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Mig Welding Risk Assessment

Mig Welding Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
  • • Pre-filled Content – Ready to Deploy Immediately
  • • Customisable – Easily Add Your Logo & Site Details
  • • Includes 2 Years of Free Compliance Updates

Mig Welding Risk Assessment

Product Overview

Identify and control organisational risks associated with Mig welding through a structured, management-level Risk Assessment that focuses on governance, planning, systems and equipment selection rather than step-by-step task instructions. This document supports your WHS Risk Management obligations under the WHS Act, strengthens Due Diligence for officers, and helps protect your business from operational and legal liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance, WHS Leadership and Legal Compliance: Assessment of senior management accountability, safety leadership, legal obligations, and integration of Mig welding risks into the organisation’s WHS management system.
  • Planning, Design and Integration of Welding Activities: Management of how Mig welding is planned, engineered and scheduled, including layout, workflow, segregation of hot work areas and integration with other site operations.
  • Procurement of Plant, Equipment and Consumables: Controls for selecting compliant Mig welders, leads, torches, shielding gases and consumables, including supplier due diligence and specification of safety features.
  • Facility Infrastructure, Ventilation and Fume Control Systems: Evaluation of building layout, extraction and general ventilation, welding bays, fume capture systems and controls to minimise welding fume and airborne contaminants.
  • Electrical Safety, Power Supply and Isolation Systems: Management of fixed and portable electrical installations, circuit protection, earthing, isolation procedures and inspection regimes for welding-related electrical risks.
  • Hazardous Chemicals, Gases and Cylinder Management Systems: Assessment of storage, handling and change-out of gas cylinders, welding wires, cleaning agents and other hazardous chemicals, including labelling, SDS access and segregation.
  • Fire, Explosion and Hot Work Permit Systems: Protocols for hot work permits, ignition source control, housekeeping, combustible material management and fire protection systems in Mig welding areas.
  • Worker Competency, Licensing and Training Systems: Oversight of competency requirements, verification of qualifications, refresher training and welding-specific induction programs for employees and supervisors.
  • Safe Systems of Work, Procedures and Work Instructions: Development and control of documented procedures, work instructions, job planning tools and integration with SWMS or JSA processes for welding activities.
  • Personal Protective Equipment (PPE) and Respiratory Protection Management: Selection, issue, fit, maintenance and replacement of welding helmets, gloves, clothing, eye protection and respiratory protection, including fit testing where required.
  • Maintenance, Inspection and Asset Management of Welding Plant: Systems for scheduled servicing, pre-use checks, defect reporting, tagging and lifecycle management of Mig welders, cables, regulators and associated plant.
  • Contractor Management and Outsourced Welding Activities: Controls for engaging, pre-qualifying and monitoring welding contractors, including interface management, site rules and verification of their safety systems.
  • Health Surveillance, Exposure Monitoring and Wellbeing: Assessment of requirements for health monitoring, welding fume and noise exposure assessments, and programs to support worker health and wellbeing.
  • Supervision, Monitoring, Consultation and Safety Culture: Management of supervisory coverage, safety observations, toolbox talks, consultation mechanisms and initiatives to strengthen a positive safety culture around welding.
  • Emergency Preparedness, Incident Management and Recovery: Planning for fire, electric shock, fume exposure and other welding emergencies, including emergency equipment, response procedures, training and post-incident review processes.

Who is this for?

