TGN-SW04

Weld Australia
Technical Guidance Note
Welding Safety:
Audit Checklist

www.weldaustralia.com.au
Foreword
This Technical Guidance Note assists users to identify hazards associated with welding and its allied processes. It
draws upon the recommendations of a range of Weld Australia’s Technical Notes and Technical Guidance Notes and
is presented in the format of a self-audit form.

It may be particularly useful when identifying hazards associated with welding and related activities, and where
additional control measures may be required.

Future Revisions
This Technical Guidance Note will be revised from time to time and comments aimed at improving its value to
industry will be welcome. This publication is copyright and extracts from this publication shall not be reprinted or
published without the Publisher’s express consent.

Disclaimer
While every effort has been made and all reasonable care taken to ensure the accuracy of the material contained
herein, the authors, editors and publishers of this publication shall not be held to be liable or responsible in any way
whatsoever and expressly disclaim any liability or responsibility for any loss or damage costs or expenses howsoever
caused incurred by any person whether the purchaser of this work or otherwise including but without in any way
limiting any loss or damage costs or expenses incurred as a result of or in connection with the reliance whether
whole or partial by any person as aforesaid upon any part of the contents of this Technical Guidance Note. Should
expert assistance be required, the services of a competent professional person should be sought.

Editor
Mr Bruce Cannon
Technical Publications Manager, Weld Australia

National Library of Australia card number and ISBN 978-0-6452630-3-9.

Weld Australia
ABN 69 003 696 526
PO Box 197, Macquarie Park BC, NSW 1670
Phone: +61 (0)2 8748 0100
www.weldaustralia.com.au

Weld Australia Technical Guidance Note | Welding Safety: Audit Checklist | © 2022
About Weld Australia
Who We Are
Weld Australia represents the welding profession in Australia. Our members are made up of individual welding
professionals and companies of all sizes. Weld Australia members are involved in almost every facet of Australian
industry and make a significant contribution to the nation’s economy.

Our primary goal is to ensure that the Australian welding industry remains both locally and globally competitive, both
now and into the future.

A not-for-profit, membership-based organisation, Weld Australia is dedicated to providing our members with a
competitive advantage through access to industry, research, education, certification, government, and the wider industrial
community. Weld Australia is the Australian representative member of the International Institute of Welding (IIW).

Our Mission
Weld Australia is the leader in facilitating growth of world class welding in Australia.

Our Vision
Weld Australia seeks to enable industry to access leading edge technologies for all types of joining processes
through technology transfer, education and certification opportunities.

Our Value Proposition

Weld Australia generates revenue through its commercial activities which is then reinvested back into the welding
community for the benefit of members.

Weld Australia brings individual and company members together to deliver:

• A forum for the exchange of ideas and the sharing of resources
• A voice to promote the interests of the welding community and shape the market for welding services
• Specialist technical problem solving and a conduit between industry and research organisations
• A pathway for learning and career development and the opportunity to benchmark against world’s
best practice

Our Services
Weld Australia provides:
• Events and Seminars
• Technical Publications
• Technical Support and Advisory Services
• Project Management
• Professional Development
• Qualification and Certification

Real Solutions to Real Problems…

Weld Australia has a team of highly qualified welding engineers and technologists available to provide expert
advisory services on all welding related matters. With expertise in a wide range of industries, ranging from
biotechnology to heavy engineering we have a unique capability to solve your welding problems.

Our advice can help you substantially increase the operational life of your plant and equipment and thereby reduce
your maintenance and repair overheads.

Further Information
For further information about Weld Australia and how we can help your business, visit: www.weldaustralia.com.au.

Weld Australia Technical Guidance Note | Welding Safety: Audit Checklist | © 2022
Introduction
This Technical Guidance Note assists users to identify hazards associated with welding and its allied processes.
Presented in the format of a self-audit form, it draws upon the recommendations of a range of Weld Australia’s
Technical Notes and Technical Guidance Notes including:

• Weld Australia Technical Note 7 Health and safety in welding, 2019

• Weld Australia Technical Note 22 Welding electrical safety, 2019
• Weld Australia Technical Guidance Note TGN-SW01 Fume Minimisation Guidelines — Welding, Cutting, Brazing
and Soldering, 2021
• Weld Australia Technical Guidance Note TGN-SW03 Welding electrical safety— Electric shock injury and
electrocution reporting, A supplement to Technical Note 22, 2021
• Weld Australia Technical Guidance Note TGN-SW07 Health and safety in welding—Guides and forms, A
supplement to Technical Notes 7 and 22, 2021

Prior to the commencement of any welding or allied activity, a risk assessment or Job Safety and Environmental
Analysis (JSEA) should be conducted to identify the specific hazards associated with the designated work, and the
control measures required to mitigate against the risks identified. Reference should also be made to Weld Australia’s
Technical Notes and Technical Guidance Notes, relevant Australian standards, and State and National Regulatory
Authorities’ Codes of Practice for additional guidance.

