Product Overview

Summary: This Welding and Cutting in Steel Fixing Safe Operating Procedure sets out clear, practical steps for carrying out hot works on reinforcing steel safely and efficiently. It helps Australian construction and civil contractors control fire, fume, electrical, and burn risks while maintaining productivity and compliance with WHS legislation and site requirements.

Welding and cutting are routine tasks in steel fixing, yet they introduce significant risks when performed around formwork, combustible materials, confined areas and other trades. This SOP provides a structured, step‑by‑step process for planning, authorising and conducting hot works on reinforcing steel in line with Australian WHS expectations. It covers everything from pre‑start inspections and hot work permits to equipment set‑up, safe welding and oxy‑fuel cutting techniques, fume and fire control, and shutdown procedures.

By implementing this procedure, businesses can demonstrate a robust, documented system for managing the specific hazards of welding and cutting in steel fixing—such as fire spread through formwork, arc flash in congested workfaces, and trip hazards from leads and hoses. The SOP supports consistent training across crews, reduces reliance on informal practices, and provides a clear reference for supervisors, auditors and regulators. It ultimately helps organisations meet their duty of care under WHS legislation, protect workers and subcontractors, and minimise costly incidents, rework and project delays on Australian construction and civil sites.

Key Benefits

• Ensure welding and cutting activities in steel fixing comply with Australian WHS legislation, site rules and hot work permit systems.
• Reduce the risk of fire, explosions, burns and electric shock when welding and cutting reinforcing steel around formwork and other structures.
• Standardise how steel fixers and welders set up, perform and shut down hot works, improving quality and productivity across projects.
• Improve oversight and documentation for supervisors, making it easier to brief new workers, verify controls and satisfy client and regulator audits.
• Minimise project disruption from equipment damage, near misses and injuries linked to poorly controlled welding and cutting tasks.

Who is this for?

• Steel Fixers
• Welding Operators
• Site Supervisors
• Leading Hands
• Construction Project Managers
• WHS Advisors and Safety Officers
• Civil Construction Supervisors
• Formwork and Reinforcement Contractors
• Principal Contractors
• Maintenance Supervisors on Construction Sites

Hazards Addressed

• Fire and ignition of formwork, timber, void formers, insulation and other combustible materials from sparks and hot slag
• Explosion risks from flammable gases, vapours or pressurised cylinders used in welding and cutting
• Burns from hot metal, molten slag, sparks and contact with heated tools and workpieces
• Electric shock and arc flash from welding equipment and damaged leads in wet or conductive environments
• Exposure to welding fumes, gases and metal particulates, particularly in enclosed or poorly ventilated areas
• Eye damage from arc radiation, flying particles and grinding associated with weld preparation and finishing
• Noise exposure from cutting, gouging and associated power tools
• Manual handling and awkward postures when welding and cutting reinforcing bar in slabs, walls and overhead positions
• Trips and falls due to poorly managed welding leads, hoses and equipment on congested decks and scaffolds
• Cylinder handling hazards including tipping, valve damage and incorrect storage or transport of gas cylinders

Included Sections

• 1.0 Purpose and Scope – Welding and Cutting in Steel Fixing
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (Steel Fixers, Welders, Supervisors, WHS Personnel)
• 4.0 Required Competencies, Licences and Training
• 5.0 Tools, Equipment and Plant (Welders, Oxy-Fuel Sets, Leads, PPE)
• 6.0 Personal Protective Equipment (PPE) Requirements for Welding and Cutting
• 7.0 Pre-Start Planning and Hot Work Permit Requirements
• 8.0 Site Preparation and Housekeeping Around Formwork and Reinforcement
• 9.0 Gas Cylinder Handling, Storage and Transport Procedures
• 10.0 Electrical Safety for Welding Equipment and Leads
• 11.0 Safe Welding Procedures for Reinforcing Steel
• 12.0 Safe Oxy-Fuel and Mechanical Cutting Procedures for Rebar
• 13.0 Ventilation, Fume Control and Atmospheric Monitoring
• 14.0 Fire Prevention Measures, Fire Watch and Extinguishing Equipment
• 15.0 Working at Heights and in Confined or Restricted Spaces
• 16.0 Communication and Coordination with Other Trades on Site
• 17.0 Step-by-Step Shutdown, Isolation and Post-Work Inspection
• 18.0 Hazard Identification, Risk Assessment and Control Measures
• 19.0 Emergency Response Procedures for Burns, Fire and Electric Shock
• 20.0 Inspection, Maintenance and Tagging of Welding and Cutting Equipment
• 21.0 Training, Induction and Toolbox Talk Guidance
• 22.0 Recordkeeping, Permits and Audit Requirements
• 23.0 Review, Consultation and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulation 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Welding Processes
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• AS 1674.1: Safety in welding and allied processes – Fire precautions
• AS 1674.2: Safety in welding and allied processes – Electrical
• AS/NZS 1554 (series): Structural steel welding
• AS/NZS 4839: The safe use of portable and mobile oxy-fuel gas systems for welding, cutting, heating and allied processes
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 2161 (series): Occupational protective gloves