Oxy-Acetylene Cutting SWMS
This SWMS covers oxy-acetylene cutting activities, addressing the specific hazards, risk controls and safe work procedures required under WHS Regulation 2025. While not classified as high-risk constru
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Oxy-acetylene cutting uses a fuel gas (acetylene) and oxygen to preheat metal and then cut it with a jet of high-purity oxygen. The process creates extreme heat (3,500°C), molten metal slag, fume, and noise. Acetylene is highly flammable and explosive — cylinders must be stored, transported and used with extreme care. Flashback and backfire are specific risks where flame travels back into the hose or regulator.
While this specific activity may not always constitute high-risk construction work under Schedule 1 of the WHS Regulation 2025, the PCBU's primary duty of care under Section 19 of the WHS Act 2011 (NSW) requires the systematic identification and control of workplace hazards. Preparing a SWMS for this activity demonstrates proactive compliance with that duty and provides auditable evidence of the risk management process. Many Principal Contractors require a SWMS for all construction activities regardless of HRCW status — this document meets that commercial requirement while also ensuring regulatory compliance. It is authored by a Certified Industrial Hygienist (CIH, MAIOH) against the current regulatory baseline, including the WHS Act 2011 and the WHS Regulation 2025.
Hazards identified
9 hazards covered, sorted by priority.
Fatal — explosion, fire This hazard requires specific controls documented in the SWMS hazard register with both inherent and residual risk ratings.
Hose fire, regulator explosion This hazard requires specific controls documented in the SWMS hazard register with both inherent and residual risk ratings.
Severe burns, fire below cutting area
Metal fume fever, zinc fume fever, respiratory irritation
Fire This hazard requires specific controls documented in the SWMS hazard register with both inherent and residual risk ratings.
Accelerated fire, clothing combustion
Eye damage, skin burns This hazard requires specific controls documented in the SWMS hazard register with both inherent and residual risk ratings.
Hearing damage This hazard requires specific controls documented in the SWMS hazard register with both inherent and residual risk ratings.
Stress This hazard requires specific controls documented in the SWMS hazard register with both inherent and residual risk ratings.
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Flashback arrestors fitted to BOTH torch and regulator on BOTH hoses — non-negotiable
- 2Cylinder storage: upright, secured, oxygen and acetylene separated by 3 metres or fire-rated barrier
- 3Leak testing of all connections with soapy water — never use oil or grease near oxygen fittings
- 4Never use acetylene above 100 kPa gauge pressure (acetylene decomposes explosively above this)
- 5Fire blanket or fire-resistant mat below cutting area to catch slag
- 6Fire extinguisher within 3 metres
- 730-minute fire watch after cutting
- 8Never use oxygen to dust off clothing — oxygen-saturated clothing ignites explosively
- 9P2 respirator when cutting coated metals (painted, galvanised, primed)
- 10Filter lens shade 4-6 for cutting (lower than welding)
- 11Pre-use inspection of hoses, connections, regulators, torch (psychosocial control — safe equipment = confidence)
- 12All workers must hold a valid White Card (General Construction Induction Training, CPCCWHS1001) before entering any construction workplace in Australia.
- 13Conduct a daily pre-start toolbox talk covering the day's work scope, identified hazards, required PPE, emergency procedures, and any changes since the previous shift. Record attendance and topics in the SWMS consultation section.
- 14PPE baseline for all workers: safety eyewear compliant with AS/NZS 1337.1, Class I or Class II safety footwear with protective toecap per AS/NZS 2210.3, high-visibility clothing where required by site rules, and task-specific RPE, hearing protection, and gloves as identified in the hazard register.
- 15Display the emergency plan at the work area showing first aid kit location, emergency contacts (000, site emergency number, nearest hospital with address), evacuation routes, and assembly point. Review with all workers at pre-start.
- 16Consult workers on WHS matters affecting them per Section 47 of the WHS Act 2011 (NSW). Record the consultation — who was consulted, what issues were raised, what was decided — in the SWMS consultation section. If an HSR has been elected, obtain their acknowledgement.