Where action(s) recommended in this Technical Guidance Note have not been implemented, or additional control
measures are recommended (i.e. a red response), audit comments should be recorded, and corrective actions
undertaken before welding commences. Irrespective of the audit outcome, all identified hazards and control
measures implemented must be managed via the JSEA or risk assessment.

References
For additional information on the hazards of welding and allied processes, refer to:

1. Weld Australia Technical Note 7 Health and safety in welding, 2019

2. Weld Australia Technical Note 22 Welding electrical safety, 2019
3. Weld Australia Technical Guidance Note TGN-SW01 Fume Minimisation Guidelines — Welding, Cutting, Brazing
and Soldering, 2021
4. Weld Australia Technical Guidance Note TGN-SW03 Welding electrical safety— Electric shock injury and
electrocution reporting, A supplement to Technical Note 22, 2021
5. Weld Australia Technical Guidance Note TGN-SW07 Health and safety in welding—Guides and forms, A
supplement to Technical Notes 7 and 22, 2021
6. Code of Practice Welding processes, Safe Work Australia, 2020
7. Code of Practice Confined spaces, Safe Work Australia, 2018
8. Australian Standard AS 1674.1 Safety in welding and allied processes Part 1: Fire precautions Standards
Australia, 1997
9. Australian Standard AS 1674.2 Safety in welding and allied processes Part 2: Electrical, Standards Australia, 2007
10. Australian Standard AS 2865 Safe working in confined space, Standards Australia, 2009

Weld Australia Technical Guidance Note | Welding Safety: Audit Checklist | © 2022
 Location: Date:

Auditor: Contact:

Phone/email: Phone/email:

Note: This form is interactive and may be completed on a computer, tablet device or similar if required.

AS 1674.2 Welding environment

Category A Category B Category C
Low risk, dry, welder insulated Dry, high risk of welder in contact Damp/humid/hot/sweaty and welder in contact
from the work with the work with the work, high risk of electric shock

General hazards and risks Yes No

Is the work covered by the JSEA or risk assessment?
Does the JSEA or risk assessment consider risks and controls for the environment category?
For Category A environment, is the work area dry and the welder insulated from the work?
For Category B environment, is the work area including the welder’s clothing and PPE dry?
For Category B environment, is it likely to become Category C e.g. due to changes in ambient
temperature, contact with moisture or the welder and/or assistant sweating etc?
Is the area suitable for hot work (see AS 1674.1)?
Is the welding equipment inspected daily or before commences (pre-start checks)?
Is the work area free of hazards e.g. slip and trip hazards?
Is the area free of flammable or combustible hazards?
Is there firefighting equipment on hand or nearby?
Comments:

Clothing and PPE Yes No

Is the welder’s and assistant’s clothing cotton drill, woollen or ISO 11611 compliant?
Is the welder’s and assistant’s clothing clean, dry and in good condition?
Is the welder’s PPE and assistant’s PPE dry, in good condition, and suitable for the work?
Is the welder’s gloves and assistant’s gloves dry, free of holes, and in good condition?
Does the welder’s and assistant’s clothing and PPE cover all exposed skin?
Is the welders and assistant’s helmet (or face shield) approved and suitable for welding?
Are the welders and assistants always wearing approved safety glasses (with side shields)?
Requires comment and additional controls to be
Proceed put in place before work commences

Weld Australia Technical Guidance Note | Welding Safety: Audit Checklist | © 2022 1
Clothing and PPE (continued) Yes No
Are the welders and assistants wearing safety footwear and spats or furnace boots or similar?
When required by JSEA, welders and assistants are wearing leather apron, jacket, or armlets.
Comments:

Dampness and heat hazards and risks Yes No

Is the work area dry?
Is location of welding near water or in a splash zone?
Will perspiration, humidity or dampness be an issue on the job?
Will ambient temperature be ≥25° and/or humidity ≥70%?
Will preheat (if required) raise the ambient temperature near the welder r assistant ≥25°C?
Is rain forecast?
Is a cool change forecast?
Are cotton glove liners required?
Comments:

Requires comment and additional controls to be put

Proceed in place before work commences

Weld Australia Technical Guidance Note | Welding Safety: Audit Checklist | © 2022 2
 Recommended Clothing and PPE When Welding

The recommended minimum protective

clothing and PPE required when welding is
outlined below.

Approved welding helmet, safety glasses

and PAPR.

Balaclava (cotton drill, woollen or ISO 11611

compliant).

