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Welding and fabrication · Australia

SWMS for steel fabrication

By Safety PaperworkBuilt from Safe Work Australia and state regulator guidance · How we write and check theseUpdated

Yes. Steel fabrication usually includes high risk construction work (work in an area with movement of powered mobile plant), so a SWMS is required by law before work starts.

It must list the hazards, the controls and how they will be put in place, monitored and reviewed, and the workers must be consulted and sign before starting. The main hazards are welding and cutting fumes, being hit by mobile plant, fire from hot works and saw cuts and kickback.

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SWMS example: steel fabrication

This is a complete SWMS for steel fabrication, with 6 job steps. Open it in the builder to add your site, crew and signatures, change anything, and download a PDF. Or download the free Word template below and fill it in by hand.

Safe Work Method Statement (SWMS)
Workshop steel fabrication · Welding and fabrication · Example
Document SWMS-001 · Rev 1

High risk construction work covered

Work in an area with movement of powered mobile plant

Job steps, hazards and controls

#Job stepHazardsRisk beforeControlsRisk after
1Move steel with a forklift or overhead crane, keeping walkways clear
  • Being hit by mobile plant
  • Crane and lifting failure
Extreme
  • Separate people and plant with barriers, exclusion zones and marked walkways. Isolate
  • Use plant with working reversing alarms, cameras and lights. Engineering
  • Have a traffic management plan showing plant routes, loading areas and pedestrian paths. Administrative
  • Use a spotter when reversing or working near people. Administrative
  • Make eye contact with the operator before going near. Stay out of the swing radius. Administrative
  • Operators hold a High Risk Work Licence where needed (for example forklift) and are trained and assessed on other plant. Administrative
  • Do a pre-start check on each machine every day and record it. Administrative
  • Wear hi-vis clothing and a hard hat. PPE
  • Barricade the lift zone and keep everyone out from under the load. Isolate
  • Use a crane rated for the load at the radius, set up on firm ground with outrigger pads. Engineering
  • Check slings, chains, shackles and hooks before use. Remove anything damaged or not tagged. Engineering
  • Plan the lift: weight, radius, ground, path and landing area. Use a written lift plan for complex lifts. Administrative
  • Crane operators and doggers or riggers hold the right High Risk Work Licence. Administrative
  • Use tag lines to control loads and agree on clear radio or hand signals. Administrative
  • Stop lifting in high wind or when the operator cannot see the signaller. Administrative
  • Never ride on a load or hook. Administrative
  • Wear a hard hat, hi-vis, gloves and safety boots. PPE
Medium
2Cut and drill steel with guards in place
  • Saw cuts and kickback
  • Angle grinder injuries
  • Loud noise
High
  • Keep blade guards fitted and working, and use the riving knife on table saws. Engineering
  • Use push sticks and clamps, and support long pieces so they do not pinch the blade. Engineering
  • Use a sharp, undamaged blade made for the material. Administrative
  • Stand to one side of the blade line, out of the kickback path. Administrative
  • Let the blade stop fully before reaching in or putting the saw down. Administrative
  • Use a guarded saw or a different tool where you can. Substitute
  • Keep the guard on and use the side handle. Never remove the guard. Engineering
  • Use the right disc for the job, rated for the grinder's speed. Check it for cracks first. Administrative
  • Only trained people change discs, with the grinder unplugged or the battery out. Administrative
  • Keep both hands on the grinder and let the disc stop before putting it down. Administrative
  • Use quieter tools and methods, such as cut-to-size materials, low-noise machines and battery tools. Substitute
  • Keep noisy plant away from work areas, and use screens or distance between the noise and people. Isolate
  • Keep tools maintained and use mufflers on compressors and generators. Engineering
  • Limit time on noisy tools and rotate workers. Administrative
  • If you have to shout to be heard 1 metre away, wear hearing protection. Administrative
  • Keep exposure below 85 dB(A) over 8 hours. Give hearing tests to workers who often need hearing protection. Administrative
Medium
3Weld in a booth with extraction
  • Welding and cutting fumes
  • Eye injuries
  • Fire from hot works
Extreme
  • Remove paint, galvanising and coatings from the weld area first, or use a process that makes less fume. Substitute
  • Use fume extraction (local exhaust ventilation) close to the weld. Engineering
  • Weld outdoors or in a well-ventilated area, and keep your head out of the fume plume. Engineering
  • Never weld or cut in a confined space without testing the air and using forced ventilation. Administrative
  • Wear a powered air respirator or fitted respirator when extraction is not enough. PPE
  • Use tool guards and screens to stop flying particles. Engineering
  • Use dust extraction and water to keep dust out of the air. Engineering
  • Keep others out of the area when cutting, grinding or chipping. Administrative
  • Keep an eye wash station or eye wash bottles on site. Administrative
  • Wear safety glasses at all times, goggles for dust and chemicals, and a face shield for grinding. PPE
  • Use cold work methods where you can, such as bolting, press fittings or cutting with a saw instead of a torch. Eliminate
  • Move anything that can burn at least 15 metres away (AS 1674.1), or protect it with fire blankets or screens. Isolate
  • Use fire-resistant screens to stop sparks reaching people or gaps in walls and floors. Engineering
  • Get a hot work permit before starting. Administrative
  • Keep a charged fire extinguisher and fire blanket at the work spot. Administrative
Medium
4Handle hot and sharp parts with gloves
  • Burns from hot surfaces
  • Cuts from sharp edges
Medium
  • Isolate heating systems and let parts cool before you touch them. Eliminate
  • Fit guards or insulation on hot pipes and equipment. Engineering
  • Mark hot items with chalk or a "HOT" sign so others know. Administrative
  • Keep a first aid kit and cool running water nearby for burns. Administrative
  • Wear heat-resistant gloves and long sleeves. PPE
  • Deburr or cover sharp edges, and fit edge protectors on exposed sheet metal. Engineering
  • Use knives with retractable or self-retracting blades. Engineering
  • Cut away from your body and keep your other hand clear. Administrative
  • Put used blades in a blade bin or sharps container. Administrative
  • Use two people to handle large sheets of metal or glass. Administrative
  • Wear cut-resistant gloves and long sleeves. PPE
Low
5Store gas bottles upright and chained
  • Flammable liquids and gases
  • Compressed air
High
  • Use non-flammable or water-based products where you can. Substitute
  • Keep ignition sources away: no smoking, no hot work and no running engines near flammables. Isolate
  • Store fuels and solvents in approved, closed containers in a ventilated area away from the work. Engineering
  • Refuel equipment outdoors with the engine off and cool. Administrative
  • Keep only what you need for the day on site. Administrative
  • Store gas cylinders upright, secured and outdoors. Administrative
  • Keep a suitable fire extinguisher where flammables are used or stored. Administrative
  • Wear chemical gloves and safety glasses when pouring or mixing. PPE
  • Fit whip checks (safety cables) on hose joints and check hoses before use. Engineering
  • Fit a pressure regulator and keep pressure to the tool's rating. Engineering
  • Turn off and bleed the line before disconnecting. Administrative
  • Never use compressed air to clean clothes or skin, or point it at anyone. Administrative
  • Wear safety glasses and hearing protection. PPE
Medium
6Sweep up slag and offcuts
  • Poor housekeeping and waste
Medium
  • Order materials to size and send packaging back where you can. Eliminate
  • Put skip bins and waste chutes close to the work. Engineering
  • Clean as you go, and do a full clean up at the end of each day. Administrative
  • Keep exits, stairs and walkways clear at all times. Administrative
  • Stack materials neatly on level ground, away from edges. Administrative
  • Wear gloves when handling waste. PPE
Low

