Important: This SWMS template is provided as a starting point only. It must be reviewed and customised to reflect the specific conditions, hazards, and controls for your workplace and task. The PCBU remains responsible for ensuring the SWMS is suitable for the specific work. This template does not constitute legal advice. Refer to your state or territory WHS regulator for compliance requirements.

Welding & Hot Work

Arc Welding (MMA / MMAW) — Safe Work Method Statement

Safe Work Method Statement for Manual Metal Arc (MMA/MMAW) stick welding operations including site preparation, electrode handling, active welding, and post-weld activities in compliance with Australian WHS legislation.

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Personal Protective Equipment

Welding helmet (auto-darkening or fixed shade, minimum shade 10)Leather welding gauntletsFlame-resistant welding jacketLeather welding spats or boots with leather uppersP2 respirator or LEV systemSafety glasses (for slag chipping)Hearing protection (minimum SLC80 20)

High Risk Construction Work Types

•Work in an area that may have a contaminated or flammable atmosphere
•Work involving demolition of a structure

Risk Assessment

1.Welding machine setup and electrical safety checks

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Electric shock from welding equipment or leads	High	Before commencing, inspect the welding machine, electrode holder, work return clamp, and all leads for damaged insulation, cracked connectors, or exposed conductors. Remove any defective equipment from service and apply a red danger tag. Connect the welding set to an RCD-protected power supply. Ensure the work return clamp provides a low-resistance path by connecting as close as practicable to the weld. Never allow welding cables to run through puddles or wet areas. Do not change electrodes while the machine is energised — switch off first. Open-circuit voltage (OCV) on MMA sets can reach 80 V and is lethal in wet conditions.	Low	Welder / Electrician (for fixed installations)
Incorrect welding current causing weld defects or equipment damage	Low	Set welding current within the range specified by the electrode manufacturer (referenced on the electrode packet). Select the correct polarity (DCEP, DCEN, or AC) for the electrode type. Check the machine duty cycle rating and do not exceed it to prevent overheating. Allow machine to cool if overheating warnings activate. Record machine settings in the welding procedure record if applicable.	Low	Welder

2.Electrode storage and handling

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Moisture-contaminated electrodes causing hydrogen cracking or porosity	Moderate	Store low-hydrogen electrodes in a heated electrode oven at the manufacturer-specified temperature (typically 120–150°C for E7018). Inspect electrode packaging for damage and check expiry dates on receipt. Do not leave electrodes exposed to the atmosphere for longer than the manufacturer's specified exposure time (typically 4 hours for low-hydrogen rods). Redry electrodes per the manufacturer's instructions if exposure time is exceeded. Segregate and label different electrode types to prevent misuse.	Low	Welder / Site Supervisor

3.Active arc welding operations

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
UV and IR radiation causing arc eye and skin burns	High	The operator must wear an auto-darkening or fixed shade welding helmet (minimum shade 10) for all MMA welding. Erect opaque welding screens or flash curtains to protect all workers within 5 metres from arc flash exposure. Ensure all skin is covered by flame-resistant clothing. Post warning signs in the surrounding area indicating arc welding in progress. Check the helmet lens for cracks or damage before each use. Never look at an arc without appropriate eye protection, even briefly.	Low	Welder / Site Supervisor
Inhalation of welding fumes causing respiratory damage	High	Install LEV positioned 150–300 mm from the arc to capture fumes at the source. Ensure ventilation achieves a minimum of 10 air changes per hour in enclosed areas. When welding stainless steel, coated, or galvanised materials, wear a minimum P2 respirator; a supplied-air respirator is required in confined spaces or for prolonged operations. Review the electrode SDS for specific fume hazards. Position the welder's head to the side of the fume plume, not directly above it. Monitor air quality where exposure to manganese or hexavalent chromium is possible.	Moderate	Welder / Safety Officer
Fire from welding spatter landing on combustibles	High	Issue a hot work permit before commencing in areas with fire risk. Remove or protect all combustibles within 5 metres. MMA welding generates significant spatter — fit a spatter guard to the work area and direct the weld away from combustibles where possible. Post a fire watcher during the operation and for 30 minutes after completion. Ensure a serviceable fire extinguisher is within 5 metres. Inspect the area for smouldering material after each session.	Moderate	Welder / Fire Watcher

4.Slag removal and weld inspection

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Eye injury from flying slag during chipping operations	High	Always wear a full-face shield or safety glasses when chipping slag from welds. Allow the weld to cool to a safe handling temperature before chipping. Use a proper chipping hammer and wire brush — never use screwdrivers, chisels, or improvised tools. Position the body so that slag chips are directed away from the face. Ensure other workers in the vicinity also wear eye protection during chipping operations. Dispose of slag chips in a metal waste bin.	Low	Welder

5.Hot work area shutdown and fire watch

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Smouldering fire igniting after work is complete	High	Post a dedicated fire watch for a minimum of 30 minutes after all welding is completed, or longer if the fire risk warrants it. The fire watcher must inspect all surfaces, crevices, and areas below the work where spatter or slag may have settled. Remove hot stubs of used electrodes using pliers and place them in a steel electrode stub bin — never discard on the ground. Confirm with a thermal camera or touch test that no hot spots remain. Sign off the hot work permit to confirm the area has been cleared.	Low	Welder / Fire Watcher / Site Supervisor

Relevant Codes of Practice

Worker Acknowledgement

By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.

Name: ___________________Date: ___________________