BlueSafe
Electric Welding Arc MIG TIG and Spot Welding Risk Assessment

Electric Welding Arc MIG TIG and Spot Welding Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
  • • Pre-filled Content – Ready to Deploy Immediately
  • • Customisable – Easily Add Your Logo & Site Details
  • • Includes 2 Years of Free Compliance Updates

Electric Welding Arc MIG TIG and Spot Welding Risk Assessment

Product Overview

Identify and control organisational risks associated with Electric Welding Arc, MIG, TIG and Spot Welding through a structured, management-level WHS Risk Management framework that focuses on systems, planning and governance rather than step-by-step work instructions. This Risk Assessment supports executive Due Diligence, alignment with the WHS Act, and reduction of operational liability across your welding operations.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Governance, Duties and Consultation: Assessment of officer due diligence, PCBU obligations, consultation with workers and HSRs, and integration of welding risks into the broader WHS management system.
  • Competency, Licensing and Training Systems: Management of welding competency requirements, verification of licences and trade qualifications, refresher training, and competency assessment records for all welding personnel.
  • Plant Procurement, Design and Selection of Welding Equipment: Controls for specification, selection and purchase of welding plant, including suitability for task, safety features, guarding, and compliance documentation from suppliers.
  • Plant Registration, Inspection, Maintenance and Isolation Systems: Systems for asset registers, pre-use checks, periodic inspections, preventative maintenance schedules, tagging, lock-out/tag-out and decommissioning of welding equipment.
  • Electrical Safety and Energy Isolation Management: Assessment of electrical supply arrangements, RCD use, cable management, fault detection, and procedures for isolating and verifying de-energisation of welding circuits and associated plant.
  • Welding Area Layout, Enclosures and Access Control: Management of welding bays, screens and barriers, segregation from other workgroups, ventilation design, signage, and restricted access controls to minimise exposure to non-welding personnel.
  • Fume, Gas and Fire/Explosion Risk Management: Controls for welding fumes and gases, ventilation and extraction systems, hot work permitting, combustible materials management, and ignition source control to prevent fires and explosions.
  • PPE, PAPR Welding Helmets and Flash Protection Systems: Selection, issue and maintenance of appropriate PPE, including PAPR helmets, eye and face protection, gloves, clothing, and flash protection measures for workers and bystanders.
  • Safe Work Procedures and Integration with SWMS: Development and governance of documented welding procedures, integration with task-specific SWMS, authorisation processes, and periodic review to ensure procedures remain current and effective.
  • Automation, Cobot and Robot Welding Safety Management: Assessment of automated welding cells, collaborative robots, interlocks, light curtains, guarding, and programming/change management controls for robotic welding systems.
  • Manual Handling, Ergonomics and Work Organisation: Management of lifting, positioning and supporting workpieces, workstation design, rotation of tasks, and ergonomic controls to reduce musculoskeletal injury risk in welding operations.
  • Hazardous Substances, RF/HF Exposure and Post-Weld Heat Treatment Control: Controls for welding consumables, shielding gases, cleaning and pre-treatment chemicals, RF/HF exposure from specialised processes, and management of post-weld heat treatment operations.
  • Housekeeping, Cleanup After Welding and Waste Management: Systems for managing offcuts, slag, spatter, dust, and waste materials, including safe cleanup methods, segregation and disposal of hazardous waste, and prevention of slip, trip and fire hazards.
  • Emergency Preparedness, Incident Response and First Aid: Planning for welding-related emergencies including burns, electric shock, eye injuries and fires, with documented response procedures, first aid provisions, training and incident reporting protocols.

Who is this for?

