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Oxy-Acetylene Cutting and Thermal Lancing Risk Assessment

This risk assessment covers oxy-acetylene cutting and thermal lancing, from work area review and equipment checks through to shutdown.

Activities covered include

  • Reviewing the work area and permit requirements
  • Performing oxy-acetylene cutting work
  • Isolating equipment and handling hot items after work

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Oxy-Acetylene Cutting and Thermal Lancing 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

Product Overview

This risk assessment covers oxy-acetylene cutting and thermal lancing, from work area review and equipment checks through to shutdown. It supports planning and risk management for fire, gas release, fumes, intense heat, molten material and enclosed-area hazards.

Activities & Risks Covered

This assessment addresses activities and risks including:

  • Reviewing the work area and permit requirements
  • Setting up gas cylinders, regulators and hoses
  • Isolating the area and managing ventilation and atmosphere conditions
  • Inspecting equipment and completing functional checks
  • Performing oxy-acetylene cutting work
  • Performing thermal lancing work
  • Monitoring adjacent areas and maintaining a fire watch
  • Managing work in confined or enclosed areas
  • Isolating equipment and handling hot items after work

Who is this for?

Suitable for contractors, workers, supervisors and businesses carrying out oxy-acetylene cutting or thermal lancing activities.

Activities & Hazards Covered

Activity Potential Hazards
Work area assessment and permit review
  • Ignition of flammable vapours, gases or combustible dusts in the work area
  • Hot work started in a hazardous area without proper controls
  • Unrecognised residues in tanks, pipes, vessels or low-lying areas
  • Unauthorised access by other workers or the public
Gas cylinders, regulators and hose set-up
  • Cylinder fall or impact causing valve damage and sudden gas release
  • Acetylene or oxygen leak leading to fire, explosion or oxygen enrichment
  • Incorrect regulator, damaged hose or poor connection integrity
  • Manual handling strain while moving cylinders and equipment
Area isolation, ventilation and atmosphere control
  • Build-up of fuel gas, fumes or oxygen-enriched atmosphere
  • Asphyxiation in enclosed, poorly ventilated or low-lying areas
  • Ignition from other plant, vehicles or electrical sources nearby
  • Poor visibility and worker exposure due to inadequate fume control
Pre-use equipment inspection and functional checks
  • Flashback, hose failure or uncontrolled flame due to faulty equipment
  • Fire from leaking connections during ignition or use
  • Burns during lighting, adjustment or shutdown
  • Use of out-of-test or poorly maintained equipment
Oxy-acetylene cutting operations
  • Fire or explosion from sparks, slag and hot metal contacting fuel sources
  • Burns to operator or nearby workers from flame, hot surfaces and molten material
  • Eye injury and skin damage from heat, glare, ultraviolet and infrared radiation
  • Unexpected movement or collapse of the item being cut
Thermal lancing operations
  • Intense heat and violent ejection of sparks, slag and molten material
  • Rapid ignition of combustibles due to longer spark travel and higher heat output
  • Line-of-fire injuries from blowback or lance instability
  • Noise, fume and radiant heat exposure to the operator and spotter
Fire watch and adjacent area monitoring
  • Delayed ignition in nearby materials, cavities, penetrations or lower levels
  • Fire spread to adjoining processes, structures or stored materials
  • Workers re-entering the area before hot materials have cooled
  • Insufficient emergency response if a fire starts
Confined space or enclosed area considerations
  • Flammable atmosphere ignited by the hot work source
  • Oxygen deficiency or oxygen enrichment
  • Toxic fume exposure and loss of consciousness
  • Delayed rescue due to poor access or inadequate standby arrangements
Shutdown, isolation and post-work handling
  • Residual gas release after work is complete
  • Burns from hot torch components, lances, cut sections or slag
  • Re-ignition from smouldering material or poorly isolated equipment
  • Trips and contact injuries during pack-up

Need to tailor this risk assessment?

Use the BlueSafe Portal to add site-specific activities, hazards, controls, responsibilities and review details before the assessment is put into use.

Acceptance Guaranteed: If your client or principal requests changes during document review, BlueSafe will help revise the document at no extra cost and support resubmission until it is accepted.

Legislation & References

The template records model guidance used to inform the documented controls. Applicable WHS/OHS laws and adopted Codes vary by state or territory, so confirm the current local requirements when tailoring the assessment:

  • Model guidance: Model Code of Practice: Welding processes — 3.6 Compressed and liquefied gases; p. 23.
  • Model guidance: Model Code of Practice: Confined spaces — 3.4 Assessing the risks; p. 24.
  • Model guidance: Model Code of Practice: Managing risks of plant in the workplace — Plant hazard identification — Traffic movements in the workplace; p. 17.
  • Model guidance: Model Code of Practice: Managing electrical risks in the workplace — 5. Isolation, locking off and access; p. 34.
  • Model guidance: Model Code of Practice: Managing the work environment and facilities — 1.2 Managing risks associated with the work environment and facilities; p. 12.
  • Model guidance: Model Code of Practice: How to manage work health and safety risks — 3. Step 2 — How to assess risks; p. 15.
  • Model guidance: Model Code of Practice: Hazardous manual tasks — 4.1 The hierarchy of control measures; p. 31.
Standard Risk Assessment Features (Click to Expand)
  • Activity-specific hazard identification and control measures
  • Initial and residual risk ratings
  • Assigned responsible persons for each activity
  • Risk matrix and assessment classification
  • Review, monitoring and sign-off fields
  • Site-specific customisation before use

Suitable for Industries

Manufacturing and ProductionDemolitionMetal Fabrication and Welding

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