PPE

Welding helmetWelding glovesSteel cap bootsSafety glassesHearing protection (earmuffs or plugs)OverallsHi-vis shirt or vestHard hatWork glovesP2 dust maskFace shieldCut-resistant glovesHalf-face respirator (P2 or P3 filters)Safety goggles

Plant and equipment

WelderAngle grinderOxy-acetylene torchForklift: High Risk Work Licence LF (LO for order-picking forklifts)Crane (Franna or mobile): HRWL for the crane class (e.g. C2, CN, C6), plus Dogging licence (DG) where slinging needs judgement or the load is out of the operator's view

Permits and plans

Lift planHot work permit

Emergency

Call 000. Add the nearest hospital, the assembly point and the first aider for your site.

Sign-off

Supervisor and every worker sign to confirm they have read and understood this SWMS.

Free SWMS template for steel fabrication

Word (.docx) and PDF, A4 landscape, no email needed. Fill in your site details, then print or send it.

Word template (.docx)PDF template

Make yours in 2 minutes

Same document, filled in for your job. Answer a few yes or no questions, the crew signs on the phone, and you send the PDF.

Start this SWMS

Pre-start checklist for steel fabrication

Tick these off before work starts. They come from the hazards, permits and equipment in this job.

The safe sequence of work

  1. Move steel with a forklift or overhead crane, keeping walkways clear
  2. Cut and drill steel with guards in place
  3. Weld in a booth with extraction
  4. Handle hot and sharp parts with gloves
  5. Store gas bottles upright and chained
  6. Sweep up slag and offcuts

Hazards to watch on steel fabrication

The hazards most specific to this job, and the step where each one comes up.

