Thermite / Aluminothermic Welding SWMS
SWMS template for thermite / aluminothermic welding. Covers Cad-weld bonding for earthing, rail crossover.. 8-state AU coverage, CIH-reviewed editable DOCX delivered within 24 hours of payment.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
Thermite (aluminothermic) welding uses an exothermic reaction reaching 2500°C to fuse copper conductors or rail joints. Common for earthing bonds (Cad-weld) and rail crossovers. Triggers WHS Regulation 2011 r291 high-risk construction work due to molten metal ejection, fire risk and metal fume exposure requiring documented SWMS before ignition.
Hazards identified
3 hazards covered, sorted by priority.
Severe burns, ignition of clothing or surroundings
Metal fume fever, respiratory irritation
Bushfire, plant damage, third-party injury
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Dry crucible and conductors per AS/NZS 1768; preheat to eliminate moisture-induced ejection.
- 2Establish 3m fire exclusion zone, charged extinguisher, hot work permit and fire watch 60 minutes post-weld.
- 3Wear leather gauntlets, face shield, P2 respirator and flame-resistant clothing during ignition and tap.
Applicable Codes of Practice
Specifies aluminothermic bonding requirements for earthing systems.
Hot work, fume control and PPE duties under WHS Act.
High-Risk Construction Work triggered
Not applicable — listed only where rail crossover work intersects civil structures.
Rail corridor thermite welding occurs near track machines and rail traffic interfaces.
Without SWMS before HRCW commences, PCBU faces Category 2 WHS prosecution.
What you receive
- ✓Editable Microsoft Word DOCX SWMS template, fully customisable to your project
- ✓State-specific WHS legislation schedule covering all 8 Australian jurisdictions
- ✓Pre-populated hazard register aligned to thermite welding risks
- ✓Worker sign-on register meeting WHS Regulation r300 consultation requirements
Related legislation
- WHS Act 2011 s19 — Primary duty of care
- WHS Regulation 2011 r291 — High Risk Construction Work SWMS
- WHS Regulation 2011 r49 — Airborne contaminant exposure standards