Applicable Codes of Practice
This Code becomes legally binding under Section 26A of the WHS Act from 1 July 2026. PCBUs must either comply with this Code or demonstrate that their alternative approach achieves an equivalent or higher standard of health and safety. SafeWork NSW inspectors can issue improvement notices specifically for non-compliance.
This Code becomes legally binding under Section 26A of the WHS Act from 1 July 2026. PCBUs must either comply with this Code or demonstrate that their alternative approach achieves an equivalent or higher standard of health and safety. SafeWork NSW inspectors can issue improvement notices specifically for non-compliance.
The foundational Code for all construction SWMS. Covers HRCW categorisation, SWMS preparation requirements, principal contractor duties, and general construction safety. Becomes legally binding under Section 26A from 1 July 2026.
The universal risk management Code applicable to all workplaces. Establishes the risk management framework (identify, assess, control, review) that underpins every SWMS. Legally binding from 1 July 2026.
Applies to the manual handling components of this activity. Covers risk factors (repetitive movement, sustained posture, force, vibration) and control strategies.
Who this is for
- →Welder or boilermakers performing oxy-acetylene cutting on construction sites across NSW and other Australian jurisdictions.
- →Apprentices and trainees in the welding trade working under the direct supervision of a qualified tradesperson, using this SWMS as part of their competency development.
- →Subcontractors engaged by a Principal Contractor who require a documented SWMS for oxy-acetylene cutting before commencing work on a managed construction site.
- →Self-employed tradespeople operating as a PCBU who need to demonstrate compliance with WHS Act s.19 primary duty of care for their own work activities.
- →WHS managers, site supervisors, and safety coordinators reviewing subcontractor SWMS documentation during pre-start and ongoing compliance checks.
What you receive
- ✓Editable Microsoft Word document (.docx) fully compatible with Microsoft Word 2016 and newer, Google Docs, and LibreOffice Writer.
- ✓Title page with editable fields for PCBU name, ABN, site address, project name, principal contractor details, and document revision date.
- ✓Signed approval block with signature lines for PCBU representative, Principal Contractor (if applicable), and nominated site supervisor.
- ✓Hazard register containing 9 hazards specific to oxy-acetylene cutting — each with a documented consequence, inherent risk rating (using a 5x5 likelihood-consequence matrix), hierarchy-of-control measures, and residual risk rating after controls are applied.
- ✓Control measures listed in hierarchy-of-control order (elimination, substitution, isolation, engineering, administrative, PPE) with cross-references to the specific WHS Regulation section, Code of Practice, or Australian Standard that mandates or recommends each control.
- ✓Worker consultation record section per WHS Act s.47 for documenting consultation with workers and HSRs on the content of this SWMS.
- ✓Worker sign-on register (blank, single page, expandable) for recording daily worker acknowledgement of the SWMS content, hazards, and required controls.
- ✓Applicable legislation and Codes of Practice schedule pre-populated for NSW with a state-variance reference table covering VIC (OHS Act 2004), QLD, SA, WA, TAS, NT, and ACT.
- ✓Emergency procedure template with fields for emergency contacts, nearest hospital, first aid officer, evacuation assembly point, and incident reporting procedure.
- ✓Revision log for documenting SWMS reviews, amendments, and version history as required by WHS Regulation r.300.
Worked example
A sole trader with one labourer is subcontracted to perform oxy-acetylene cutting at a car dealership showroom in Terrigal, western Sydney. The project is managed by a Principal Contractor under a $2.1 million head contract. Before mobilising to site, the welder or boilermaker downloads this SWMS and customises it: entering the PCBU name and ABN, the site address, and the Principal Contractor details on the title page. The 9 hazards are reviewed against the specific site conditions — acetylene explosion, flashback, molten metal and slag are confirmed as relevant. Although not classified as HRCW for this specific scope, the Principal Contractor requires a SWMS for all subcontractor activities as part of their WHS Management Plan. At the Monday pre-start meeting, the welder or boilermaker briefs the crew on the SWMS content, walks through the hazard register, confirms PPE requirements, and has all workers sign the sign-on register. The signed SWMS is stored in the site shed and a digital copy emailed to the PC's document controller. On Wednesday, an unexpected underground service is discovered — the SWMS is amended to add the new hazard, the crew is re-briefed, and all workers re-sign the updated version. The revision is logged in the revision history.
Related legislation
- Work Health and Safety Act 2011 (NSW) — Section 19 primary duty of care; Section 27 officer due diligence; Section 47 consultation with workers; Section 272 offences relating to duties.
- WHS Regulation 2025 (NSW) — r.298 (meaning of HRCW and when SWMS required), r.299 (preparation and content of SWMS), r.300 (review, update, and availability of SWMS).
- WHS Regulation 2025 (NSW) — Schedule 1 (18 categories of high-risk construction work).
- Code of Practice: Construction Work (SafeWork Australia, 2018) — principal contractor duties, SWMS requirements, site management obligations.
- WHS Act 2011 (NSW) — Section 26A (amendment commencing 1 July 2026): 34 approved Codes of Practice become legally binding duties.
- Building Code of Australia (National Construction Code, 2022) — applicable volumes and parts for the class of building work.
Frequently asked questions
What specific hazards does this Oxy-Acetylene Cutting SWMS cover?
This SWMS identifies and assesses 9 hazards specific to oxy-acetylene cutting, including acetylene explosion, flashback, molten metal and slag, and fume. Each hazard is documented with a realistic worst-case consequence, an inherent risk rating using a 5x5 likelihood-consequence matrix, specific control measures ordered by the hierarchy of controls, and a residual risk rating after controls are applied. The controls reference the applicable WHS Regulation section, Code of Practice, or Australian Standard so you can demonstrate regulatory compliance.
Is this SWMS written for WHS Regulation 2025 or 2017?
This SWMS is written against WHS Regulation 2025 (NSW) — the current regulation that commenced on 22 August 2025 and replaced the superseded WHS Regulation 2025. All regulation references (r.298, r.299, r.300, Schedule 1) cite the 2025 Regulation. Many competitor SWMS templates still reference the 2017 Regulation — those templates are referencing repealed legislation and should not be used without updating the regulatory citations.
Can I use this SWMS in states other than NSW?
Yes, with amendments. The SWMS includes a state-variance reference table covering all Australian jurisdictions. For Queensland, South Australia, Tasmania, NT, ACT, and Western Australia, the core WHS framework is similar (model WHS Act) and the amendments are minor — primarily regulator contact details and penalty unit values. Victoria requires more significant amendment because it operates under the OHS Act 2004 and OHS Regulations 2017, uses different terminology (Compliance Codes rather than Codes of Practice), and does not have Section 26A. The state-variance table identifies the key differences for each jurisdiction.
How do I customise this SWMS for my specific project?
Open the DOCX in Microsoft Word and complete the title page fields — PCBU name, ABN, site address, project name, and Principal Contractor details. Review the 9 hazards against your actual site conditions: confirm which hazards apply, add any site-specific hazards not already listed (e.g. proximity to a school, heritage constraints, contaminated ground), and adjust control measures to reflect your available equipment, crew competencies, and site access arrangements. Replace the emergency contacts with the actual site emergency number, nearest hospital, and your first aid officer. Add your company logo to the document header. Have the PCBU sign the approval block, brief all workers on the content, and collect sign-on register signatures before work commences.
Is this SWMS compliant with the Section 26A changes commencing 1 July 2026?
Yes. From 1 July 2026, 34 approved Codes of Practice become legally binding under Section 26A of the WHS Act (NSW). A PCBU must either comply with each applicable Code or demonstrate an equivalent or higher standard. This SWMS already cites the relevant Codes that will become binding — no amendment is required for the July 2026 transition. The applicable Codes are listed in the legislation schedule with their Section 26A status clearly marked.
Document details
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