Product Overview

Summary: This Metal Cutting Safe Operating Procedure sets out a clear, step-by-step method for carrying out metal cutting tasks safely and efficiently in Australian workplaces. It helps control risks from rotating blades, hot work, sparks and noise while supporting compliance with WHS legislation and Australian Standards.

Metal cutting is a core activity in fabrication, construction, manufacturing and maintenance, but it brings a combination of high-risk hazards: rotating blades, abrasive wheels, flying metal fragments, hot surfaces, sparks, noise and manual handling. Without a structured procedure, workers can be exposed to lacerations, eye injuries, burns, fire, equipment failure and long-term hearing damage, while businesses face downtime, rework and regulatory scrutiny. This Metal Cutting Safe Operating Procedure provides a practical, WHS-aligned framework for planning and carrying out cutting tasks safely with equipment such as drop saws, cold saws, band saws, angle grinders and oxy-fuel or plasma cutters.

Developed for Australian conditions, the SOP guides your team through pre-start inspections, safe work area setup, selection of the correct cutting method, blade or disc selection, guarding requirements, clamping and support of workpieces, and step-by-step cutting techniques. It also addresses housekeeping, offcut management, hot work controls, and shutdown procedures. By embedding this SOP into your training and day-to-day operations, you create consistent standards across shifts and sites, reduce incident rates, and demonstrate due diligence under WHS law. The document is designed to be easily adapted to different workshop layouts and industry sectors, from small fabrication shops to large infrastructure projects.

Key Benefits

• Reduce the risk of lacerations, eye injuries, burns and amputations during metal cutting tasks.
• Ensure consistent, compliant metal cutting practices across workshops, sites and shifts.
• Support compliance with Australian WHS legislation, relevant Codes of Practice and Australian Standards.
• Improve productivity and cut quality by standardising equipment setup, workpiece support and cutting techniques.
• Strengthen induction and refresher training with a clear, documented procedure for workers and apprentices.

Who is this for?

• Fabrication Workshop Managers
• Boilermakers
• Fitters and Turners
• Metal Fabricators
• Welders
• Maintenance Technicians
• Construction Site Supervisors
• Engineering Managers
• WHS Advisors and Safety Officers
• Apprentice Coordinators and Trainers

Hazards Addressed

• Contact with rotating blades, abrasive wheels and cutting discs
• Flying metal fragments, swarf and sparks causing eye and facial injuries
• Burns from hot metal, sparks and heated equipment components
• Fire and explosion risks from hot work near flammable materials
• Noise-induced hearing loss from powered cutting equipment
• Manual handling strains from lifting and positioning heavy metal sections
• Trips and slips from offcuts, swarf and leads in the work area
• Equipment failure or disc shattering due to incorrect selection, mounting or speed
• Electric shock from damaged cords, plugs or tools
• Inhalation of metal fumes or dust from certain cutting processes

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Metal Cutting Equipment
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required PPE and Safety Equipment
• 6.0 Pre-Start Inspections and Equipment Checks
• 7.0 Work Area Setup and Housekeeping Requirements
• 8.0 Selection of Cutting Method, Blades, Discs and Consumables
• 9.0 Workpiece Preparation, Clamping and Support
• 10.0 Step-by-Step Operating Procedure for Fixed Saws (Drop, Cold and Band Saws)
• 11.0 Step-by-Step Operating Procedure for Handheld Grinders and Cut-Off Saws
• 12.0 Step-by-Step Operating Procedure for Oxy-Fuel and Plasma Cutting (where applicable)
• 13.0 Hazard Identification and Risk Control Measures
• 14.0 Hot Work Controls, Fire Watch and Permits (if required)
• 15.0 Managing Noise, Dust, Fumes and Ventilation
• 16.0 Manual Handling and Handling of Offcuts and Swarf
• 17.0 Shutdown, Isolation and Post-Use Maintenance
• 18.0 Emergency Procedures and Incident Response
• 19.0 Training, Induction and Competency Verification
• 20.0 Recordkeeping, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and corresponding state and territory legislation)
• Work Health and Safety Regulations 2011 (Cth and corresponding state and territory 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 (for elevated cutting tasks)
• Safe Work Australia – Code of Practice: Welding Processes (for oxy-fuel and plasma cutting operations)
• AS 4024.1: Safety of machinery – Series
• AS/NZS 2161: Occupational protective gloves – Series
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1270: Acoustics – Hearing protectors
• AS 1674.1: Safety in welding and allied processes – Fire precautions