Product Overview

This Safe Work Method Statement (SWMS) sets out the high-risk work activities, hazards, and control measures associated with Poly Welding Butt Fusion and Electro-Fusion on Australian worksites. It is a comprehensive, contractor-ready document that streamlines WHS compliance across all stages of poly pipe welding, jointing, and quality assurance.

Activities & Specific Tasks Covered

This document includes specific risk controls for:

• Butt fusion welding of polyethylene (PE) pipework, including preparation, alignment, heating and fusion cycles
• Electro-fusion jointing of poly pipe systems using approved electro-fusion fittings and control units
• Set-up and safe operation of poly welding machines, generators, and associated electrical equipment
• Selection, inspection, and maintenance of welding plates, clamps, trimmers, and fusion equipment
• Safe handling, cutting, bevelling, and positioning of poly pipe lengths and fittings
• Management of heat, hot surfaces, and burn risks during butt fusion and electro-fusion processes
• Control of fumes, vapours, and airborne contaminants generated during poly welding activities
• Use of appropriate personal protective equipment (PPE) for welding, cutting, and handling hot materials
• Electrical safety for electro-fusion units, extension leads, and temporary power supply on site
• Manual handling techniques to minimise strain and injury when moving and aligning pipe sections
• Work area set-up, barricading, and housekeeping to prevent slips, trips, falls, and unauthorised access
• Environmental controls for managing offcuts, waste, and potential contamination of soil and waterways
• Inspection, testing, and verification of welded joints, including pressure testing and documentation

Who is this for?

This SWMS is designed for civil and plumbing contractors, pipeline construction crews, irrigation installers, utility maintenance teams, and site supervisors involved in poly pipe welding and installation.

Specific Job Steps & Hazards Covered

Legislation & References

This document was researched and developed to align with:

• Code of Practice: Construction Work – Managing WHS risks associated with construction-related poly welding and pipe installation activities
• Code of Practice: Managing the Risk of Falls at Workplaces – Where welding and jointing are undertaken in excavations, on embankments, or uneven ground
• Code of Practice: Hazardous Manual Tasks – Controls for lifting, carrying, and positioning heavy poly pipes and welding equipment
• Code of Practice: Managing Noise and Preventing Hearing Loss at Work – Guidance for controlling noise exposure from generators and powered equipment
• Code of Practice: Managing Electrical Risks in the Workplace – Requirements for safe use of electro-fusion units, leads, and temporary power
• AS/NZS 2033: Installation of Polyethylene Pipe Systems for Industrial Applications – Guidance on installation practices for PE pipe systems
• AS/NZS 4130: Polyethylene (PE) Pipes for Pressure Applications – Requirements for PE pipe materials used in butt fusion and electro-fusion
• AS/NZS 4129: Fittings for Polyethylene (PE) Pipes for Pressure Applications – Specifications for electro-fusion and butt fusion fittings
• AS/NZS 3000: Electrical Installations (Wiring Rules) – General electrical safety principles relevant to on-site welding equipment
• Work Health and Safety Act 2011
• Work Health and Safety Regulations 2017