Structural Bolting & Torquing SWMS
SWMS template for structural bolting & torquing. Covers Bolt grade, torque verification, slip-critical joints.. 8-state AU coverage, CIH-reviewed editable DOCX, available as an instant download.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
Structural bolting and torquing is the critical load-transfer activity that ties fabricated steel members into a stable frame, and it is performed almost exclusively at height on partially erected structures where the work platform, the load path and the connection itself are all in transition. The work involves handling high-strength bolt assemblies (typically 8.8 and 10.9 grade), positioning them through aligned holes, snug-tightening, then achieving the design preload through turn-of-nut, calibrated wrench or direct tension indicator methods in accordance with AS 4100 and AS/NZS 5131. Because the task is performed at heights above 2 metres on incomplete structures, involves powered torque tools generating significant reaction forces, and presents a continuous falling-object exposure to workers below, it falls squarely within High Risk Construction Work under WHS Regulation 2011 r291. A documented Safe Work Method Statement is therefore mandatory before work commences, must be developed in consultation with the bolting crew, and must remain accessible on site for the duration of the activity.
Hazards identified
7 hazards covered, sorted by priority.
Fatal or catastrophic injury from falls exceeding 2 metres; PCBU prosecution under WHS Act s32 reckless conduct provisions
Penetrating head trauma, fatality, or third-party injury triggering Category 1 offence and worksite shutdown
Fractured radius, rotator cuff tear, or worker thrown from platform leading to secondary fall injury
Cumulative lumbar disc injury, shoulder impingement, workers compensation claims and lost-time injury notifications
Joint slip under service load, progressive frame instability, structural failure and AS 4100 non-conformance
Hand-arm vibration syndrome, noise-induced hearing loss exceeding 85 dB(A) exposure standard under WHS Reg r57
Degloving, amputation of fingertips, crush fractures requiring surgical intervention and notifiable incident reporting
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Elimination — Where design permits, specify shop-installed or ground-level pre-bolted sub-assemblies lifted as a single module so the connection is made before exposure to height.
- 2Elimination — Sequence the erection so all permanent edge protection, perimeter handrails and infill flooring are installed prior to commencing bolt-up of the next tier.
- 3Substitution — Replace pneumatic impact wrenches with electric shear-wrench tools for tension control bolts (TCB) to eliminate compressed air hoses and reduce noise and vibration exposure.
- 4Substitution — Use direct tension indicator (DTI) washers in lieu of turn-of-nut on slip-critical joints to remove subjective torque judgement and provide visual verification per AS/NZS 1252.
- 5Engineering — Install continuous catch platforms, debris nets and kickboards beneath all bolting zones, with hard barricades and signage establishing a 6-metre exclusion zone at ground level.
- 6Engineering — Provide tool tethering lanyards rated to tool weight, bolt bags with closed tops, and magnetic socket retainers to eliminate dropped-object events per AS/NZS 5532.
- 7Administrative — Issue a calibrated torque tool register with monthly calibration certificates, bolt grade colour-coding system, and a documented torque verification log signed by the bolting supervisor.
- 8Administrative — Conduct daily pre-start SWMS sign-on, exclusion zone walk, and confirm joint sequence with the engineer's bolt-up procedure before any torque is applied.
- 9PPE — Mandatory dual-point harness with shock-absorbing lanyard anchored to engineered anchor or static line rated to AS/NZS 1891, with rescue plan rehearsed weekly.
- 10PPE — Hard hat with chin strap, impact gloves (EN 388 4X42F), Class 5 hi-vis, safety glasses, Class 5 hearing protection and steel-cap boots worn continuously in the work area.
Applicable Codes of Practice
Mandates bolt category (4.6/S, 8.8/S, 8.8/TB, 8.8/TF), tensioning method and inspection regime for snug-tight and fully tensioned joints.
Sets the bolting execution class, qualification of bolting personnel and documentation of torque verification records required for sign-off.
Triggered by all work above 2 m on structural steel; requires hierarchy of fall control, anchor design and documented rescue procedures.
Requires a SWMS before commencement, consultation with workers, monitoring of control effectiveness and retention of the SWMS for the project duration.
High-Risk Construction Work triggered
Bolt-up of beam-to-column and splice connections is performed on partially erected frames where unprotected leading edges routinely exceed 2 metres in height.
Incorrect torque sequence, mismatched bolt grade or premature de-rigging of temporary bracing during bolting can cause partial or full frame collapse during erection.
Bolts, washers, sockets, drift pins and torque tools are continuously handled overhead, creating a direct falling-object exposure to workers and public below.
PCBU must prepare, consult on and monitor the SWMS before HRCW commences and retain it for the project duration; penalties are substantial and indexed, with the current maximum following the prevailing WHS schedule.
Who this is for
- →Structural steel erectors and bolting crews on commercial builds
- →Principal contractors managing Tier 1 and Tier 2 steel packages
- →Site supervisors and steelwork foremen coordinating bolt-up sequences
- →WHS managers and engineering consultants auditing AS 4100 compliance
What you receive
- ✓Editable DOCX template — Microsoft Word compatible
- ✓State-specific WHS legislation schedule (NSW/VIC/QLD/SA/WA/TAS/NT/ACT)
- ✓Hazard register with risk ratings + hierarchy-of-control mapping
- ✓Worker sign-on register, pre-start checklist, and incident escalation flow
Worked example
On a four-storey commercial frame project in a regional industrial estate, the bolting crew arrives at 6:30 am to complete the level 3 perimeter beam-to-column connections. The leading hand opens the Structural Bolting & Torquing SWMS at the site shed and walks the three-person crew through the hazard register, flagging the leading-edge fall risk on grid line E where decking is not yet installed and the slip-critical splice at grid C4 that requires DTI washers. Each worker signs the SWMS sign-on sheet, confirming they hold a current working-at-heights ticket and have inspected their harness. The crew walks the exclusion zone, establishing hard barricades 6 metres from the building footprint and posting a spotter. During the morning shift, the supervisor identifies that the wind has picked up to 38 km/h, exceeding the SWMS trigger of 35 km/h for handling loose bolt buckets at height. Work pauses, the SWMS is re-opened, and the crew documents the change: bolt buckets are now hoisted in closed-lid containers rather than open trays, and tool tethers are re-checked. The amendment is initialled by all three workers and the supervisor. At smoko the torque verification log is updated with calibrated wrench readings for each TF joint, providing the engineer's hold-point evidence required under AS/NZS 5131.
Related legislation
- WHS Act 2011 (model)
- WHS Regulation 2025
- Managing the Risk of Falls at Workplaces CoP