This Risk Assessment is designed for Business Owners, Operations Managers, Engineering Managers and Safety Professionals responsible for planning, approving and overseeing Electric Welding Arc, MIG, TIG and Spot Welding activities across workshops, fabrication facilities and project sites.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Governance, Duties and Consultation
  • • Lack of clear allocation of WHS officer and PCBU duties for welding activities under WHS Act 2011
  • • Inadequate consultation with Health and Safety Representatives (HSRs) and welders about welding risks and changes to processes
  • • Failure to integrate electric welding (MIG, TIG, SMAW, flux core, submerged arc, spot, RF/HF, cobot and robot systems) into the organisation’s WHS management system
  • • No formal process to review incidents, near misses or regulator safety alerts relating to welding operations
  • • Insufficient consideration of welding-specific risks in Board / senior management WHS reporting and due diligence activities
2. Competency, Licensing and Training Systems
  • • Inadequate verification of welder competency for different processes (MIG, TIG, SMAW, flux core, submerged arc, spot welding, RF/HF welding, pin welding, manual arc welding, gas metal arc welding, metal gas tungsten arc welding)
  • • No structured training on UV exposure, arc flash protection, flash protection safety, electrical hazards, RF/HF exposure and fumes from welding operations
  • • Lack of competency assessment for use of specialised equipment such as robot welder, cobot welding cells, PAPR welding helmets and RF/HF welders
  • • Informal “buddy” training with no documented learning outcomes or assessment of safe work practices
  • • No refresher training program to maintain awareness of new technology, standards and legislative changes
  • • Supervisors not trained to monitor and enforce correct PPE use and safe setup of welding enclosures and barriers
3. Plant Procurement, Design and Selection of Welding Equipment
  • • Procurement of electric welders, MIG welders, TIG sets, manual arc welders, flux core welders, submerged arc machines, spot welders, pin welding machines and RF/HF welders that are not compliant with relevant Australian Standards
  • • Failure to consider inherent safety features (e.g. voltage reduction devices, interlocks, emergency stops, guarding, flash protection) when purchasing welding equipment and robot welders
  • • Selection of welding plant that is incompatible with existing power supply capacity or earthing systems, increasing risk of electrical faults
  • • Insufficient specification of welding enclosure barriers, screens and local exhaust ventilation with new plant purchases
  • • Inadequate assessment of ergonomic risks (e.g. cable weight, gun handle design, manipulators for welding brackets and frames) during design and procurement
  • • No requirement for suppliers to provide technical documentation, safety instructions and maintenance schedules at the time of purchase
4. Plant Registration, Inspection, Maintenance and Isolation Systems
  • • Lack of a plant register for all electric welders, MIG/TIG units, metal resistance welding machines, metal shielded metal arc welding machines, submerged arc systems, RF/HF welders and spot welding machines
  • • Inadequate preventative maintenance systems for welding power sources, cables, torches, clamps and robot/cobot welding cells
  • • No formal test-and-tag or electrical inspection program for welding leads, extension cords and auxiliary power tools used for slag removal or wire brush cleaning slag
  • • Absence of lockout/tagout (LOTO) procedures for welding plant during maintenance, repair or modification
  • • Continued use of damaged welding equipment (e.g. cracked insulation, exposed conductors, faulty earth clamps, damaged spot welder tongs) due to poor defect reporting and repair systems
  • • Failure to inspect and maintain RF/HF shielding and interlocks on radio frequency and high frequency welders
5. Electrical Safety and Energy Isolation Management
  • • Inadequate earthing and bonding of electric welders, metal structures and workpieces, leading to shock or arc faults
  • • Overloading of circuits or use of inappropriate extension leads and power boards for high-current welding equipment
  • • Lack of system for verifying correct voltage, phase, and capacity of power supplies before connecting submerged arc, MIG, TIG or resistance spot welding machines
  • • Absence of procedures for managing stored energy in capacitors or inductive systems in RF/HF welders and spot welders
  • • Improper use of welding return leads (e.g. routing near control cables or communication lines) creating stray current hazards
  • • No documented procedures for electrical work on welding equipment by qualified electricians
6. Welding Area Layout, Enclosures and Access Control
  • • Poorly designed welding bays without adequate separation between manual welding, cobot welding and robot welding cells
  • • Absence of welding enclosure barriers, screens or curtains to control UV exposure from welding operations and protect nearby workers from flash
  • • Inadequate access control and interlocking around robot welder and cobot welding cells, increasing risk of entrapment or collision
  • • Welding conducted in ad-hoc locations without control of combustibles, ventilation or traffic management
  • • Insufficient space for safe handling of large welding brackets and frames, leading to crush and strain hazards
  • • No designated and signposted clean and dirty zones for pre-weld preparation, weld execution and cleanup after welding (including slag and spatter removal)
7. Fume, Gas and Fire/Explosion Risk Management
  • • Inadequate local exhaust ventilation and general ventilation for gas metal arc welding, flux core welding, submerged arc welding and manual arc welding, leading to harmful fume and gas exposure
  • • Failure to control fire and explosion risks where welding is undertaken near flammable vapours, gases, coatings or combustible materials
  • • No system for assessing welding fume composition (e.g. during stainless steel, galvanised or specialised alloy work) and implementing appropriate controls
  • • Insufficient procedures for hot work permits for welding in hazardous or confined spaces, or on tanks and vessels
  • • Inadequate control of fume and hot particles generated during cleanup after welding, such as remove slag from a weld and wire brush cleaning slag
  • • Poor cylinder management for shielding gases, including unsecured gas cylinders and lack of leak-check systems
8. PPE, PAPR Welding Helmets and Flash Protection Systems
  • • Workers conducting welding tasks without appropriate PPE (e.g. inadequate welding helmets, gloves, protective clothing, respiratory protection, eye and face protection)
  • • Incorrect selection, fit or maintenance of PAPR welding helmets for high-fume processes such as flux core welding and gas metal arc welding
  • • Lack of systematic approach to flash protection safety for bystanders and adjacent workers in shared workshop spaces
  • • No documented process for inspection and replacement of PPE exposed to UV, spatter and slag during welding and cleanup operations
  • • Inconsistent use of PPE during ancillary tasks such as remove slag from a weld and wire brush cleaning slag
9. Safe Work Procedures and Integration with SWMS
  • • Lack of overarching procedures describing safe systems of work for welding that integrate multiple processes (MIG, TIG, SMAW, flux core, submerged arc, spot welding, RF/HF welding, cobot and robot welding)
  • • Reliance solely on task-level SWMS without higher-level system controls and management guidance
  • • Inconsistent procedures for specialised tasks such as perform spot welds, pin welding, post-weld heat treatment, and welding brackets and frames
  • • No formal review process to ensure SWMS and procedures remain current with technology, legislation and standards
  • • Confusion among workers and supervisors about responsibility for authorising and implementing welding SWMS
10. Automation, Cobot and Robot Welding Safety Management
  • • Inadequate risk assessment of robot welder and cobot welding systems, including interaction with human workers
  • • Failure of safeguarding systems (e.g. light curtains, pressure mats, interlocks) due to poor maintenance or bypassing
  • • Lack of clear procedures for programming, teaching and fault recovery for robot welders and cobots
  • • Insufficient training for operators and maintenance personnel on the specific hazards of automated welding cells
  • • Uncontrolled changes to welding programs, fixtures or tooling for automated cells, affecting safety distances and reach envelopes
11. Manual Handling, Ergonomics and Work Organisation
  • • Poor manual handling systems for moving heavy components, jigs and welding brackets and frames in and out of welding areas
  • • Ergonomically poor workstation design for MIG, TIG, flux core and manual arc welding resulting in awkward postures and repetitive strain
  • • No rotation or job design to manage fatigue and repetitive tasks such as continuous weld runs and repetitive spot welding operations
  • • Inadequate provision of handling aids for cleanup after welding, including manoeuvring large welded assemblies for slag removal and wire brush cleaning slag
  • • Insufficient planning for shared use of cranes, forklifts and positioners, creating congestion and interaction risks in welding areas
12. Hazardous Substances, RF/HF Exposure and Post-Weld Heat Treatment Control
  • • Inadequate management of hazardous substances associated with fluxes, shielding gases, coatings, cleaners and consumables used in flux core welding, submerged arc welding and gas metal arc welding
  • • No formal system to assess and control exposure to radio frequency and high frequency emissions from RF/HF welders
  • • Insufficient procedures for safe setup and monitoring of post-weld heat treatment operations (e.g. local heating, ovens, insulated blankets), leading to burn, fire or thermal stress hazards
  • • Poor storage and labelling of chemicals and fluxes used in welding processes
  • • Lack of medical surveillance or exposure monitoring where there is potential for significant fume or RF/HF exposure
13. Housekeeping, Cleanup After Welding and Waste Management
  • • Poor housekeeping in welding areas leading to accumulation of slag, offcuts, wire, spatter and consumable waste
  • • Uncontrolled methods for cleanup after welding, including remove slag from a weld and wire brush cleaning slag, creating slip, trip and particle hazards
  • • Inadequate systems for collection and disposal of metal dusts, slag and spent welding consumables, increasing fire risk and exposure
  • • Lack of designated storage for welding tools and equipment used in cleanup, causing clutter and damage
  • • No regular inspection regime to verify cleanliness and orderliness of welding work areas
14. Emergency Preparedness, Incident Response and First Aid
  • • Inadequate emergency response planning for welding-related incidents such as burns, electric shock, eye flash, fire or fume overexposure
  • • Lack of accessible and suitable firefighting equipment (e.g. appropriate extinguishers for electrical and metal fires) in welding areas
  • • Insufficient first aid resources and trained first aiders familiar with welding-specific injuries (flash burns, slag in eye, RF/HF exposure)
  • • Poor incident reporting and investigation processes for welding near misses and equipment failures
  • • No arrangements with external emergency services that consider location and hazards of welding operations

