Product Overview

Summary: This SOP sets out a clear, practical system for managing respiratory protection in metal working environments, where fumes, dusts, mists and gases are part of daily operations. It helps Australian businesses control airborne contaminants at the source, select and maintain the right RPE, and demonstrate robust WHS compliance while protecting workers’ long-term health.

Metal working environments expose workers to a complex mix of airborne hazards, including welding fumes, grinding dust, cutting fluids, metal particulates, and occasionally hazardous gases from surface treatments or cleaning processes. Without a structured approach to respiratory protection, businesses risk serious health outcomes for workers such as occupational asthma, metal fume fever, chronic obstructive pulmonary disease (COPD) and long-term respiratory illness, as well as potential non-compliance with Australian WHS laws. This SOP provides a detailed, step-by-step framework for identifying airborne contaminants, implementing controls, and ensuring that respiratory protective equipment (RPE) is correctly selected, fitted, used, cleaned and stored.

Designed specifically for Australian metal fabrication, machining, welding and heavy engineering operations, the procedure translates legislative and standards requirements into practical workshop actions. It supports PCBUs, supervisors and safety teams to integrate respiratory protection into daily workflows, pre-start checks, job planning and contractor management. By standardising how respiratory risks are assessed and controlled across all metal working tasks—from MIG and TIG welding to plasma cutting, grinding and polishing—this SOP helps create a safer, more consistent work environment, reduces the likelihood of regulatory scrutiny, and provides clear evidence of due diligence in the event of an incident or health surveillance finding.

Key Benefits

• Ensure consistent, compliant use of respiratory protection across all metal working activities.
• Reduce workers’ exposure to welding fumes, metal dusts and chemical mists that can cause serious long-term illness.
• Standardise RPE selection, fit testing, cleaning and maintenance to extend equipment life and reliability.
• Demonstrate alignment with Australian WHS legislation and relevant AS/NZS standards for respiratory protection.
• Support effective training, toolbox talks and onboarding for new workers and contractors in metal workshops.

Who is this for?

• Workshop Managers
• Fabrication Supervisors
• Welders and Boilermakers
• Metal Machinists and CNC Operators
• Sheet Metal Workers
• Health and Safety Representatives (HSRs)
• WHS Advisors and Managers
• Maintenance Supervisors
• Engineering Managers
• Operations Managers in Manufacturing and Fabrication

Hazards Addressed

• Inhalation of welding fumes containing metals such as manganese, chromium and nickel
• Exposure to respirable crystalline silica from cutting or grinding certain materials
• Metal dust and particulate inhalation from grinding, polishing and machining operations
• Aerosols and mists from metalworking fluids and coolants
• Fumes and gases from thermal cutting, brazing and soldering
• Ozone and nitrogen oxides generated during specific welding processes
• Exposure to vapours from solvent-based cleaners, primers and coatings used on metal surfaces
• Secondary exposure from contaminated RPE, filters and poorly maintained ventilation systems

Included Sections

• 1.0 Purpose and Scope – Application to metal fabrication, welding, machining and related tasks
• 2.0 Definitions – Airborne contaminants, RPE types, fit testing, assigned protection factors
• 3.0 Roles and Responsibilities – PCBUs, supervisors, workers, HSRs and contractors
• 4.0 Hazard Identification and Airborne Contaminant Assessment in Metal Working
• 5.0 Hierarchy of Control – Engineering controls, local exhaust ventilation and process changes
• 6.0 Selection of Respiratory Protective Equipment for Metal Working Tasks
• 7.0 Fit Testing, Fit Checking and Facial Hair Requirements
• 8.0 Pre-use Inspection and Donning/Doffing Procedures
• 9.0 Safe Use of RPE During Welding, Cutting, Grinding and Machining Operations
• 10.0 Cleaning, Decontamination, Storage and Maintenance of RPE
• 11.0 Filter Change-out Schedules and End-of-Service-Life Indicators
• 12.0 Health Monitoring and Reporting of Respiratory Symptoms
• 13.0 Training, Competency and Toolbox Talk Requirements
• 14.0 Contractor and Visitor Management in Metal Working Areas
• 15.0 Emergency Situations – RPE use during spills, ventilation failures and fire events
• 16.0 Recordkeeping – Fit test records, maintenance logs and training documentation
• 17.0 Review, Audit and Continuous Improvement of the Respiratory Protection Program

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Hazardous chemicals and airborne contaminants
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Welding Processes: Code of Practice
• Safe Work Australia – Managing the Work Environment and Facilities: Code of Practice
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 4801: Occupational health and safety management systems (superseded but still referenced in many systems)
• ISO 45001: Occupational health and safety management systems (where adopted by the organisation)