Product Overview

Summary: This SOP sets out clear, practical first aid procedures tailored specifically to the hazards of metal fabrication environments. It helps Australian businesses respond quickly and confidently to injuries such as cuts, crush injuries, burns, eye damage and fume exposure, supporting WHS compliance and better outcomes for injured workers.

Metal fabrication sites present a unique mix of high‑risk hazards: cutting, grinding and welding operations, heavy plate and sections, hot work, confined spaces, chemicals, and powered mobile plant. When something goes wrong, the first few minutes are critical. This Safe Operating Procedure provides a structured, metal‑fabrication‑specific approach to first aid, from initial scene assessment and hazard control through to treatment, handover to emergency services, and post‑incident reporting. It bridges the gap between generic first aid advice and the real‑world conditions in fabrication shops, yards, and on-site installation work.

The SOP is designed to help businesses meet their duty of care under Australian WHS laws by ensuring that first aid arrangements are not only compliant but also practical and tailored to the tasks at hand. It outlines how to prepare the workplace (first aid kits, facilities, and equipment), appoint and support trained first aiders, and respond effectively to likely injuries such as lacerations from sheet metal, eye injuries from grinding, burns from hot work, crush and pinch injuries, electrical shock, and exposure to welding fumes. By standardising your first aid procedures, you improve response times, reduce the severity of injuries, support workers’ compensation processes, and demonstrate due diligence to regulators, clients and insurers.

Key Benefits

• Ensure a consistent, site‑specific first aid response to common metal fabrication injuries.
• Reduce the severity and escalation of incidents through clear, time‑critical response steps.
• Support compliance with WHS first aid requirements and demonstrate organisational due diligence.
• Streamline training and induction by providing a clear reference for first aid roles, equipment and procedures.
• Improve incident documentation and communication with emergency services, insurers and regulators.

Who is this for?

• Metal Fabrication Workshop Managers
• WHS Managers and Advisors
• Site Supervisors and Leading Hands
• First Aid Officers
• Health and Safety Representatives (HSRs)
• Production Managers
• Operations Managers
• Maintenance Supervisors
• Human Resources Managers
• Safety Trainers and Induction Coordinators

Hazards Addressed

• Severe cuts and lacerations from sheet metal, guillotines and cutting tools
• Crush and pinch injuries from presses, rollers, forklifts and overhead cranes
• Burns from welding, oxy‑cutting, grinding and hot surfaces
• Eye injuries from grinding, cutting, welding flash and flying particles
• Inhalation of welding fumes, gases and metal dusts
• Electrical shock from welding plants, power tools and extension leads
• Slips, trips and falls in workshops and yards
• Manual handling strains and sprains from handling plate, beams and heavy components
• Noise‑related incidents such as acoustic shock or disorientation
• Chemical exposure from solvents, paints, cleaners and pickling agents

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology
• 3.0 Roles and Responsibilities (PCBU, Officers, Supervisors, First Aiders, Workers)
• 4.0 First Aid Risk Assessment for Metal Fabrication Sites
• 5.0 First Aid Resources, Facilities and Equipment Requirements
• 6.0 Communication and Emergency Contact Arrangements
• 7.0 General First Aid Response Procedure (DRSABCD and Scene Safety)
• 8.0 Specific Response Procedures – Cuts, Lacerations and Amputations
• 9.0 Specific Response Procedures – Crush and Pinch Injuries
• 10.0 Specific Response Procedures – Burns and Scalds from Hot Work
• 11.0 Specific Response Procedures – Eye Injuries and Foreign Bodies
• 12.0 Specific Response Procedures – Welding Flash and UV Exposure
• 13.0 Specific Response Procedures – Electrical Shock and Arc Flash
• 14.0 Specific Response Procedures – Fume, Gas and Dust Inhalation
• 15.0 Specific Response Procedures – Sprains, Strains and Musculoskeletal Injuries
• 16.0 Specific Response Procedures – Slips, Trips and Falls
• 17.0 Use of Emergency Eyewash Stations and Safety Showers
• 18.0 Coordination with External Emergency Services (Ambulance, Fire, Police)
• 19.0 Infection Control, Hygiene and Blood/Body Fluid Spills
• 20.0 Incident Reporting, Recordkeeping and Notification Requirements
• 21.0 Training, Competency and Refresher Requirements for First Aiders
• 22.0 Inspection, Maintenance and Replenishment of First Aid Kits and Equipment
• 23.0 Review, Testing and Continuous Improvement of First Aid Procedures
• 24.0 Document Control and Version History

Legislation & References

• Safe Work Australia – Code of Practice: First Aid in the Workplace
• Safe Work Australia – Model Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Model Code of Practice: Welding Processes
• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – First Aid in the Workplace provisions
• AS 1319: Safety signs for the occupational environment
• AS/NZS 4775: Emergency eyewash and shower equipment
• AS/NZS 1891 series: Industrial fall-arrest systems and devices (where working at height is involved)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment