Product Overview

Summary: This Safe Operating Procedure sets out how Personal Protective Equipment (PPE) must be selected, worn, maintained and monitored in metalwork environments. It provides a clear, defensible framework to control common metal fabrication hazards such as sparks, hot metal, sharp edges, fumes and high noise levels, helping Australian businesses meet their WHS obligations and protect their workers.

Metalwork activities such as welding, grinding, cutting, drilling and forming expose workers to a unique combination of hazards, from flying metal fragments and hot work burns through to hazardous fumes and sustained high noise levels. This Personal Protective Equipment in Metalwork SOP provides a structured, step-by-step approach to ensuring the right PPE is selected, correctly fitted, consistently used and properly maintained for each metalworking task. It translates Australian WHS requirements into practical instructions that can be easily understood on the workshop floor.

The procedure covers the full PPE lifecycle in a metalwork setting: risk-based selection, pre-use inspection, correct donning and doffing, cleaning and storage, replacement criteria and supervisor oversight. It addresses common gaps such as inconsistent use of eye and face protection during quick grinding jobs, incorrect respiratory protection for welding fume, and inadequate hearing protection in noisy fabrication bays. By implementing this SOP, businesses can significantly reduce the likelihood of eye injuries, lacerations, burns, hearing loss and respiratory conditions, while demonstrating due diligence to regulators, clients and auditors.

Designed for Australian metal fabrication shops, maintenance workshops, TAFE training environments and engineering departments, this SOP supports both experienced tradespeople and new apprentices. It can be integrated into toolbox talks, induction programs and competency assessments, helping standardise PPE expectations across shifts, contractors and sites, and reinforcing a strong safety culture in metalwork operations.

Key Benefits

• Ensure consistent PPE use across all metalwork tasks, from light bench work to heavy fabrication and welding.
• Reduce the risk of common metalwork injuries such as eye damage, cuts, burns and hearing loss through task-specific PPE controls.
• Demonstrate compliance with Australian WHS legislation and relevant standards for eye, hearing and respiratory protection.
• Streamline training and inductions by providing clear, visual and task-based PPE requirements for metalwork activities.
• Improve PPE maintenance and replacement practices, reducing equipment failures and avoidable exposure to hazards.

Who is this for?

• Metalwork Supervisors
• Fabrication Workshop Managers
• Boilermakers
• Fitters and Turners
• Welders
• Sheet Metal Workers
• Apprentice Metalworkers
• WHS Managers and Advisors
• Engineering Managers
• Vocational Education Metalwork Trainers

Hazards Addressed

• Flying metal fragments and grinding sparks
• Hot metal, slag and spatter from welding and cutting
• Sharp edges and burrs on metal components
• Exposure to welding fumes and metal dusts
• Noise from grinders, impact tools and fabrication machinery
• UV and IR radiation from welding arcs
• Crush and pinch points when handling heavy metal sections
• Chemical exposure from solvents, cleaners and metal treatments
• Slips, trips and falls in cluttered or wet workshop areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Workers, Contractors)
• 4.0 Overview of Metalwork Hazards Requiring PPE
• 5.0 PPE Selection Matrix for Common Metalwork Tasks
• 6.0 Mandatory PPE Requirements by Work Area (Welding Bays, Grinding Stations, Fabrication Floor)
• 7.0 Pre-use Inspection of PPE (Eye, Face, Hand, Foot, Body, Respiratory, Hearing)
• 8.0 Correct Donning and Doffing Procedures
• 9.0 Use of PPE During Specific Metalwork Activities (Welding, Grinding, Cutting, Drilling, Hot Work)
• 10.0 Cleaning, Maintenance and Storage of PPE
• 11.0 PPE Replacement Criteria and Defect Reporting
• 12.0 Fit Testing and Fit Checking for Respiratory Protection
• 13.0 Training, Induction and Competency Requirements
• 14.0 Interaction with Other Controls (Guards, Ventilation, Isolation)
• 15.0 Managing Visitors, Apprentices and Contractors in Metalwork Areas
• 16.0 Recordkeeping and Compliance Monitoring
• 17.0 Review, Audit and Continuous Improvement of PPE Practices
• 18.0 References, Legislation and Applicable Standards
• Appendix A – PPE Selection Charts and Task Checklists
• Appendix B – Pre-start PPE Inspection Checklist
• Appendix C – Example Toolbox Talk: PPE in Metalwork

Legislation & References

• Work Health and Safety Act 2011 (Cth) and mirror State/Territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Part 3.2 General workplace management and Part 3.1 Managing risks to health and safety
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Code of Practice: Managing noise and preventing hearing loss at work
• Safe Work Australia – Code of Practice: Welding processes
• AS/NZS 1337.1: Personal eye protection – Eye and face protectors for occupational applications
• AS/NZS 1338.1: Filters for eye protectors – Welding and allied processes
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 2210.1: Occupational protective footwear – Guide to selection, care and use
• AS/NZS 1270: Acoustics – Hearing protectors