This Risk Assessment is designed for Business Owners, General Managers, WHS Managers and Safety Officers responsible for planning, approving and overseeing Mig welding operations within their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Leadership and Legal Compliance
  • • Lack of clear organisational accountability for welding safety leading to unmanaged risks
  • • Senior management not fully aware of duties under the WHS Act 2011 and WHS Regulations regarding welding and hazardous chemicals
  • • Inadequate integration of welding risks into the overall WHS management system and risk register
  • • Absence of a formal Mig welding safety policy or welding-specific standards and procedures
  • • Poor consultation with workers and Health and Safety Representatives (HSRs) on welding-related decisions
  • • Failure to monitor and review compliance with Australian Standards and Codes of Practice related to welding and fume control
2. Planning, Design and Integration of Welding Activities
  • • Welding introduced into the workplace without formal planning or change management
  • • Poor workshop layout leading to congestion, inadequate separation from other tasks, and uncontrolled ignition sources
  • • Inadequate assessment of interaction between Mig welding and concurrent activities (e.g. hot work near flammable liquid storage, compressed gas handling, painting, grinding)
  • • No systematic pre-implementation risk assessment for new welding processes, consumables, or materials
  • • Lack of standard criteria for establishing designated welding bays or booths, including ventilation and fire separation
  • • Insufficient consideration of ergonomics and manual handling in welding design (e.g. fixture height, rotation devices, work positioning)
3. Procurement of Plant, Equipment and Consumables
  • • Purchase of Mig welding machines, gas systems, and accessories that do not comply with relevant Australian Standards or are unsuitable for the intended task
  • • Lack of specification for safety features (e.g. voltage reduction devices, over-temperature protection, appropriate IP ratings, fume extraction compatibility)
  • • Use of substandard or incompatible welding consumables (wires, shielding gases) increasing fume generation or process instability
  • • Procurement of gas cylinders and regulators from multiple suppliers without standardisation, leading to misuse and compatibility issues
  • • Absence of safety and technical documentation (manuals, data sheets, certificates of conformity, Safety Data Sheets) at the point of purchase
  • • Inadequate evaluation of lifecycle costs, including maintenance, calibration, and replacement parts availability, leading to deferred maintenance
4. Facility Infrastructure, Ventilation and Fume Control Systems
  • • Inadequate general ventilation and lack of local exhaust ventilation resulting in accumulation of welding fumes and gases
  • • Poorly designed or unmaintained extraction systems leading to ineffective capture at the arc
  • • Ventilation that interferes with shielding gas coverage, resulting in weld defects and rework pressures
  • • Lack of monitoring of airborne contaminants and welding fume exposure against workplace exposure standards
  • • Insufficient segregation of welding fumes from adjacent work areas and office spaces
  • • Inadequate design of make‑up air, creating negative pressures and unintended airflow paths
  • • Noise amplification due to hard surfaces and extraction systems not considered in acoustic design
5. Electrical Safety, Power Supply and Isolation Systems
  • • Inadequate electrical design leading to overloading of circuits, overheating, or increased fire risk
  • • Lack of appropriate earthing and bonding for welding circuits, increasing risk of electric shock or equipment damage
  • • Improper use of extension leads, adaptors, and power boards introducing trip and fire hazards
  • • Absence of formal isolation, lockout and tagout procedures for welding equipment during maintenance and fault finding
  • • Insufficient testing and tagging of portable electrical equipment and leads
  • • Electrical supply and earthing not adapted for outdoor or field welding, exposing workers to increased shock risk in damp conditions
6. Hazardous Chemicals, Gases and Cylinder Management Systems
  • • Poorly controlled storage and handling of shielding gases resulting in risk of cylinder rupture, leaks, or projectiles
  • • Inadequate separation of flammable and oxidising gases in storage and at point of use
  • • Lack of system for maintaining Safety Data Sheets and communicating hazardous chemical information to workers
  • • Incorrect regulator selection, installation, or maintenance leading to gas release or explosion
  • • Inadequate controls to prevent oxygen enrichment or asphyxiation in confined or poorly ventilated spaces
  • • Unsystematic management of welding-related chemicals (cleaners, anti-spatter, paints) creating uncontrolled exposure and fire risk
7. Fire, Explosion and Hot Work Permit Systems
  • • Mig welding conducted in areas containing combustible materials, flammable liquids, or dusts without formality of a hot work process
  • • Lack of systematic hot work permitting for non-routine or high‑risk welding activities
  • • Inadequate fire detection, fire fighting equipment, or emergency response planning in welding areas
  • • Poor housekeeping leading to accumulation of combustibles, offcuts, and flammable residues near welding operations
  • • No formal post‑weld fire watch or monitoring system for smouldering materials
  • • Incompatible hot work activities conducted simultaneously by different work groups or contractors without coordination
8. Worker Competency, Licensing and Training Systems
  • • Workers performing Mig welding without adequate theoretical and practical competency
  • • Supervisors unable to recognise unsafe welding practices or ineffective controls due to lack of training
  • • No structured induction on welding-specific risks such as fumes, radiation, heat, electrical hazards, and manual handling
  • • Insufficient training on use, care and limitations of PPE and respiratory protective equipment
  • • Competency not re-assessed when new materials, processes, or equipment are introduced
