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

Oxy-Acetylene Cutting — Safe Work Method Statement

Safe Work Method Statement for oxy-acetylene cutting operations including cylinder handling, equipment setup, cutting procedures, and post-work shutdown in compliance with Australian WHS legislation and AS 4839.

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Personal Protective Equipment

Oxy-cutting goggles (shade 5 minimum)Leather welding gauntletsFlame-resistant jacket and trousersSteel-capped leather safety bootsP2 respiratorLeather apronHearing protection where required

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.Cylinder receipt, inspection, and storage

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Cylinder leak or rupture causing fire, explosion, or asphyxiation	Catastrophic	Inspect all cylinders on receipt for damage, corrosion, expiry dates, and correct colour coding (oxygen: black with white shoulder; acetylene: maroon). Check that valve protection caps are fitted. Store oxygen and acetylene cylinders at least 3 metres apart or separated by a 30-minute fire-rated wall, in a well-ventilated, upright, and secured location. Never store acetylene cylinders on their side. Do not store more than the minimum required quantity. Segregate empty from full cylinders and label clearly.	Moderate	Site Supervisor / Storesperson
Manual handling injury when moving cylinders	Moderate	Use an approved cylinder trolley fitted with a chain restraint for all cylinder movements. Remove regulators and fit valve caps before moving. Never roll, drag, or drop cylinders. Two persons required for cylinders over 50 kg. Inspect trolley wheels and condition before use. Secure cylinders on trolleys with the chain before moving. Train all personnel in manual handling of gas cylinders.	Low	Welder / Labourer

2.Equipment assembly and leak testing

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Gas leak at fittings causing fire or explosion	Catastrophic	Assemble all fittings, hoses, and regulators in accordance with AS 4839. Fit flashback arrestors at both the torch and regulator ends for both oxygen and acetylene circuits. After assembly, perform a leak test using approved leak detection solution — never use a naked flame. Open cylinder valves slowly (maximum one quarter turn for acetylene). Check that oxygen connections are right-hand thread and acetylene connections are left-hand thread (notched nut). Do not use oil, grease, or petroleum-based products near oxygen equipment.	Moderate	Welder
Backfire or flashback causing equipment damage or injury	High	Ensure flashback arrestors are installed and in serviceable condition on both torch and regulator connections for both gases. Inspect hoses for damage, kinking, or excessive wear before use. Set correct working pressures per the cutting nozzle manufacturer specifications (acetylene never to exceed 100 kPa gauge). Keep hoses clear of heat, sparks, and sharp edges during operation. In the event of backfire (pop and flame extinguishes), immediately close both valves and identify the cause before relighting.	Low	Welder

3.Hot cutting operations

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Fire from ignition of combustibles by cutting sparks and molten metal	Catastrophic	Issue and comply with a hot work permit. Clear combustibles within 5 metres of the cutting area. Cover immovable combustibles with fire-rated welding blankets. Identify and protect cable trays, pipe insulation, and timber framing. Post a dedicated fire watch throughout the operation and for a minimum of 30 minutes after completion. Position a serviceable 9 kg extinguisher within immediate reach. Wet down nearby surfaces where practicable. Check below the cutting area for falling hot metal and sparks.	Moderate	Welder / Fire Watcher
Burns to operator from molten metal and flame contact	High	Wear full leather welding gauntlets, flame-resistant jacket, leather apron, and steel-capped leather boots for all cutting operations. Position the body to avoid the line of travel of the cutting sparks and molten stream. Never cut overhead material without a purpose-built spark and slag catcher shield. Allow cut material to cool before handling and mark with chalk. Ensure the cutting torch valve is closed when not actively cutting.	Low	Welder
Inhalation of fumes from coated, galvanised, or painted materials	High	Identify the material being cut and consult the SDS. For galvanised, zinc-coated, painted, or unknown materials, mandatory respiratory protection (minimum P2 respirator; supplied-air for enclosed areas) must be worn. Install LEV at the source or use forced dilution ventilation. Increase ventilation rates for all operations on coated materials. Do not cut materials containing lead-based paint without a full lead management plan. Provide clean air breaks every 45 minutes.	Moderate	Welder / Safety Officer

4.Shutdown and post-work cylinder securing

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Oxygen-enriched atmosphere from improper shutdown causing fire risk	High	Follow the correct shutdown sequence: close the cutting oxygen lever, close the heating oxygen valve, close the fuel valve, close the oxygen cylinder valve, close the acetylene cylinder valve, then open torch valves to bleed all pressure from hoses and regulators before closing torch valves. Remove the regulator and fit cylinder valve caps. Inspect the area for oxygen enrichment by checking for rapid ignition, increased flame size, or using an oxygen monitor. Store cylinders in a secured, ventilated storage area.	Low	Welder

5.Handling and disposal of cut metal waste

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Burns and laceration from sharp hot metal offcuts	Moderate	Allow cut metal pieces to cool completely before handling; use thermal stickers or chalk to confirm safe temperature. Use metal tongs or a magnetic lifter for small offcuts. Wear leather gauntlets when handling any cut metal regardless of temperature. Dispose of metal waste in a designated, clearly labelled fire-safe metal skip or bin. Do not place hot metal near rubber hoses, cables, or flammable debris. Ensure cut-off pieces cannot fall onto personnel below.	Low	Welder / Labourer

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: ___________________