Product Overview

Summary: This SOP provides a structured, practical framework for controlling dust in metal fabrication facilities, protecting workers from harmful airborne contaminants and reducing fire and explosion risks. It aligns with Australian WHS expectations and guides businesses in implementing effective engineering, administrative and PPE controls for a cleaner, safer, and more compliant workplace.

Metal fabrication processes such as cutting, grinding, linishing, drilling, blasting and welding can generate significant levels of metallic and non-metallic dust. Left unmanaged, these airborne contaminants can lead to serious respiratory illness, skin and eye irritation, housekeeping issues, and in some cases combustible dust fire and explosion risks. This Safe Operating Procedure sets out a clear, step-by-step approach to identifying dust-generating tasks, implementing suitable control measures, and maintaining those controls so they remain effective over time.

Developed specifically for Australian metal fabrication environments, this SOP helps businesses translate WHS duties into practical controls on the workshop floor. It covers the full lifecycle of dust control – from initial risk assessment and selection of local exhaust ventilation and on-tool extraction, through to housekeeping methods, waste disposal, equipment maintenance, and worker training. By standardising how dust is managed across shifts and locations, the procedure supports consistent work practices, easier onboarding of new staff, and stronger evidence of compliance if audited or investigated by a regulator.

Key Benefits

• Reduce worker exposure to hazardous metal and nuisance dusts, lowering the risk of respiratory disease and other health issues.
• Ensure alignment with Australian WHS legislation and relevant codes of practice for airborne contaminants and hazardous substances.
• Standardise dust control practices across all fabrication areas, shifts and sites for consistent, repeatable outcomes.
• Minimise housekeeping problems, equipment contamination and product quality defects caused by uncontrolled dust.
• Lower the likelihood of dust-related fires, explosions and regulatory enforcement action through documented, defensible controls.

Who is this for?

• Metal Fabrication Workshop Managers
• WHS Managers and Advisors
• Health and Safety Representatives (HSRs)
• Production Supervisors
• Maintenance Supervisors
• Fabricators and Boilermakers
• Welders and Cutting Operators
• Occupational Hygienists
• Operations Managers
• Small Metal Workshop Owners

Hazards Addressed

• Inhalation of respirable and inhalable metal dust (e.g. steel, aluminium, stainless steel, galvanised coatings)
• Exposure to mixed dusts from grinding discs, coatings, paints and surface contaminants
• Combustible dust fire and explosion risks, particularly with fine aluminium or magnesium dusts
• Eye and skin irritation from airborne particles and settled dust
• Slip, trip and fall hazards from accumulated dust and offcuts on floors and walkways
• Contamination of electrical equipment and ventilation systems by fine dust
• Secondary exposure to dust during cleaning, maintenance and waste handling activities

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (PCBU, Officers, Supervisors, Workers, Contractors)
• 4.0 Overview of Dust Hazards in Metal Fabrication
• 5.0 Risk Assessment for Dust-Generating Tasks
• 6.0 Hierarchy of Controls for Dust Management
• 7.0 Engineering Controls (Local Exhaust Ventilation, On-Tool Extraction, Isolation)
• 8.0 Administrative Controls (Work Practices, Scheduling, Restricted Areas)
• 9.0 Personal Protective Equipment (Selection, Fit, Use and Maintenance)
• 10.0 Housekeeping, Cleaning Methods and Waste Disposal
• 11.0 Control of Combustible and Fine Metal Dusts
• 12.0 Equipment Inspection, Maintenance and Testing of Ventilation Systems
• 13.0 Air Monitoring, Health Monitoring and Performance Review
• 14.0 Training, Instruction and Competency Requirements
• 15.0 Incident, Near Miss and Health Concern Reporting
• 16.0 Emergency Response for Dust-Related Events (Fires, Explosions, Spills)
• 17.0 Recordkeeping and Documentation
• 18.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and corresponding state and territory WHS Acts)
• Work Health and Safety Regulations 2011 (Cth and corresponding state and territory WHS Regulations) – including provisions for airborne contaminants and hazardous chemicals
• Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace: Code of Practice
• Safe Work Australia – Managing the Work Environment and Facilities: Code of Practice
• Safe Work Australia – Welding Processes: Code of Practice (for associated fume and particulate control)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 1668.2: The use of ventilation and airconditioning in buildings – Mechanical ventilation in buildings
• AS/NZS ISO 45001: Occupational health and safety management systems – Requirements with guidance for use