedule 14
- 6Establish a documented hot-work permit system with 30-minute fire watch post-completion, suitable extinguishers (COβ and dry powder) within 10 m, and removal of combustibles within a 11 m radius per AS 1674.1
- 7Provide dedicated change facilities, lockers separating street and work clothing, and laundering of fume-contaminated overalls by the PCBU β workers must not take contaminated clothing home
- 8Brief all welders on metal fume fever symptoms, the 4β12 hour latency, the duty to report under WHS Act s.28, and the prohibition on self-medicating with paracetamol/ibuprofen prior to medical assessment
- 9Restrict galvanised welding in confined spaces to permit-controlled entry under WHS Reg Part 4.3, with continuous mechanical ventilation delivering β₯20 air changes per hour and atmospheric monitoring
- 10Prohibit eating, drinking and smoking in the welding area; provide wash facilities meeting AS 4024 hygiene requirements at the boundary of the work zone
Applicable Codes of Practice
Primary code defining acceptable controls for fume, radiation and hot work; compliance presumed to discharge WHS duty under s.26A
Applies to zinc oxide fume as a hazardous chemical; sets out risk assessment and control hierarchy
Establishes the legally enforceable 2 mg/mΒ³ TWA for zinc oxide (inhalable) and standards for trace metals in coatings
Mandatory reference for PAPR selection, fit testing and assigned protection factors
Performance requirements for P3 filters used in galvanised welding PAPR systems
Hot-work permit, fire watch and combustible clearance requirements
Sampling methodology for zinc oxide exposure monitoring against the WES
Who this is for
- βBoilermakers and structural welders fabricating from galvanised RHS, SHS, purlins or handrail
- βMaintenance fitters cutting or repair-welding galvanised plant, walkways and access structures
- βMetal fabrication shop supervisors and PCBUs responsible for hot-work permit systems
- βWHS managers and CIHs designing exposure monitoring and health surveillance programs
- βApprentice welders and labourers assisting with grinding, fit-up and weld preparation on coated steel
- βSite managers on construction projects where galvanised members are welded in-situ
What you receive
- βFully editable Microsoft Word (DOCX) SWMS pre-populated for galvanised steel welding
- βState-specific legislation schedule covering NSW, VIC, QLD, WA, SA, TAS, ACT and NT WHS Regulations 2025
- βHazard register with all 8 identified hazards, risk-rated using a 5Γ5 matrix aligned to ISO 31000
- βWorker sign-on register meeting WHS Reg 39 consultation evidence requirements
- βPre-start atmospheric monitoring checklist referencing zinc oxide WES of 2 mg/mΒ³
- βPAPR daily inspection and fit-test record template aligned to AS/NZS 1715
- βHot work permit template compliant with AS 1674.1
- βMetal fume fever symptom recognition card for issue to each welder
- βHealth monitoring referral letter template for occupational physicians under WHS Reg 50
Worked example
A fabrication shop in Wetherill Park is welding a galvanised steel mezzanine balustrade β approximately 60 metres of 50 NB galvanised pipe handrail to galvanised RHS posts. The welder, Daniel, reviews this SWMS at pre-start with his leading hand. Following the elimination control, Daniel uses a HEPA-extracted angle grinder to remove zinc coating 50 mm either side of each joint, captures the swarf into a labelled waste drum, and confirms the bright bare steel before tacking. He fits up the MIG torch with the integrated on-gun fume extraction set to 200 mΒ³/h and dons his 3M Versaflo PAPR with P3 filter, fit-tested under AS/NZS 1715 the previous month. Mid-morning, the shop CIH conducts personal monitoring per AS 3640. The 4-hour TWA returns 0.8 mg/mΒ³ zinc oxide β within the 2 mg/mΒ³ WES but triggering the SWMS review point at 50% of the standard. Daniel notices a metallic taste at lunch and reports it under the SWMS communication procedure; the supervisor stands him down from galvanised work for the remainder of the shift, documents the early symptom in the health monitoring log, and arranges a same-day GP review. Because the SWMS process was followed, the symptom is captured before progressing to full metal fume fever, the exposure record satisfies SafeWork NSW inspector enquiry, and the officer due-diligence trail under WHS Act s.27 is intact.
Related legislation
- Work Health and Safety Act 2011 (Cth model) β sections 19, 27, 28
- Work Health and Safety Regulation 2025 β Part 3.1 Airborne Contaminants (Reg 49β50)
- Work Health and Safety Regulation 2025 β Part 4.1 Hazardous Chemicals
- Work Health and Safety Regulation 2025 β Part 4.3 Confined Spaces
- Workplace Exposure Standards for Airborne Contaminants (Safe Work Australia, 2024)
- Hazardous Chemical Information System (HCIS) β Zinc oxide entry
- Poisons Standard (SUSMP) β relevant where coatings contain lead pigments
Frequently asked questions
Is welding galvanised steel classified as High Risk Construction Work (HRCW)?
No. Galvanised steel welding does not fall within any of the 18 HRCW categories listed in WHS Regulation 291. However, a SWMS is still strongly recommended β and treated by regulators as expected practice β because zinc oxide is a hazardous chemical under WHS Regulation Part 4.1, and metal fume fever is a notifiable serious illness in most jurisdictions. The SWMS also forms a key part of officer due diligence under WHS Act s.27.
Can a P2 disposable mask be used for galvanised welding?
No. P2 disposables are not acceptable for routine galvanised welding. Zinc oxide fume is in the ultrafine range (<0.3 ΞΌm) and produced at concentrations that frequently exceed the assigned protection factor of a half-face P2 (APF 10). This SWMS specifies a Powered Air Purifying Respirator with P3 filters (APF 50) selected and fit-tested in accordance with AS/NZS 1715:2009.
What is the legal exposure standard for zinc oxide fume?
The Safe Work Australia Workplace Exposure Standard for zinc oxide is 2 mg/mΒ³ as an 8-hour Time Weighted Average (inhalable fraction), with a Short Term Exposure Limit of 10 mg/mΒ³ over 15 minutes. These values are legally enforceable under WHS Regulation 49, and exceedance is a contravention regardless of whether a worker reports symptoms.
Do I need health monitoring for welders working with galvanised steel?
Health monitoring is required under WHS Regulation 50 where there is a significant risk of exposure to a hazardous chemical with known adverse health effects. For workers welding galvanised material more than 4 hours per week, or where atmospheric monitoring shows exposures above 50% of the WES, this SWMS triggers baseline and periodic monitoring including urinary zinc and (where lead is present in coatings) blood lead under Schedule 14.
How quickly does metal fume fever appear after welding galvanised steel?
Symptoms typically appear 4 to 12 hours after exposure, often after the worker has gone home. The latency means workers frequently mistake the illness for influenza. This SWMS includes a symptom recognition card and a mandatory reporting clause under WHS Act s.28 so that delayed-onset cases are captured, medically reviewed and recorded for trend analysis.
Is this SWMS valid in all Australian states and territories?
Yes. The SWMS is built on the model WHS Act 2011 and WHS Regulation 2025 framework adopted in NSW, QLD, SA, TAS, ACT, NT and WA, and is supplied with a Victorian schedule mapping equivalent provisions of the OHS Act 2004 and OHS Regulations 2017. The state-specific legislation schedule is updated to reflect 2025 regulatory amendments.