Product Overview

Summary: This SOP sets out clear, practical instructions for safe fabrication work and the correct use of fabrication equipment in Australian workplaces. It helps businesses control high‑risk activities such as cutting, welding, grinding and forming metals, ensuring workers operate tools and machinery safely, consistently and in compliance with WHS requirements.

Metal fabrication workshops combine high‑energy equipment, sharp materials and fast-paced production pressures, making them a high‑risk environment under Australian WHS law. This Fabricators' Safety and Equipment Use SOP provides a structured, step‑by‑step framework for how fabrication work must be planned, set up and carried out, from initial job assessment and material handling through to cutting, welding, grinding, drilling and final clean‑up. It clarifies the safe operating limits for common fabrication equipment, defines mandatory PPE, and sets out the controls required for noise, fumes, hot work and mechanical hazards.

By implementing this SOP, businesses create a consistent, defensible standard for fabrication activities that aligns with Australian WHS legislation and relevant Codes of Practice. It helps supervisors and fabricators move beyond informal “on‑the‑job” habits to a documented system that reduces injuries, protects apprentices and new starters, and supports regulatory compliance. The procedure also supports improved equipment care and housekeeping, reducing downtime from damaged tools, unplanned maintenance and avoidable incidents, while strengthening your safety culture and due diligence in the eyes of regulators, clients and insurers.

Key Benefits

• Ensure consistent, safe operation of fabrication equipment across shifts, sites and teams.
• Reduce the risk of lacerations, crush injuries, burns and eye injuries in fabrication workshops.
• Demonstrate compliance with Australian WHS legislation, Codes of Practice and relevant Australian Standards.
• Standardise induction and refresher training for fabricators, apprentices and contractors.
• Extend the service life of fabrication equipment through defined pre‑use checks and safe operating limits.

Who is this for?

• Fabricators
• Boilermakers
• Welders
• Sheet Metal Workers
• Workshop Supervisors
• Production Managers
• WHS Advisors and Safety Officers
• Engineering Managers
• Apprentice Coordinators
• Small Metal Fabrication Business Owners

Hazards Addressed

• Contact with moving machinery parts (rollers, presses, drills, saws, grinders)
• Lacerations and puncture wounds from sharp edges, offcuts and swarf
• Burns and fires from welding, oxy‑cutting, grinding sparks and hot work
• Exposure to welding fumes, metal dusts and airborne contaminants
• Noise-induced hearing loss from cutting, grinding and hammering operations
• Eye injuries from flying particles, grinding sparks and UV/IR radiation from welding arcs
• Crush injuries and sprains from manual handling of heavy plate, beams and components
• Electric shock from faulty welding plants, extension leads and power tools
• Slip, trip and fall hazards from offcuts, leads, hoses and poor housekeeping
• Entanglement in rotating equipment due to loose clothing, gloves or jewellery

Included Sections

• 1.0 Purpose, Scope and Application
• 2.0 Definitions and Abbreviations
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Assessment for Fabrication Tasks
• 6.0 Required PPE and Workshop Dress Standards
• 7.0 General Workshop Safety Rules and Housekeeping
• 8.0 Pre‑Use Inspection and Maintenance of Fabrication Equipment
• 9.0 Safe Use of Cutting Equipment (saws, guillotines, plasma, oxy‑fuel)
• 10.0 Safe Use of Welding and Thermal Processes
• 11.0 Safe Use of Grinding, Linishing and Finishing Equipment
• 12.0 Safe Use of Drills, Presses, Rollers and Forming Equipment
• 13.0 Manual Handling and Mechanical Aids for Materials Movement
• 14.0 Control of Welding Fumes, Dust and Noise
• 15.0 Lockout/Tagout and Isolation Procedures for Plant
• 16.0 Hot Work Permits and Fire Prevention Controls
• 17.0 Working with Contractors, Visitors and Apprentices in the Workshop
• 18.0 Emergency Procedures, First Aid and Incident Reporting
• 19.0 Training, Induction, Supervision and Competency Verification
• 20.0 Recordkeeping, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Welding Processes
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• AS/NZS 4024 series: Safety of machinery
• AS 1674.1: Safety in welding and allied processes – Fire precautions
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 1801: Occupational protective helmets
• AS/NZS 1270: Acoustics – Hearing protectors