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

TIG Welding — Safe Work Method Statement

Safe Work Method Statement for Tungsten Inert Gas (TIG) welding operations, including setup, operation, and post-work procedures in compliance with Australian WHS regulations.

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Personal Protective Equipment

Auto-darkening welding helmet (minimum shade 10)Leather welding gauntletsFlame-resistant welding jacket or sleevesSteel-capped safety bootsP2 respirator or supplied-air respirator for stainless steelSafety glasses (worn under welding helmet)Hearing protection where noise exceeds 85 dB(A)

High Risk Construction Work Types

•Work involving the use of explosives
•Work in an area that may have a contaminated or flammable atmosphere

Risk Assessment

1.Pre-work area preparation and inspection

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Fire and explosion from flammable materials near welding area	Catastrophic	Conduct a hot work permit assessment before commencing. Remove all flammable and combustible materials within a 3-metre radius of the welding area, or shield them with fire-resistant blankets. Inspect the area for fuel sources including solvents, oils, and gases. Ensure a minimum 9kg dry powder or CO2 fire extinguisher is immediately accessible and the operator is trained in its use. Post a fire watch during welding and for 30 minutes after completion. Check that fire suppression systems are operational and not isolated.	Moderate	Site Supervisor / Welder
Inadequate ventilation leading to toxic fume inhalation	High	Assess the workspace for adequate natural or mechanical ventilation before commencing. For enclosed or semi-enclosed spaces, install local exhaust ventilation (LEV) positioned within 150–300mm of the welding arc to capture fumes at the source. When welding stainless steel, galvanised, or coated materials, mandatory P2 or supplied-air respiratory protection must be worn due to hexavalent chromium or zinc oxide fume hazards. Check the SDS for base and filler materials. Monitor oxygen levels in confined spaces using a gas detector.	Low	Welder / Safety Officer

2.TIG welding equipment setup and gas cylinder handling

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Compressed gas cylinder falling and causing physical injury or gas release	High	Secure all gas cylinders (argon shielding gas) in an upright position using a dedicated cylinder trolley with chain restraints, or chain/strap them to a fixed wall bracket. Never leave cylinders unsecured or laid on their side. Transport cylinders only on approved trolleys with regulators removed and valve caps fitted. Inspect cylinders for damage, correct labelling, and current test dates before use. Store cylinders away from heat sources and direct sunlight.	Low	Welder
Electric shock from TIG welding equipment	High	Inspect the welding unit, leads, and torch before each use. Tag-out and remove from service any equipment with damaged insulation, frayed leads, or defective connectors. Ensure the welding unit is connected to a residual current device (RCD). Never change tungsten electrodes while the unit is energised. Wear dry leather welding gloves at all times. Ensure the work clamp is securely connected as close as practicable to the weld area. In damp or wet conditions, cease welding operations until conditions improve.	Low	Welder
UV/IR radiation causing eye and skin burns (arc eye)	High	Use an auto-darkening welding helmet with a minimum shade 10 lens for TIG welding. Ensure all personnel within a 5-metre radius wear appropriate eye protection (minimum shade 5 safety glasses or welding screens). Erect opaque welding screens or curtains to prevent arc flash exposure to other workers. Cover all exposed skin with flame-resistant clothing. Inspect the helmet lens for cracks or damage before use and replace if compromised.	Low	Welder / Site Supervisor

3.Active TIG welding operations

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Burns from contact with hot work piece or spatter	Moderate	Allow welded components to cool before handling; use thermal chalk or temperature-indicating stickers to confirm safe handling temperature. Mark hot work pieces with chalk or a "HOT METAL" sign. Wear leather welding gauntlets and flame-resistant jacket at all times during welding and immediately after. Do not place hot components on flammable surfaces. Use insulated tongs or clamps to handle hot material.	Low	Welder
Musculoskeletal strain from awkward welding postures	Moderate	Set up the workpiece at a comfortable working height using adjustable welding tables or stands to minimise bending, twisting, and overhead welding where possible. Rotate tasks to reduce sustained static postures. Use welding positioners or jigs to reposition the workpiece rather than repositioning the welder. Take regular breaks every 45 minutes when performing sustained welding in awkward positions. Conduct a manual task risk assessment for repetitive welding operations.	Low	Welder / Site Supervisor

4.Post-weld inspection and cleanup

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Contact with hot slag or metal particles during cleaning	Moderate	Allow welds and parent material to cool adequately before inspection and cleaning. Wear leather gauntlets, safety glasses, and face shield when chipping or brushing welds. Ensure grinding and brushing activities are performed away from combustible materials. Dispose of metal waste in a designated fire-resistant metal waste bin. Never use compressed air to blow metal particles as this creates projectile hazards.	Low	Welder
Improper gas cylinder shutdown creating leak hazard	High	Follow the standard shutdown procedure: close the cylinder valve first, then purge residual gas from the regulator and hoses by holding the torch trigger, then close the regulator. Inspect all fittings, hoses, and connections for leaks using an approved leak detection solution (never a naked flame). Store cylinders in a cool, dry, well-ventilated area with valve protection caps fitted. Record cylinder contents and report any cylinder damage to the supplier.	Low	Welder

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: ___________________