Long sleeved shirt and long trousers, or

overalls (cotton drill, woollen or ISO 11611
compliant). Polyester and other synthetic
clothing and/or undergarments must not be
worn.

Leather apron (or leather jacket)

Dry leather “gauntlet” welding gloves

Safety boots and leather spats to be worn

whilst welding, or furnace boots.

NOTES:
1. The welder should use a powered air purifying
respirator (PAPR) to minimise weld fume exposure.
2. Safety glasses should be worn at all times to
protect against stray arc flash etc whilst the
welding helmet is in the raised position.
3. All clothing and PPE must be dry and in good
condition, free of holes and/or fraying.
4. For further information, refer to Weld Australia’s
Technical Note 7. Health and Safety in Welding

Weld Australia Technical Guidance Note | Welding Safety: Audit Checklist | © 2022 3
 Weld fume hazards and risks Yes No
Is the work area well ventilated?
Is the work area a confined space?
Is the work area a restricted space or require assisted ventilation or fume extraction?
Does the work require welding with stainless steel or non-ferrous consumables?
Does the work require welding through coatings (e.g. zinc, other metals, paint, polymers etc)
or surface contaminants (e.g. oil, grease, water, etc.)?
Comments:

Arc flash hazards and risks Yes No

Is the welding flash screened from those nearby, or in line of sight (e.g. overhead cranes)?
Is the welder’s helmet (and assistant’s helmet) fitted with the correct darkened filter?
Are the welder (and assistant) wearing safety glasses with side shields?
Are all people in proximity (<10m) wearing safety glasses with side shields?
Comments:

Electric arc welding hazards and risks Yes No

Is the power supply RCD protected?
Is the RCD tested at least every three months e.g. by pressing the “Test” button?
Is the power cable and plug rating greater than I1eff on the power source’s rating plate?
Has the power supply cable and plug been “tagged and tested” with a valid tag attached?
Is the power supply cable and plug in good condition i.e. free of cuts, damage, fraying and
exposed wires?
Has the welding power source been inspected within the last 12 months?
Is the power source, switches, indicator lights, controls etc fully functional and free of damage?
Is the power source insulated from or located adjacent to the work (i.e. the welding machine’s
case is not in direct contact with the work)?
Are welding cable connections in good condition, clean and correctly tightened?
Are welding cable connections fully insulated and firmly anchored to fittings?
If terminal posts are used, do they have brass washers and an insulated brass nut in place
(including unused terminal posts)?
Work and return cables are free of cuts, burns, damage, fraying that may expose live wires.
Work and return cables are of the same current capacity, and rated for the maximum current
and duty cycle for the welding work.

Requires comment and additional controls to

Proceed
be put in place before work commences

Weld Australia Technical Guidance Note | Welding Safety: Audit Checklist | © 2022 4
 Electric arc welding hazards and risks (continued) Yes No
Cable extension connections are fully insulated with clean contact surfaces and all fittings are
tightened properly with no conductors exposed.
Electrode holder (or welding torch/gun) is in good condition and is fully insulated.
The electrode holder (or welding torch/gun) is rated for the maximum current and duty cycle
of the welding activity.
Is the work return clamp or connection securely connected to the work return cable?
Is the work return lead correctly connected directly to the work?
Is the welding power source suitable for the work?
If a VRD is used (MMAW, GTAW, air-carbon arc), the indicator lights or voltmeter are
functioning and indicating low voltage (e.g. safe = green, and high voltage or unsafe = red).
Is the use of an insulating mat, wooden duck boards or other insulation materials required?
Are all cables routed away from hot objects, heat sources and walkways?
Comments:

Additional MMAW (stick) arc welding hazards and risks Yes No

Is the MMAW power source DC?
Is the MMAW power source fitted with a working voltage reduction device (VRD)?
If a VRD is used, the indicator lights or voltmeter are functioning and indicating low voltage.
Does the welding work require a safety cut-out switch?
Comments:

Additional GTAW (Tig) arc welding hazards and risks Yes No

Is the GTAW (Tig) power source DC?
Is the GTAW (Tig) power source fitted with a working voltage reduction device (VRD)?
If a VRD is used, the indicator lights or voltmeter are functioning and indicating low voltage.
Does the welding work require a safety cut-out switch?

Is the tungsten in use thoriated?

Is HF arc starting in use?
Comments:

Requires comment and additional controls to

Proceed
be put in place before work commences

Weld Australia Technical Guidance Note | Welding Safety: Audit Checklist | © 2022 5
 Additional air-carbon arc hazards and risks Yes No
Is the power source DC?
Is the power source fitted with a working voltage reduction device (VRD)?
If a VRD is used, the indicator lights or voltmeter are functioning and indicating low voltage.
Does the welding work require a safety cut-out switch?

