Welding SWMS: Cheatsheet with 20 hazard & controls (Free PDF)
Covers arc and gas welding, cutting, grinding and fabrication for structural steel and site metalwork. No signup, no email required.
Hazards & controls
1. Arc eye (flash burn) and UV radiation exposure to eyes and skin
- ✓ Welding helmet with correct filter shade worn for the process and current
- ✓ Welding screens set up to shield bystanders and other trades
- ✓ Long sleeves and gloves worn to cover exposed skin
2. Exposure to welding fume (manganese, metal oxides, chromium)
- ✓ Local exhaust ventilation or fume extraction used at the point of welding
- ✓ P2/P3 respirator worn where extraction is not sufficient
- ✓ Welding scheduled in well-ventilated areas where practical
3. Fire from sparks, spatter or hot work igniting nearby combustibles
- ✓ Hot work permit obtained before welding or cutting near combustible materials
- ✓ Combustible materials removed or shielded within the spark radius
- ✓ Fire extinguisher and fire watch maintained during and after hot work
4. Electric shock from welding equipment or damaged leads
- ✓ Welding leads and equipment inspected before each use
- ✓ Damaged leads or connectors taken out of service immediately
- ✓ Equipment earthed and tested per manufacturer requirements
- ✓ Welding not carried out in wet conditions without additional isolation
5. Burns from hot metal, slag, spatter or the welding torch
- ✓ Leather gloves and flame-resistant clothing worn during welding and cutting
- ✓ Hot workpieces marked or segregated until cooled
- ✓ Slag chipped away from the body, not toward other workers
6. Explosion or fire from oxy-acetylene or LPG gas cylinders
- ✓ Cylinders stored upright, secured and separated by class
- ✓ Flashback arrestors fitted to hoses and regulators
- ✓ Hoses and fittings inspected for leaks before use
- ✓ Cylinders shut off and hoses depressurised at the end of each shift
Show all 20 hazards & controls
7. Confined space welding fume build-up and oxygen depletion
- ✓ Atmosphere tested before and during welding in confined spaces
- ✓ Forced ventilation used for all confined space welding
- ✓ Standby person and rescue plan in place for confined space entry
8. Contact with energised electrical installations during welding or cutting repairs
- ✓ Services located and isolated before welding or cutting near switchboards or cabling
- ✓ Isolation confirmed and tested before work begins
- ✓ Licensed electrician engaged for any service relocation
9. Metal fume fever from welding zinc-coated (galvanised) or painted metal
- ✓ Coatings removed or ground back before welding where practical
- ✓ Local exhaust ventilation used for coated or painted metal
- ✓ Symptoms reported and work stopped if metal fume fever is suspected
10. Manual handling of steel sections, plate and fabricated assemblies
- ✓ Mechanical lifting aids used for heavy or long steel sections
- ✓ Team lifts used for awkward assemblies
- ✓ Materials staged close to the welding position
11. Falls from height during elevated welding or fabrication work
- ✓ Edge protection or guardrails installed before elevated welding begins
- ✓ Harness and anchor point used for work above 2 metres
- ✓ EWP or scaffold used for elevated work, not ladders
12. Noise exposure from grinding, air arc gouging and fabrication tools
- ✓ Hearing protection worn for all high-noise tools
- ✓ Task rotation used to limit individual exposure duration
- ✓ Low-noise tool selection used where available
13. Eye and hand injuries from grinding, cutting discs and wire brushing
- ✓ Guards fitted and checked on grinders and cutting equipment
- ✓ Safety glasses or face shield worn for grinding and wire brushing
- ✓ Cut-resistant gloves worn during grinding and edge preparation
14. Struck by mobile plant or vehicles on active fabrication or construction sites
- ✓ High-visibility clothing worn at all times on site
- ✓ Spotter used when working near reversing plant
- ✓ Site traffic management plan followed
15. Silica or metal dust exposure from grinding and surface preparation
- ✓ On-tool dust extraction used for grinding and surface preparation
- ✓ P2 respirator worn for extended grinding tasks
- ✓ Work area ventilated during and after grinding
16. Bystander exposure to arc flash, UV radiation or spatter
- ✓ Welding screens or curtains erected around the work area
- ✓ Exclusion zone maintained for non-welding personnel
- ✓ Warning signage displayed during active welding
17. Fire re-ignition from smouldering material after hot work is complete
- ✓ Fire watch maintained for at least 30 minutes after hot work finishes
- ✓ Work area rechecked before leaving it unattended
- ✓ Fire extinguisher kept accessible throughout the fire watch period
18. Hand-arm vibration from extended use of grinders and power tools
- ✓ Tool use time limited and rotated between crew members
- ✓ Low-vibration tools selected where available
- ✓ Any tingling or numbness reported and reviewed
19. Heat stress from welding in enclosed or hot working environments
- ✓ Hydration breaks scheduled during hot conditions
- ✓ Ventilation or cooling used in enclosed welding areas
- ✓ Work rescheduled to cooler parts of the day where practical
20. Trip and struck-by hazards from welding leads, hoses and cables across walkways
- ✓ Leads and hoses routed away from walkways and elevated where practical
- ✓ Work area kept clear of offcuts and packaging
- ✓ Cords and hoses inspected for damage before use
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Welding SWMS Cheatsheet
All 20 hazards & controls for structural and fabrication welding, cutting and grinding, laid out as a printable one-pager for your site file.
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Frequently asked questions
What is a SWMS?
A Safe Work Method Statement (SWMS) is a legally required document for high-risk construction work. It sets out the job steps, the hazards involved, and the controls you'll use to manage them before work starts.
Do I need a SWMS for structural and fabrication welding, cutting and grinding?
If the work falls into one of the 18 high-risk construction work categories under the WHS Regulations, a SWMS is mandatory before work can start. This template is pre-mapped to the categories that typically apply to welding work of this kind.
Is this template really free?
Yes. Join with your Google account in 10 seconds, no card required, and it's saved to your account ready to customise, publish and get signed by your crew online.
Can I use this template as-is?
Treat it as a starting point, not a finished document. Every site is different — add your site-specific hazards, confirm the controls suit the actual job, and have it reviewed before workers sign it.
This template is a starting point only. Review and adapt it for your actual site conditions before use — it is not a substitute for a competent person's own risk assessment.