Product Overview

Summary: This Fire Safety in Metal Fabrication Facilities SOP sets out clear, practical steps to prevent, detect and respond to fires in high-risk fabrication environments. It helps Australian businesses manage hot work, flammable materials and electrical loads safely, while demonstrating compliance with WHS duties and relevant fire safety standards.

Metal fabrication facilities are inherently high-risk environments for fire due to the combination of hot work, combustible dust, flammable gases, cutting fluids and heavy electrical loads. This Safe Operating Procedure provides a structured, end-to-end approach to managing fire risk, from workshop layout and housekeeping through to hot work permitting, equipment maintenance and emergency response. It translates Australian WHS requirements and fire safety expectations into clear, usable instructions for supervisors and workers on the floor.

The SOP is designed for real-world metal fabrication operations, including welding bays, cutting and grinding areas, spray booths and storage zones for gas cylinders and flammable liquids. It addresses common problem areas such as poor segregation of hot work, ad‑hoc storage of LPG and oxy-acetylene bottles, build-up of metal offcuts and dust, and untested fire equipment. By implementing this procedure, businesses can reduce the likelihood of fires starting, limit the consequences if they do occur, and provide verifiable evidence of due diligence during regulator inspections, insurer reviews and incident investigations.

Key Benefits

• Reduce the likelihood of fires caused by welding, grinding, cutting and other hot work activities.
• Ensure compliance with Australian WHS legislation and fire safety obligations specific to industrial workshops.
• Standardise fire prevention, detection and response practices across all shifts and work areas.
• Improve readiness of workers and fire wardens through clear emergency response steps and training prompts.
• Demonstrate due diligence to regulators, clients and insurers with a documented, risk-based fire safety procedure.

Who is this for?

• Metal Fabrication Workshop Managers
• WHS Managers and Advisors
• Operations Managers
• Production Supervisors
• Boilermakers and Welders
• Sheet Metal Workers
• Maintenance Supervisors
• Health and Safety Representatives (HSRs)
• Facility Managers
• Fire Wardens and Emergency Response Team Members

Hazards Addressed

• Ignition of flammable gases from welding and cutting operations
• Fire from sparks and hot slag contacting combustible materials
• Combustible metal dust and swarf accumulation (e.g. aluminium, magnesium)
• Overloaded or damaged electrical circuits and equipment
• Improper storage and handling of gas cylinders and flammable liquids
• Blocked or poorly maintained fire exits and evacuation routes
• Inadequate fire detection and suppression equipment in work areas
• Uncontrolled hot work in non-designated or confined spaces
• Delayed or ineffective emergency response due to lack of training or clear procedures
• Secondary explosions or flash fires from vapours and aerosols (e.g. paints, solvents, cutting fluids)

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles and Responsibilities (PCBU, Officers, Supervisors, Workers, Fire Wardens)
• 4.0 Fire Risk Profile of Metal Fabrication Facilities
• 5.0 Hazard Identification and Fire Risk Assessment Process
• 6.0 Fire Prevention Controls in Metal Fabrication Areas
• 7.0 Hot Work Management and Permit-to-Work Requirements
• 8.0 Storage and Handling of Flammable Liquids and Gas Cylinders
• 9.0 Control of Metal Dust, Swarf and Combustible Waste
• 10.0 Electrical Safety and Equipment Maintenance Requirements
• 11.0 Fire Detection, Alarm and Suppression Systems
• 12.0 Housekeeping, Workshop Layout and Separation of Incompatible Activities
• 13.0 Inspection, Testing and Maintenance of Fire Safety Equipment
• 14.0 Emergency Response Procedures and Evacuation
• 15.0 Training, Induction and Competency Requirements
• 16.0 Incident Reporting, Investigation and Corrective Actions
• 17.0 Review, Audit and Continuous Improvement
• 18.0 Document Control and Recordkeeping

Legislation & References

• Work Health and Safety Act 2011 (Cth) and relevant state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory regulations
• Safe Work Australia – Code of Practice: Managing the Risk of Fire and Explosions at the Workplace
• Safe Work Australia – Code of Practice: Welding Processes
• AS 1674.1: Safety in welding and allied processes – Fire precautions
• AS 1674.2: Safety in welding and allied processes – Electrical
• AS 1940: The storage and handling of flammable and combustible liquids
• AS 4332: The storage and handling of gases in cylinders
• AS 3745: Planning for emergencies in facilities
• AS/NZS 60079 series: Explosive atmospheres (where applicable to vapours and dusts)
• AS 1851: Routine service of fire protection systems and equipment