  • • Lack of documented evidence of worker competency and training completion
9. Safe Systems of Work, Procedures and Work Instructions
  • • Absence of documented safe systems of work for Mig welding activities
  • • Procedures that focus only on production outcomes and not on controlling health and safety risks
  • • Inconsistent work practices between shifts, teams, and contractors leading to unpredictable risk levels
  • • Procedures not updated when new technology, processes, or legislation changes occur
  • • Complex or impractical procedures that workers bypass in order to meet production targets
  • • Safe work procedures not integrated with other relevant systems (e.g. confined space, working at height, hazardous chemicals)
10. Personal Protective Equipment (PPE) and Respiratory Protection Management
  • • PPE selected on an ad hoc basis without formal risk assessment, leading to inadequate protection
  • • Inconsistent use of welding helmets, eye protection, gloves, and protective clothing due to poor supervision or comfort issues
  • • Respiratory protective equipment not matched to the level and type of welding fume generated
  • • Lack of fit testing, maintenance and storage systems for tight‑fitting RPE
  • • PPE not integrated with other equipment (e.g. compatibility between helmets, RPE, and communication devices)
  • • Over-reliance on PPE instead of prioritising higher order controls such as elimination, substitution, and engineering controls
11. Maintenance, Inspection and Asset Management of Welding Plant
  • • Welding equipment used with damaged cables, torches, connectors, or gas hoses due to lack of systematic inspection
  • • Preventive maintenance not undertaken leading to overheating, electrical faults, and poor weld quality
  • • Calibration of machines not verified, resulting in out-of-specification welds and rework pressure
  • • Spare parts and consumables (e.g. liners, tips, nozzles) not managed, encouraging unsafe improvisation
  • • Repairs performed by unqualified personnel, bypassing safety features
  • • Maintenance records not kept, preventing identification of recurrent failures or systemic issues
12. Contractor Management and Outsourced Welding Activities
  • • Contractors performing Mig welding without meeting the organisation’s WHS standards
  • • Inadequate pre-qualification of welding contractors regarding competency, licences, and safety performance
  • • Poor communication of site-specific hazards, procedures, and emergency arrangements to contractors
  • • Overlap between contractor welding activities and internal operations creating uncoordinated risks
  • • Lack of monitoring and supervision of contractor compliance with welding safety controls
  • • Contractor use of unverified welding equipment and consumables
13. Health Surveillance, Exposure Monitoring and Wellbeing
  • • Chronic exposure to welding fumes, gases and noise without adequate long-term health monitoring
  • • Lack of systems to identify workers at higher health risk (e.g. pre-existing respiratory or cardiovascular conditions)
  • • Early signs of overexposure (respiratory symptoms, skin conditions, eye irritation) not systematically captured or investigated
  • • No coordinated approach to audiometric testing for workers exposed to welding-related noise
  • • Insufficient support for workers affected by heat stress, fatigue, or musculoskeletal strain from sustained welding work
14. Supervision, Monitoring, Consultation and Safety Culture
  • • Insufficient frontline supervision of welding activities leading to unsafe shortcuts and non-compliance with controls
  • • Limited worker engagement in identifying hazards and suggesting improvements to welding processes
  • • Near misses and minor incidents during welding not reported, investigated, or shared for learning
  • • Production pressure overriding safety considerations in welding tasks
  • • Poor safety culture where repeated low-level deviations from welding procedures are tolerated
15. Emergency Preparedness, Incident Management and Recovery
  • • Lack of clear emergency procedures specific to welding incidents such as fires, electric shock, gas leaks, and eye injuries
  • • Emergency equipment (fire extinguishers, eyewash, first aid kits) not readily accessible from welding locations
  • • Workers and supervisors not trained in initial response to welding-related emergencies
  • • Inadequate coordination with external emergency services for complex welding environments (e.g. confined spaces, multi-storey work)
  • • Poor incident investigation processes leading to repeated welding-related events

Need to add specific hazards for your workplace?

Don't worry if a specific hazard isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom hazards at no extra cost. We take care of the hard work—creating the risk ratings and control measures for free—to ensure your document is compliant within minutes.

Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Model Code of Practice – Welding Processes: Guidance on managing health and safety risks associated with welding, including Mig welding.
  • Model Code of Practice – How to Manage Work Health and Safety Risks: Framework for identifying hazards, assessing and controlling risks.
  • Model Code of Practice – Managing the Work Environment and Facilities: Requirements for ventilation, amenities and work environment standards.
  • Model Code of Practice – Managing Risks of Hazardous Chemicals in the Workplace: Controls for storage, handling and use of welding gases and chemicals.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS 1674.1: Safety in welding and allied processes – Fire precautions.
  • AS 1674.2: Safety in welding and allied processes – Electrical.
  • AS/NZS 4836: Safe working on or near low-voltage electrical installations and equipment.
  • AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment.
  • AS/NZS 1716: Respiratory protective devices.
  • AS/NZS 2161: Occupational protective gloves – Selection, use and maintenance.
  • AS/NZS 1337 & 1338: Eye and face protection for occupational applications and filters for welding.
  • AS 2865: Confined spaces (where welding is undertaken in confined environments).
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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