Fabrication of structural steel beams and columns for a commercial building frame. Work involves oxy-acetylene cutting of steel plate and sections, MIG and stick welding of structural connections, grinding of weld preparations and completed welds, and assembly of components on fabrication jigs. All work conducted within a dedicated workshop bay with overhead crane access.
This SWMS does not cover site erection of fabricated steelwork, surface treatment (blasting/painting), or transport of completed assemblies.
| Hazard | Inherent Risk | Control Measures | Residual Risk |
|---|---|---|---|
| Fire and explosion Sparks, slag, and molten metal from welding/cutting igniting combustible materials; oxy-acetylene cylinder leaks or flashback |
4 x 5 = 20 Extreme |
Elimination Remove all combustible materials within 10m radius of hot work area; non-combustible flooring in workshop Engineering Flashback arrestors fitted to all oxy-acetylene regulators; cylinders stored upright and secured with chains Engineering Fire extinguishers (dry chemical and CO2) within 5m of all hot work stations; fire blanket available Administrative Hot work permit system for any work outside designated welding bays; fire watch for 30 minutes after hot work ceases |
2 x 5 = 10 High |
| Burns Contact with hot metal, sparks, slag, or UV radiation causing skin burns to welder and nearby workers |
4 x 3 = 12 High |
Isolation Welding screens (dark-tinted) positioned around welding bays to protect adjacent workers from sparks and UV Administrative Hot metal marked with soapstone "HOT" and allowed to cool in designated area before handling PPE Leather welding jacket, gauntlet welding gloves, leather apron, and spats covering boot tops PPE Long-sleeved cotton clothing (no synthetic fabrics) for all personnel in hot work area |
2 x 3 = 6 Medium |
| Welding fumes Inhalation of metal fumes (iron oxide, manganese, chromium, zinc) from MIG and stick welding processes |
4 x 4 = 16 High |
Substitution Use low-fume welding consumables where structurally acceptable Engineering Local exhaust ventilation (LEV) — articulated fume extraction arm positioned within 300mm of weld zone at all times Engineering General workshop ventilation with minimum 6 air changes per hour PPE P2 particulate respirator when welding in positions where LEV cannot be effectively positioned (overhead welds) |
2 x 4 = 8 Medium |
| UV radiation (arc eye) Exposure to intense UV radiation from welding arc causing photokeratitis (arc eye) and skin burns |
4 x 3 = 12 High |
Isolation Welding screens around all active welding stations; warning signs "Welding in Progress — Do Not Look at Arc" Engineering Auto-darkening welding helmets with appropriate shade number (Shade 10-12 for MIG, Shade 10-14 for stick) PPE Safety glasses with side shields (AS/NZS 1337) worn under welding helmet and at all times in workshop PPE All exposed skin covered — no short sleeves or open collars in welding area |
2 x 3 = 6 Medium |
| Electric shock Contact with live welding circuit — electrode holder, work clamp, or damaged cables carrying welding current |
3 x 5 = 15 High |
Engineering Voltage reducing device (VRD) fitted to all stick welding machines to reduce open-circuit voltage to safe levels Engineering All welding leads inspected daily for insulation damage; damaged leads replaced immediately Administrative Welding machines electrically tested and tagged; RCD protection on supply circuits PPE Dry leather welding gloves; insulated welding boots; never weld on wet surfaces |
1 x 5 = 5 Medium |
| Noise exposure Sustained noise from grinding (up to 105 dBA), hammering, and general workshop activity exceeding 85 dBA TWA |
4 x 3 = 12 High |
Substitution Use flap discs instead of grinding wheels where possible — lower noise output by 5-8 dBA Engineering Acoustic barriers between grinding stations and other work areas Administrative Schedule grinding work to minimise concurrent noise sources; noise monitoring with dosimeters PPE Class 5 earmuffs (AS/NZS 1270) mandatory in all designated hearing protection zones |
2 x 3 = 6 Medium |
If fire cannot be extinguished with available extinguishers within 60 seconds, evacuate the workshop immediately. Close cylinder valves if safe to do so. Activate the building fire alarm and call 111. Account for all personnel at the assembly point. Do not re-enter until cleared by Fire and Emergency NZ.
For thermal burns, cool the affected area under running water for 20 minutes. Do not remove clothing stuck to burns. For arc eye symptoms (gritty, painful eyes), irrigate with clean water and seek medical attention. Do not rub eyes. Apply eye pads and arrange transport to emergency department.
All workers must read and understand this SWMS before commencing work. By signing below, each worker confirms they have been briefed on the hazards, controls, and emergency procedures, and agree to follow them.
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