Product Overview

Summary: This Safe Operating Procedure provides a clear, step-by-step method for conducting risk assessments in metal workshops, where high‑energy tools, hot work and heavy materials create significant hazards. It helps Australian businesses systematically identify, assess and control risks, ensuring safer day‑to‑day operations and stronger WHS compliance across fabrication, machining and maintenance activities.

Metal workshops are high‑risk environments, combining powered machinery, hot work, hazardous chemicals and heavy manual handling in close proximity. Without a structured approach to risk assessment, hazards such as entanglement in rotating equipment, eye injuries from flying swarf, burns from welding and grinding, or exposure to welding fumes can easily be overlooked. This SOP sets out a practical, workshop‑specific framework for identifying hazards, assessing risk levels and implementing effective control measures before work begins and whenever processes change.

Designed for Australian metal fabrication, machining and repair businesses, the procedure translates WHS legislative requirements into clear, repeatable steps that supervisors and workers can actually follow on the workshop floor. It guides users through pre‑task risk assessments (including Job Safety Analysis and Safe Work Method Statements where applicable), consultation with workers and apprentices, selection of appropriate controls using the hierarchy of control, and documentation requirements to demonstrate due diligence. By implementing this SOP, businesses can reduce incident rates, support consistent decision‑making across shifts and sites, and provide clear evidence of compliance during audits, regulator inspections or insurance reviews.

Key Benefits

• Ensure a consistent, defensible approach to risk assessment across all metal workshop tasks and shifts.
• Reduce the likelihood of injuries from machinery, hot work, sharp edges and hazardous substances through systematic hazard control.
• Strengthen compliance with Australian WHS legislation and Codes of Practice specific to metal fabrication and machining environments.
• Improve worker engagement and safety culture by embedding consultation and participation in every risk assessment.
• Streamline documentation for audits, incident investigations and insurance purposes with clear records of identified risks and controls.

Who is this for?

• Workshop Managers
• Fabrication Supervisors
• WHS Managers
• Health and Safety Representatives (HSRs)
• Metal Fabricators and Boilermakers
• Fitters and Turners
• Maintenance Supervisors
• Operations Managers
• Apprentice Coordinators
• Small Metal Workshop Owners

Hazards Addressed

• Entanglement in rotating machinery (lathes, drills, mills, pedestal grinders)
• Contact with moving parts on presses, guillotines, rollers and cutting equipment
• Eye and face injuries from flying metal swarf, sparks and fragments
• Burns from welding, oxy‑fuel cutting, plasma cutting and hot surfaces
• Exposure to welding fumes, metal dusts and gases in poorly ventilated areas
• Noise exposure from grinders, hammers, compressors and impact tools
• Hand and finger injuries from sharp edges, burrs and manual handling of sheet and plate
• Crush injuries from handling and storing heavy steel sections, plates and gas cylinders
• Fire and explosion risks from hot work near flammable liquids, gases or combustible materials
• Electric shock from faulty welding plants, extension leads and portable tools
• Slips, trips and falls due to offcuts, swarf, hoses and leads on the workshop floor
• Musculoskeletal disorders from repetitive tasks, awkward postures and heavy lifting

Included Sections

• 1.0 Purpose and Scope – Application of risk assessment to metal fabrication, machining and maintenance tasks
• 2.0 Definitions – Key WHS and metal workshop terminology (risk, hazard, reasonably practicable, plant, hot work)
• 3.0 Roles and Responsibilities – Duties of PCBUs, managers, supervisors, workers and HSRs in the risk assessment process
• 4.0 Applicable Legislation, Standards and Codes of Practice – Summary of WHS requirements for metal workshops
• 5.0 Risk Management Framework – Overview of the four‑step process: identify, assess, control, review
• 6.0 Hazard Identification in Metal Workshops – Checklists for machinery, hot work, manual handling, chemicals and environment
• 7.0 Risk Assessment Methodology – Likelihood and consequence ratings, risk matrix and prioritisation of controls
• 8.0 Control Measures and the Hierarchy of Control – Workshop‑specific examples for eliminating or minimising risks
• 9.0 Pre‑Task Risk Assessments – Procedures for JSAs, SWMS and toolbox talks before starting high‑risk work
• 10.0 Plant and Equipment Risk Assessments – Requirements for new, modified and hired machinery and tools
• 11.0 Hot Work and Welding Risk Assessments – Additional controls for fire, explosion and fume exposure
• 12.0 Documentation and Record Keeping – Templates, checklists and retention requirements for risk assessments
• 13.0 Consultation, Communication and Training – Involving workers, apprentices and contractors in the process
• 14.0 Review, Monitoring and Continuous Improvement – Triggers and timeframes for reviewing existing risk assessments
• 15.0 Incident and Near‑Miss Integration – Using incident data to update and improve risk controls
• 16.0 Audit and Compliance Checklist – Internal review tool to verify implementation of this SOP in the workshop

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent State/Territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent State/Territory WHS Regulations
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Welding Processes
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• AS/NZS ISO 45001:2018 Occupational health and safety management systems
• AS 4024 series: Safety of machinery
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1337.1: Personal eye protection