Product Overview

Summary: This Thermal Cutting and Burning Safety Safe Operating Procedure provides a clear, step‑by‑step framework for managing oxy-fuel, plasma and other hot work activities in line with Australian WHS requirements. It helps you control fire, explosion, fume and burn risks, while giving supervisors and workers a practical, defensible method for carrying out hot work safely on any site.

Thermal cutting and burning operations – including oxy-acetylene cutting, oxy-LPG cutting, air-arc gouging and plasma cutting – are routine in many Australian workshops, construction sites and maintenance environments, yet they present a high potential for catastrophic fires, explosions, serious burns and harmful fume exposure. This Safety Operating Procedure sets out a structured, repeatable method for planning, authorising and carrying out hot work so that these risks are systematically identified, controlled and monitored. It aligns with Australian WHS legislation and recognised industry guidance, giving you a clear line of sight between day-to-day practice and your legal duty of care.

The document goes beyond generic hot work rules by addressing the specific hazards of thermal cutting and burning: gas cylinder handling and storage, flashback and backfire risks, management of sparks and slag, cutting near flammable materials, working at heights, and controlling fumes, noise and UV/IR radiation. It provides practical tools for pre-start inspections, hot work permitting, isolation and atmosphere testing, PPE selection, fire watch duties and emergency response. By implementing this SOP, businesses can standardise their approach across multiple sites, improve worker competency and confidence, reduce downtime from incidents, and demonstrate robust WHS governance to clients, insurers and regulators.

Key Benefits

• Ensure consistent, legally defensible control of thermal cutting and burning risks across all worksites.
• Reduce the likelihood of fires, explosions, flashbacks and serious burn injuries during hot work activities.
• Improve worker competency through clear, task-specific instructions, checklists and PPE requirements.
• Streamline hot work permit, pre-start inspection and sign-off processes for supervisors and contractors.
• Demonstrate compliance with Australian WHS legislation, relevant standards and client safety expectations.

Who is this for?

• WHS Managers
• Site Supervisors
• Workshop Supervisors
• Boilermakers and Welders
• Fabricators
• Maintenance Technicians
• Construction Project Managers
• Manufacturing Managers
• Safety Officers
• Hot Work Permit Issuers and Fire Watchers

Hazards Addressed

• Fire and explosion from sparks, slag and ignition of combustible or flammable materials
• Gas leaks, flashbacks and backfires in oxy-fuel cutting systems
• Burns from hot metal, molten slag, flames and heated equipment
• Inhalation of welding and cutting fumes, gases and vapours (including metal fumes and ozone)
• Oxygen-enriched atmospheres increasing fire intensity and risk
• UV and IR radiation exposure causing eye damage and skin burns
• Noise exposure from cutting and burning equipment
• Electric shock risks associated with certain thermal cutting processes
• Cylinder handling, transport and storage hazards (rupture, falls, manual handling injuries)
• Working at heights and confined space hazards when performing hot work in elevated or restricted areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Thermal Cutting and Burning
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Assessment for Hot Work
• 6.0 Hot Work Permit and Authorisation Requirements
• 7.0 Equipment Selection, Inspection and Maintenance (Oxy-fuel, Plasma, Gouging)
• 8.0 Gas Cylinder Handling, Storage and Transport Procedures
• 9.0 Pre-Start Site Preparation and Isolation of Flammable Materials
• 10.0 Personal Protective Equipment (PPE) Requirements
• 11.0 Safe Operating Procedure – Step-by-Step Thermal Cutting and Burning
• 12.0 Ventilation, Fume and Atmospheric Control Measures
• 13.0 Fire Prevention, Fire Watch Duties and Post-Work Monitoring
• 14.0 Working at Heights, Confined Spaces and Restricted Areas
• 15.0 Emergency Procedures and Incident Response
• 16.0 Training, Induction and Competency Verification
• 17.0 Record Keeping, Monitoring and Continuous Improvement
• 18.0 Review, Audit and Document Control

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Welding Processes
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• AS 4839: The safe use of portable and mobile oxy-fuel gas systems for welding, cutting, heating and allied processes
• AS 1674.1: Safety in welding and allied processes – Fire precautions
• AS 1674.2: Safety in welding and allied processes – Electrical
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 4501: Occupational protective clothing
• AS/NZS 1269: Occupational noise management