Need to add specific hazards for your workplace?

Don't worry if a specific hazard isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom hazards at no extra cost. We take care of the hard work—creating the risk ratings and control measures for free—to ensure your document is compliant within minutes.

Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Model Code of Practice – Welding Processes: Guidance on managing health and safety risks associated with welding.
  • Model Code of Practice – How to Manage Work Health and Safety Risks: Framework for identifying, assessing and controlling workplace risks.
  • Model Code of Practice – Managing Electrical Risks in the Workplace: Requirements and guidance for electrical safety and isolation.
  • Model Code of Practice – Managing the Work Environment and Facilities: Requirements for layout, ventilation, amenities and general work environment.
  • Model Code of Practice – Hazardous Chemicals: Management of hazardous substances including welding fumes, gases and related chemicals.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS 1674.1: Safety in welding and allied processes – Fire precautions.
  • AS 1674.2: Safety in welding and allied processes – Electrical.
  • AS/NZS 4836: Safe working on or near low-voltage electrical installations and equipment.
  • AS/NZS 2161 Series: Occupational protective gloves – Selection and use for welding tasks.
  • AS/NZS 1337 & AS/NZS 1338: Eye and face protection for occupational applications, including welding.
  • AS/NZS 1715 & AS/NZS 1716: Selection, use and maintenance of respiratory protective equipment for welding fumes and gases.
  • AS/NZS ISO 45001:2018: Occupational health and safety management systems – Requirements with guidance for use.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

$79.5

Safe Work Australia Aligned