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Welding Risk Assessment Template

Ensuring safe practices during welding operations

Welding Risk Assessment Template

The Welding Risk Assessment Template is intended for personnel involved in welding tasks. It offers a clear, step-by-step framework to identify, evaluate, and control the unique hazards linked to welding work.

The template covers critical safety, health, and environmental factors to guarantee comprehensive risk evaluation and the application of appropriate protective measures.

Welding Risk Assessment

1. Task Description

2. Hazard Identification

3. Risk Evaluation

4. Control Measures

5. Health and Safety Requirements

6. Environmental Requirements

7. Monitoring and Review

Additional Notes/Comments

Assessor

Supervisor/Manager Approval (if required)

Regular completion of the Welding Risk Assessment Template is essential for safe welding practices. It enables systematic hazard identification, accurate risk evaluation, and effective implementation of control measures.

Consistent use of this template supports full compliance with health and safety regulations while promoting the safety and welfare of everyone involved in or affected by welding operations.

Welding is one of the most hazardous processes in manufacturing, construction, and repair work. A systematic welding risk assessment is essential to identify hazards, evaluate risks, and implement effective controls to protect workers and comply with regulations (e.g., OSHA 1910 Subpart Q, COSHH in the UK, ISO 15012 series, etc.).

1. Main Hazards in Welding

Hazard Category

Specific Hazards

Common Consequences

Thermal

Arc radiation (UV, IR), hot metal, sparks, molten spatter

Burns, arc eye (photokeratitis), fires

Electrical

Electric shock from arc welding equipment, live parts

Electrocution, cardiac arrest

Fumes & Gases

Metal fumes (Mn, Cr(VI), Zn, Al), ozone, nitrogen oxides, carbon monoxide, shielding gases (Ar, CO₂)

Metal fume fever, lung disease, cancer (Cr(VI)), asphyxiation

Physical

Noise, vibration (from grinders), ergonomic issues, confined spaces

Hearing loss, HAVS, musculoskeletal disorders, oxygen deficiency

Fire & Explosion

Flammable gases (acetylene, propane), combustible materials

Fires, explosions

Mechanical

Flying particles, sharp edges, heavy equipment

Eye injuries, cuts, crush injuries

Chemical

Fluxes, coatings, cleaning solvents

Dermatitis, chemical burns

2. Step-by-Step Welding Risk Assessment Process (based on HSE/ILO 5-Step Model)

Step 1 – Identify the Hazards

  • Review welding processes used (MIG/MAG, MMA, TIG, plasma, oxy-fuel, etc.)
  • Examine materials (mild steel, stainless, aluminum, galvanized, painted/coated metals)
  • Consider location (workshop, confined space, height, outdoors)
  • Involve welders and supervisors in walk-through inspections

Step 2 – Decide Who Might Be Harmed and How

  • Welders and welders’ helpers
  • Adjacent workers (bystanders)
  • Cleaners, maintenance staff, contractors
  • Vulnerable groups (young workers, pregnant workers, sensitized individuals)

Step 3 – Evaluate Risks and Decide on Precautions (Apply Hierarchy of Controls)

Risk Level

Example Controls (in order of preference)

Elimination

Replace welding with mechanical fasteners where possible; use pre-fabricated components

Substitution

Use lower-fume processes (e.g., TIG instead of flux-cored); use lead-free or Cr(VI)-free consumables

Engineering

Local exhaust ventilation (LEV) – moveable capture hoods, on-torch extraction, downdraft tables; welding screens with UV-filtering curtains; automatic voltage reduction devices

Administrative

Permit-to-work systems for hot work and confined spaces; job rotation to limit exposure time; training and supervision; fume exposure monitoring (WEL/TLV compliance)

PPE (last resort)

Auto-darkening welding helmets (EN 379 / ANSI Z87.1), flame-resistant clothing (EN ISO 11611), respiratory protection (FFP3 or powered air-purifying respirators with welding filters), hearing protection, safety glasses under helmet

Step 4 – Record Significant Findings

Create a written risk assessment that includes:

  • Description of tasks
  • Hazards and risk ratings (High/Medium/Low or numerical 1–25 matrix)
  • Existing and additional control measures
  • Responsible persons and completion dates
  • Review date (at least annually or after incidents/equipment change)

Step 5 – Review and Update

Triggers for review:

  • New equipment or consumables
  • Incident or near-miss
  • Changes in legislation or exposure limits
  • Air monitoring results exceeding limits
  • New medical evidence (e.g., sensitisation cases)

3. Specific High-Risk Scenarios & Recommended Controls

Scenario

Key Additional Controls

Welding stainless steel

Mandatory Cr(VI) monitoring, RPE with APF ≥40, health surveillance for asthma/Cr(VI) effects

Galvanized or coated metals

Pre-grinding to remove coating, high-efficiency LEV, zinc fume fever awareness training

Confined spaces

Forced ventilation, continuous gas monitoring, rescue plan, permit-to-work

Welding at height

Fire watch below, flame-resistant mats, hot-work permit, fall protection

Manganese exposure (high in MMA/MIG on steel)

Neurological health surveillance, keep below 0.05 mg/m³ (new OSHA/UK recommendation)

4. Exposure Limits (2024–2025 values – always check current national regulations)

Substance

8-hr TWA (UK WEL / OSHA PEL / ACGIH TLV)

Welding fume (total)

5 mg/m³ (UK proposed 2024) / No specific OSHA limit (nuisance dust)

Manganese

0.02 mg/m³ inhalable, 0.01 mg/m³ respirable (ACGIH 2024)

Hexavalent chromium

0.0002 mg/m³ (OSHA 2016), 0.05 µg/m³ proposed UK 2024

Ozone

0.1 ppm (ACGIH TLV)

Carbon monoxide

20 ppm (UK), 50 ppm (OSHA)

5. Practical Tools & Templates

  • HSE (UK) Welding Fume Risk Assessment Template
  • American Welding Society (AWS) Safety & Health Fact Sheets
  • IIW (International Institute of Welding) “Welding in the World” guidance documents
  • Free online calculators: British Welding Research Association (TWI) fume generation rate estimator

6. Key Takeaways for Management

  1. Treat all welding fume as carcinogenic (IARC classification since 2017).
  2. Ventilation is almost always required – natural ventilation is rarely sufficient.
  3. Respiratory protection alone is not an acceptable long-term solution.
  4. Health surveillance (lung function, dermatology, neurological) is mandatory in many jurisdictions for high-risk welding.
  5. Training must be specific to the process and material, not generic.

By following a structured risk assessment and rigorously applying the hierarchy of controls, welding can be performed safely and in compliance with modern regulations.