Poly Welding Butt Fusion and Electro-Fusion Risk Assessment

Product Overview

This risk assessment covers poly welding using butt fusion and electro-fusion methods, including preparation, joining, cooling, inspection and pack-up. It supports planning by identifying hazards around equipment, pipe handling, heat, electricity and work conditions so risks can be managed throughout the task.

Activities & Risks Covered

This assessment addresses activities and risks including:

• Complete planning, pre-start checks and review relevant equipment information
• Set up the work area and manage access around the welding zone
• Inspect and use fusion equipment, leads and electrical supplies
• Handle, position and align pipes, fittings and welding equipment
• Prepare, face, scrape and clean pipe ends and fittings
• Carry out butt fusion heating and joining tasks
• Complete electro-fusion connections and welding activities
• Manage fire, fumes and hazardous atmospheres in the work area
• Allow joints to cool, then inspect and manage pressure-related hazards
• Shut down equipment, maintain housekeeping and prepare for emergencies

Who is this for?

Suitable for contractors, workers, supervisors and businesses carrying out poly welding butt fusion and electro-fusion activities.

Activities & Hazards Covered

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 — 1.3 What is involved in managing risks associated with welding processes?; p. 10.
• Model guidance: Model Code of Practice: Managing electrical risks in the workplace — 2.1 Identifying the hazards; p. 14.
• Model guidance: Model Code of Practice: Managing risks of hazardous chemicals in the workplace — 2.2 Safety Data Sheets (SDS); p. 16.
• Model guidance: Model Code of Practice: Hazardous manual tasks — 4.1 The hierarchy of control measures; p. 31.
• Model guidance: Model Code of Practice: Excavation work — 2.3. Controlling the risks; p. 17.
• Model guidance: Model Code of Practice: First aid in the workplace — 3. First aid equipment, facilities and training; p. 12.
• Model guidance: Model Code of Practice: Managing the work environment and facilities — 2.8 Heat and cold; p. 21.
• 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: Managing risks of plant in the workplace — Plant hazard identification — Traffic movements in the workplace; p. 17.

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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