Are the welder, assistant and those nearby wearing suitable hearing protection?
Are the welder, assistant and those nearby wearing fume protection?
Comments:

Plasma cutting hazards and risks Yes No

Handpiece is in good condition.
Cutting area is shielded by welding curtains and people nearby are protected from arc flash.
Fume extraction system is operating and area is well ventilated and suitable for plasma
cutting.
Work return cables are in good condition and connected directly to the work.

Operator’s gloves are clean, dry, hole-free and in good condition, and suitable for
plasma cutting,
Is the operator’s clothing dry, and cotton drill, woollen or ISO 11611 compliant?
Are the people operating plasma equipment wearing suitable UV, face and eye
protection?
Are the people operating plasma cutting equipment wearing hearing protection?
Comments:

Requires comment and additional controls to

Proceed
be put in place before work commences

Weld Australia Technical Guidance Note | Welding Safety: Audit Checklist | © 2022 6
 Gas storage, regulators, and hoses hazards and risks Yes No
Are the gas regulators inspected for damage at least quarterly?
Are the regulators in good condition and free of damage?
Are the regulators compatible for the gas in use?
Are the O rings clean and oxygen compatible?

Are the regulators less than 5 years of age?

Are all gas bottles stored vertically and restrained from falling?
Are all gas bottles stored in approved facilities?
Are different gas cylinders separated and segregated from empty bottles?
Are the hoses compliant with, and colour coded to AS/NZS 1335 (ISO 3821)?
Are all hoses in good condition and free of cracks or damage?
Comments:

Flame cutting hazards and risks Yes No

Is the regulator/hose assembly pressure tested daily prior to use?
Is a daily start-up inspection and pre-start checklist used?
Are the hoses in good condition, free of nicks, cuts and damage?
Are flash back arrestors connected to both the regulator and the blowpipe?

Are the flash-back arrestors suitable for the flow rate required?
Are the flash-back arrestors tested annually?
Is the area where flame cutting occurs well ventilated and suitable for flame cutting?
Are the people operating flame cutting equipment wearing suitable eye protection?
Are the people operating flame cutting equipment wearing suitable hearing
protection?
Comments:

Requires comment and additional controls to

Proceed
be put in place before work commences

Weld Australia Technical Guidance Note | Welding Safety: Audit Checklist | © 2022 7
Weld Australia Technical Notes

TN 7 - Health and Safety in Welding

Provides information on all aspects of health and safety in welding and cutting. Designed to provide this information
in such a way that it is readily useable for instruction in the shop and to provide guidance to management.
Recommendations are given for safe procedures to be adopted in a wide variety of situations in welding fabrication.

TN 22 - Welding Electrical Safety

Provides information and guidance on welding electrical safety issues (welding equipment, the human body and
the workplace), including investigation of welding current related electric shock injuries and electrocution, including
investigation of welding current related electric shock injuries and electrocution.

Weld Australia Technical Guidance Notes

TGN-SW01 Fume Minimisation Guidelines — Welding, Cutting, Brazing and Soldering

This Technical Guidance Note provides weld fume control guidelines to assist users to comply with the national
Code of practice – Managing the risks of hazardous chemicals, and to provide advice on the control measures which
could be introduced to achieve this. It includes comment from the International Institute of Welding’s Commission VIII
Health, Safety and Environment on the 2017 ruling from IARC (an agency of the World Health Organisation) in relation
to weld fume being classified to Group 1 Carcinogenic to Humans.

TGN-SW03 Welding electrical safety — Electric shock injury and electrocution

reporting, A supplement to Technical Note 22
This Technical Guidance Note contains the guide and form entitled Welding electric shock injury and electrocution
report form referenced within Weld Australia’s Technical Note 22 Welding electrical safety. It is designed to be read in
conjunction with the Technical Note, and, to assist users in its application when investigating welding current related
electric shocks or electrocutions.

TGN-SW07 Health and safety in welding — Guides and forms, A supplement to

Technical Notes 7 and 22
This Technical Guidance Note contains the guides and forms referenced within Weld Australia’s Technical Note 7
Health and safety in welding and Technical Note 22 Welding electrical safety. It is designed to be read in conjunction
with Technical Notes 7 and 22, and, to assist users in their application. Users are encouraged to apply the guidelines
and forms in their workplace where welding and related activities are utilised.

Availability
Please visit Weld Australia’s website for further information on the availability of these publications:
www.weldaustralia.com.au.

Weld Australia Technical Guidance Note | Welding Safety: Audit Checklist | © 2022
Notes

Weld Australia Technical Guidance Note | Welding Safety: Audit Checklist | © 2022
 Weld Australia
ABN 69 003 696 526
PO Box 197, Macquarie Park BC, NSW 1670
Phone: +61 (0)2 8748 0100
www.weldaustralia.com.au