Product Overview

This Safe Work Method Statement (SWMS) is developed specifically for metal cutting saws, plasma and thermal cutting operations to help you control risks, protect workers, and demonstrate WHS compliance on site. It is a comprehensive, ready-to-use document that covers multiple aspects of metal cutting, grinding, and thermal cutting activities across a wide range of equipment and applications.

Activities & Specific Tasks Covered

This document includes specific risk controls for:

• Planning and setup of metal cutting work areas, including segregation, signage, barricades, and safe pedestrian and vehicle access
• Selection, inspection, and maintenance of cold cutting equipment such as cold saws, bandsaws, and power hacksaws
• Safe operation of cold cutting tasks to minimise kickback, jamming, and entanglement risks
• Use of cold saws for precision cutting of steel and non-ferrous metals, including clamping, guarding, and feed control
• Commencement and control of high-volume metal cutting tasks, including production line operations and fatigue management
• Cutting and grinding metal sheets with angle grinders and bench grinders, including wheel selection, guarding, and hot work controls
• Operation of metal bandsaws and power hacksaws for cutting bar, plate, and structural steel sections
• Use of metal tube cutting machines for pipes and hollow sections, including secure support, alignment, and cut-off management
• Set-up and operation of plasma cutters, including gas supply, electrical safety, and control of fumes and hot sparks
• Thermal and plasma cutting of steel, stainless, and alloy components, including slag management and fire watch procedures
• Steel cutting operations involving repetitive tasks, manual handling, and the safe stacking, storage, and handling of cut materials
• Control of noise, vibration, and airborne contaminants generated during cutting and grinding activities
• Implementation of hot work permits, fire prevention, and emergency response for cutting and grinding operations

Who is this for?

This SWMS is designed for metal fabricators, boilermakers, welders, engineering workshops, steel processing yards, construction contractors, and site supervisors overseeing metal cutting, grinding, plasma, and thermal cutting activities.

Specific Job Steps & Hazards Covered

Legislation & References

This document was researched and developed to align with:

• Managing Risks of Plant in the Workplace Code of Practice: Guidance on the safe use, inspection, and maintenance of metal cutting machinery and associated plant
• Managing the Risk of Falls at Workplaces Code of Practice: Relevant where access to elevated work platforms or structures is required for cutting operations
• Managing Noise and Preventing Hearing Loss at Work Code of Practice: Controls for high-noise cutting, grinding, and thermal cutting processes
• Managing the Work Environment and Facilities Code of Practice: Requirements for ventilation, lighting, and general work environment in cutting and fabrication areas
• Hazardous Manual Tasks Code of Practice: Guidance for managing risks from handling heavy metal stock and cut components
• Welding Processes Code of Practice: Applicable to plasma and thermal cutting processes that generate fumes, UV radiation, and hot work hazards
• AS/NZS 4024 Safety of Machinery (series): Principles for guarding, emergency stops, and safe control systems on cutting equipment
• AS 1674.1 Safety in Welding and Allied Processes – Fire Precautions: Requirements for hot work, including fire prevention and control during thermal and plasma cutting
• AS/NZS 1715 Selection, Use and Maintenance of Respiratory Protective Equipment: Guidance for respiratory protection when cutting and grinding generate fumes and particulates
• AS/NZS 2161 Occupational Protective Gloves (series): Selection of appropriate hand protection for metal handling and cutting operations
• AS/NZS 1337.1 Personal Eye Protection: Requirements for eye and face protection during cutting, grinding, and thermal cutting tasks
• Work Health and Safety Act 2011
• Work Health and Safety Regulations 2017