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

Plasma Cutting — Safe Work Method Statement

Safe Work Method Statement for plasma arc cutting operations including equipment setup, active cutting, and post-work procedures, in compliance with Australian WHS legislation and relevant Australian Standards.

Download this template

Personal Protective Equipment

Auto-darkening welding helmet (minimum shade 8–10 depending on amperage)Leather welding gauntletsFlame-resistant welding jacketSteel-capped leather safety bootsP2 respiratorHearing protection (SLC80 20 minimum)Safety glasses under helmet

High Risk Construction Work Types

•Work in an area that may have a contaminated or flammable atmosphere

Risk Assessment

1.Plasma cutter setup and consumable inspection

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Electric shock from high-voltage plasma cutting circuit	High	Plasma cutters operate at open-circuit voltages up to 400 V. Inspect the machine, torch leads, power cable, and plug before each use. Remove from service any equipment with cracked torch bodies, damaged leads, or faulty pilot arc circuits. Connect via an RCD-protected outlet. Ensure the work clamp has a firm, low-resistance connection to the workpiece. Never change consumables (nozzle, electrode, shield cup) with the machine energised — isolate and wait 5 seconds before touching the torch tip. Wear dry leather gloves during setup.	Low	Operator
Compressed air failure causing arc instability and torch damage	Moderate	Check that the air supply pressure meets the manufacturer's specification (typically 5.5–6.9 bar / 80–100 PSI). Drain the air compressor tank of moisture before commencing. Check the inline moisture separator/filter and drain if required. Test pilot arc and cutting arc before production cutting. Ensure hose connections are secure and free from leaks. Keep the air supply hose clear of the cutting area and heat sources.	Low	Operator

2.Active plasma cutting operations

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Fire from plasma sparks and molten metal stream	Catastrophic	Issue a hot work permit. The plasma arc creates a high-velocity stream of molten metal that can travel up to 5 metres. Remove all combustibles within a 5-metre radius or shield with fire-resistant welding blankets. Position the cut so the molten stream is directed downward or into a non-combustible catcher. Never plasma cut over or near flammable liquids, gases, or vapours. Post a fire watch during cutting and for 30 minutes after completion. Position a serviceable fire extinguisher within immediate reach.	Moderate	Operator / Fire Watcher
Arc flash causing eye and skin injury to operator and bystanders	High	The operator must wear an auto-darkening welding helmet set to shade 8 for currents below 100 A and shade 10 for 100–200 A. Erect opaque welding screens or flash curtains around the cutting area to prevent arc flash exposure to other workers. Ensure all bystanders maintain a minimum 5-metre exclusion zone or wear appropriate eye protection. Never look at the plasma arc directly, even for a moment. Inspect helmet lens condition before every use.	Low	Operator / Site Supervisor
Fume and ozone inhalation from plasma cutting process	High	Plasma cutting produces ozone, nitrogen oxides, and metal-specific fumes at high concentrations. Ensure adequate ventilation or install LEV at the source. For stainless steel, galvanised, or coated materials, a supplied-air respirator is required; a minimum P2 respirator is required for mild steel in well-ventilated conditions. Review the SDS for the base material. Monitor air quality in confined or semi-enclosed areas. Do not cut materials with unknown coatings without first identifying the coating chemistry.	Moderate	Operator / Safety Officer
Hearing damage from plasma cutter noise (95–110 dB(A))	High	Plasma cutting typically generates 100–110 dB(A). Mandatory hearing protection (minimum SLC80 20 earmuffs or earplugs) must be worn by the operator and all workers within 5 metres. Limit continuous plasma cutting to 30-minute intervals. Schedule high-noise cutting during low-occupancy periods where practicable. Erect acoustic barriers for prolonged operations in occupied areas.	Low	Operator / Site Supervisor

3.Handling cut material and waste disposal

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Burns and lacerations from hot cut edges and offcuts	Moderate	Allow cut material to cool before handling. Plasma-cut edges can reach temperatures above 300°C immediately after cutting. Wear leather welding gauntlets when handling cut pieces. Mark hot material with chalk. Use tongs or a magnetic lifter for small offcuts. Dispose of metal offcuts in a designated metal waste skip. Ensure offcuts cannot fall on personnel below the working level; use drop-containment trays or barriers.	Low	Operator / 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: ___________________