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Welding Cutting and Grinding General Hot Works Risk Assessment

This risk assessment covers general hot works, including planning, equipment set-up, welding, cutting, grinding, ventilation and post-work checks.

Activities covered include

  • Assess the work area, nearby materials, access and emergency readiness before starting
  • Carry out welding, cutting and grinding while managing heat, sparks, glare and moving parts
  • Complete fire watch, cool-down, isolation and post-work area checks

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Welding Cutting and Grinding General Hot Works 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

Product Overview

This risk assessment covers general hot works, including planning, equipment set-up, welding, cutting, grinding, ventilation and post-work checks. It supports planning and risk management by identifying fire, explosion, electrical, airborne contaminant and interaction hazards before, during and after work.

Activities & Risks Covered

This assessment addresses activities and risks including:

  • Assess the work area, nearby materials, access and emergency readiness before starting
  • Set up welding equipment, power sources, leads and hoses safely
  • Isolate flammable, combustible and other fire or explosion hazards
  • Manage ventilation, fumes, gases and airborne grinding dust
  • Handle cylinders and gas equipment during use and storage
  • Carry out welding, cutting and grinding while managing heat, sparks, glare and moving parts
  • Assess restricted or enclosed work areas and changing atmospheric conditions
  • Coordinate hot work around pedestrians, mobile plant and adjacent activities
  • Manage heat, hydration, fatigue, wind and hot environmental conditions
  • Complete fire watch, cool-down, isolation and post-work area checks

Who is this for?

Suitable for workers, supervisors, contractors and businesses carrying out welding, cutting, grinding or other general hot works.

Activities & Hazards Covered

Activity Potential Hazards
Pre-start planning and work area assessment
  • Starting hot work in an unsuitable area
  • Unidentified flammable or combustible materials in or near the job
  • Other workers or adjacent activities entering the hot work area
  • Work commencing without clear authority, consultation or emergency readiness
Set-up of equipment, leads, hoses and power sources
  • Electric shock from damaged welding sets, leads or plugs
  • Fire from faulty electrical equipment or poor connections
  • Trips from poorly routed leads and hoses
  • Gas leaks or hose failure during set-up
Isolation of fire and explosion hazards
  • Ignition of flammable gases, vapours, liquids or combustible materials
  • Explosion from hot work on drums, tanks, pipes or vessels containing residues
  • Oxygen enrichment increasing fire intensity
  • Sparks travelling to hidden or remote fuel sources
Ventilation and airborne contaminant control
  • Exposure to welding fumes, metal fumes, gases and airborne grinding dust
  • Build-up of contaminants in poorly ventilated areas
  • Reduced visibility and irritation affecting safe work
  • Respiratory harm to the welder or nearby workers
Cylinder handling and gas equipment use
  • Cylinder falling or impact damage
  • Gas leak, flashback or hose ignition
  • Incorrect gas set-up or incompatible equipment
  • Fire or explosion during use or storage
Welding, cutting and grinding operations
  • Burns from hot metal, slag, sparks and flame
  • Eye injury from arc flash, flying particles and glare
  • Hand injury from contact with sharp edges or rotating discs
  • Disc burst or loss of control of grinder
  • Electric shock during welding
Work in restricted, enclosed or hazardous atmospheres
  • Rapid build-up of fumes or oxygen deficiency
  • Ignition in a hazardous atmosphere
  • Limited access and delayed escape in an emergency
  • Inadequate monitoring of changing conditions
Interaction with mobile plant, pedestrians and surrounding work
  • Collision with forklifts, vehicles or mobile plant
  • Other trades entering the line of fire
  • Trips, distractions and loss of tool control in shared areas
  • Damage to leads, hoses or screens from plant movement
Heat, fatigue and environmental conditions
  • Heat stress and dehydration
  • Reduced concentration leading to mistakes or poor judgement
  • Increased fire spread from wind or hot conditions
  • PPE burden increasing fatigue
Completion, fire watch and post-work checks
  • Smouldering material or delayed ignition after work stops
  • Burns from handling hot metal or tools
  • Gas release or electrical hazard left energised
  • Area handed back while still unsafe

Need to tailor this risk assessment?

Use the BlueSafe Portal to add site-specific activities, hazards, controls, responsibilities and review details before the assessment is put into use.

Acceptance Guaranteed: If your client or principal requests changes during document review, BlueSafe will help revise the document at no extra cost and support resubmission until it is accepted.

Legislation & References

The template records model guidance used to inform the documented controls. Applicable WHS/OHS laws and adopted Codes vary by state or territory, so confirm the current local requirements when tailoring the assessment:

  • Model guidance: Model Code of Practice: Welding processes — 1.3 What is involved in managing risks associated with welding processes?; p. 10.
  • Model guidance: Model Code of Practice: Managing the risk of fatigue at work — Provide sufficient breaks while at work; p. 30.
  • Model guidance: Model Code of Practice: Managing electrical risks in the workplace — 2.1 Identifying the hazards; p. 14.
  • Model guidance: Model Code of Practice: Managing the work environment and facilities — 1.2 Managing risks associated with the work environment and facilities; p. 12.
  • Model guidance: Model Code of Practice: Confined spaces — 3.4 Assessing the risks; p. 24.
  • Model guidance: Model Code of Practice: How to manage work health and safety risks — 5. Step 4 — How to review controls; p. 27.
  • Model guidance: Model Code of Practice: Managing risks of plant in the workplace — Plant hazard identification — Traffic movements in the workplace; p. 17.
Standard Risk Assessment Features (Click to Expand)
  • Activity-specific hazard identification and control measures
  • Initial and residual risk ratings
  • Assigned responsible persons for each activity
  • Risk matrix and assessment classification
  • Review, monitoring and sign-off fields
  • Site-specific customisation before use

Suitable for Industries

Building and ConstructionTransport and LogisticsManufacturing and ProductionWarehousing and DistributionCivil Construction and EarthworksMetal Fabrication and WeldingMining and Resources

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