Step 5Compressed airAn air hose whips when a fitting fails, or air blown at skin or eyes drives dirt in and causes injury.
Step 3Welding and cutting fumesWelding, cutting and brazing give off metal fumes and gases that damage the lungs and can cause cancer.
Step 4Burns from hot surfacesTouching hot pipes, tools, bitumen, solder or freshly welded metal burns the skin.
Step 5Flammable liquids and gasesPetrol, solvents, thinners and LPG catch fire or explode when vapour reaches a spark, flame or hot surface.
Step 1Crane and lifting failureA load falls or swings, or the crane tips, crushing workers under or near the lift.
Step 2Angle grinder injuriesThe disc shatters, binds or kicks back, causing deep cuts to legs and hands or eye injuries.
Almost certainLikelyPossibleUnlikelyRareHow bad it could be: Insignificant to CatastrophicBA
Highest risk on steel fabrication: Extreme before controls (B), down to Medium after controls (A), on the Australia 5 by 5 risk matrix (likely and major becomes unlikely and major).

What changes on your site

This example covers the job itself. Your site may add more. Add controls for any of these that apply (the builder asks you these as yes or no questions):

  • Will anyone work more than 2 metres off the ground?
  • Will anyone use a ladder or stepladder?
  • Will anyone work on a roof?
  • Is there a skylight, clear sheet, fibro or other fragile roofing?
  • Will you use a scaffold or mobile tower?

Licences and legal requirements in Australia

This task can involve these high risk construction work categories under the WHS Regulations:

  • Work in an area with movement of powered mobile plant

Equipment on this job that needs a licence, ticket or training:

  • Forklift: High Risk Work Licence LF (LO for order-picking forklifts)
  • Crane (Franna or mobile): HRWL for the crane class (e.g. C2, CN, C6), plus Dogging licence (DG) where slinging needs judgement or the load is out of the operator's view

A SWMS must be prepared before any high risk construction work starts. It must list the high risk work, the hazards and risks, the control measures, and how those controls will be put in place, monitored and reviewed. It must be easy for the workers to read and understand.

Rules that apply: WHS Regulation 2011, Part 5.1 Plant; WHS Regulation 2011, Part 4.5 High risk work and Part 5.1 Plant; WHS Regulation 2011, Part 4.1 Noise; AS 1674.1 Safety in welding and allied processes (fire precautions); WHS Regulation 2011, Chapter 7 Hazardous chemicals.

Each state has its own regulator and some extra rules: New South Wales, Victoria, Queensland, Western Australia, South Australia and Australian Capital Territory.

Why SWMS get rejected

Principal contractors send documents back for these reasons. This example avoids them, but check yours too.

  • It is generic: another site address, tasks that are not on this job, or no sign it was reviewed for this site. WorkSafe WA says a generic SWMS may not meet the regulations unless it is reviewed and amended for the workplace.
  • The HRCW boxes are not ticked, or the ticks do not match the tasks (for example a roof job with no falls box ticked).
  • Falls are controlled only by "be careful", training or a harness, with no edge protection or scaffold and no reason why higher controls are not reasonably practicable.
  • Workers will clip on to a harness but there is no rescue plan for someone left hanging.
  • The "how controls are implemented, monitored and reviewed" part is missing, or it says the same thing on every row.
  • No worker sign-on, no person responsible for compliance, or a date given to the principal contractor that is before they actually received it.
  • Licence or White Card details are missing for workers operating plant or doing licensed high risk work.

Questions

Do I need a SWMS for steel fabrication?

Yes. Steel fabrication usually includes high risk construction work (work in an area with movement of powered mobile plant), so a SWMS is required by law before work starts.

Who signs the SWMS?

The person conducting the business (PCBU) or their supervisor prepares it with the workers, and every worker doing the high risk work signs to show they were consulted and understand it. Give a copy to the principal contractor before work starts.

How long do I keep it?

Keep this SWMS, and every revised version, until the high risk construction work is finished, where workers and inspectors can see it on site. If a notifiable incident happens during the work, keep it for at least 2 years after the incident.

What PPE is needed for steel fabrication?

Usually Welding helmet, Welding gloves, Steel cap boots, Safety glasses, Hearing protection (earmuffs or plugs), Overalls, Hi-vis shirt or vest, Hard hat, Work gloves, P2 dust mask, Face shield, Cut-resistant gloves, Half-face respirator (P2 or P3 filters), Safety goggles. The site rules may add more, so check with the principal contractor.

More welding and fabrication SWMS

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Related jobs in other trades

ConcretingFormworkAlso involves crane and lifting failureRoofingRoof Tile ReplacementAlso involves cuts from sharp edgesPlumbingHot Water System ReplacementAlso involves burns from hot surfacesConcretingConcrete Slab PourAlso involves being hit by mobile plantDemolitionInternal Strip OutAlso involves cuts from sharp edgesTilingWet Area WaterproofingAlso involves loud noise

Toolbox talks for this job

Toolbox talkHearing Protection and NoiseToolbox talkHot Works SafetyToolbox talkAngle Grinder SafetyToolbox talkMobile Plant and Spotters

Blank SWMS template: free SWMS templates. Also for other countries: United Kingdom (RAMS) · United States (JHA) · Canada (FLHA)

Sources