Welding SWMS Template
Safe Work Method Statement for MIG, TIG, stick, and oxy-fuel welding on construction and fabrication sites
What This SWMS Covers
This SWMS covers welding operations including MIG (GMAW), TIG (GTAW), stick (SMAW/MMAW), oxy-acetylene cutting and welding, flux-cored arc welding (FCAW), and plasma cutting performed on construction sites or during on-site fabrication and maintenance. Welding becomes HRCW when performed at heights above 2m, in confined spaces, near flammable/explosive atmospheres, or near energised electrical installations.
Who Needs This SWMS
Boilermakers, welders (MIG/TIG/MMAW), fitters, metal fabricators, maintenance workers performing hot work, principal contractors engaging welding subcontractors on construction sites
Key Hazards & Control Measures
| Hazard | Risk Level | Control Measures | Hierarchy |
|---|---|---|---|
| Welding fume inhalation | Serious–Critical | LEV at source (fume extraction arm/on-gun extraction), natural ventilation positioning, P2/P3 RPE as interim control, fume exposure limit 1 mg/m³ TWA | Engineering / PPE |
| Manganese exposure (mild steel welding) | Serious | LEV + RPE, manganese-specific air monitoring, health monitoring for neurological symptoms, low-manganese consumables where feasible | Engineering / Substitution / PPE |
| Chromium VI exposure (stainless steel welding) | Critical | LEV mandatory, supplied-air RPE for sustained stainless welding, Cr VI air monitoring, health monitoring, WEL 0.05 mg/m³ | Engineering / PPE |
| UV radiation (arc eye, skin burns) | Serious | Auto-darkening helmet (shade 10–13), full coverage clothing (no exposed skin), welding curtains/screens for bystanders, UV signage | PPE / Engineering |
| Fire / explosion | Fatal | Hot work permit, 10m fire-free zone, fire watch during and 30 min after, fire extinguisher and fire blanket within 3m, remove/cover combustibles | Administrative |
| Electric shock (MMAW/GTAW) | Fatal | Dry gloves and clothing, insulated electrode holders, earth clamp positioned correctly, RCD protection, voltage reduction device (VRD) | Engineering / PPE |
| Burns (spatter, slag, hot work) | Moderate | Full-length leather gloves, leather apron/jacket, spatter-resistant footwear, hot work signage | PPE |
| Compressed gas hazards (oxy-fuel) | Critical | Cylinders secured upright in trolley, flashback arrestors on both lines, cylinder valve caps during transport, 3m separation between oxygen and fuel | Engineering / Administrative |
| Noise exposure | Moderate | Hearing protection during grinding/hammering, noise assessment for sustained arc gouging, quieter processes where feasible | PPE / Substitution |
| Confined space welding | Fatal | Confined space entry permit, continuous atmospheric monitoring (O₂, LEL, CO), forced ventilation, rescue plan, supplied-air RPE | Administrative / Engineering |
PPE Requirements
Frequently Asked Questions
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