Arc Welding (MMA / MMAW) — Safe Work Method Statement
Safe Work Method Statement for Manual Metal Arc (MMA/MMAW) stick welding operations including site preparation, electrode handling, active welding, and post-weld activities in compliance with Australian WHS legislation.
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Manual Metal Arc (MMA or stick) welding is the most widely used welding process in Australian construction and maintenance due to its portability and versatility — it requires no shielding gas, tolerates dirty or rusted surfaces, and can be used outdoors in wind conditions that would disrupt gas-shielded processes. These same characteristics make it the dominant process for on-site structural and maintenance welding. While MMA welding is not inherently HRCW under the model WHS Regulations, it is routinely performed in conjunction with HRCW activities and a SWMS is standard practice on construction sites.
Electric shock is the primary acute hazard. The open-circuit voltage of a MMA welding machine can range from 45 to 80 volts AC, sufficient to cause electrocution if the welder contacts both the electrode holder and the work-piece or earth clamp in a low-impedance path. The risk is substantially elevated in wet conditions — welding in rain, standing water, or damp confined spaces requires additional insulation precautions including dry insulating matting, dry welding gloves, and ideally a constant-voltage DC machine rather than an AC transformer. The welding machine must be tested and tagged in accordance with AS/NZS 3760 and the supply circuit must be protected by an RCD rated at 30 mA or less.
Welding fume — classified by IARC as a Group 1 carcinogen — is generated at high rates during MMA welding due to the consumable electrode coating and the relatively high spatter rate compared with wire-feed processes. Local exhaust ventilation positioned within 300 mm of the arc, or a weld fume extraction torch attachment, is the engineering control of choice. For structural welding of coated or painted steel, the coating must be removed from the weld area to prevent generation of toxic decomposition products including lead, chromium, and isocyanates from paint coatings.
Customise this template with the base metals and electrode specifications, the fume extraction method, the welding machine test date, the hot work permit reference, the welder's structural qualification (if applicable), and the fire watch arrangements.
Personal Protective Equipment
High Risk Construction Work Types
- •Work in an area that may have a contaminated or flammable atmosphere
- •Work involving demolition of a structure
Risk Assessment
1.Welding machine setup and electrical safety checks
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Electric shock from welding equipment or leads | High | Before commencing, inspect the welding machine, electrode holder, work return clamp, and all leads for damaged insulation, cracked connectors, or exposed conductors. Remove any defective equipment from service and apply a red danger tag. Connect the welding set to an RCD-protected power supply. Ensure the work return clamp provides a low-resistance path by connecting as close as practicable to the weld. Never allow welding cables to run through puddles or wet areas. Do not change electrodes while the machine is energised — switch off first. Open-circuit voltage (OCV) on MMA sets can reach 80 V and is lethal in wet conditions. | Low | Welder / Electrician (for fixed installations) |
| Incorrect welding current causing weld defects or equipment damage | Low | Set welding current within the range specified by the electrode manufacturer (referenced on the electrode packet). Select the correct polarity (DCEP, DCEN, or AC) for the electrode type. Check the machine duty cycle rating and do not exceed it to prevent overheating. Allow machine to cool if overheating warnings activate. Record machine settings in the welding procedure record if applicable. | Low | Welder |
2.Electrode storage and handling
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Moisture-contaminated electrodes causing hydrogen cracking or porosity | Moderate | Store low-hydrogen electrodes in a heated electrode oven at the manufacturer-specified temperature (typically 120–150°C for E7018). Inspect electrode packaging for damage and check expiry dates on receipt. Do not leave electrodes exposed to the atmosphere for longer than the manufacturer's specified exposure time (typically 4 hours for low-hydrogen rods). Redry electrodes per the manufacturer's instructions if exposure time is exceeded. Segregate and label different electrode types to prevent misuse. | Low | Welder / Site Supervisor |
3.Active arc welding operations
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| UV and IR radiation causing arc eye and skin burns | High | The operator must wear an auto-darkening or fixed shade welding helmet (minimum shade 10) for all MMA welding. Erect opaque welding screens or flash curtains to protect all workers within 5 metres from arc flash exposure. Ensure all skin is covered by flame-resistant clothing. Post warning signs in the surrounding area indicating arc welding in progress. Check the helmet lens for cracks or damage before each use. Never look at an arc without appropriate eye protection, even briefly. | Low | Welder / Site Supervisor |
| Inhalation of welding fumes causing respiratory damage | High | Install LEV positioned 150–300 mm from the arc to capture fumes at the source. Ensure ventilation achieves a minimum of 10 air changes per hour in enclosed areas. When welding stainless steel, coated, or galvanised materials, wear a minimum P2 respirator; a supplied-air respirator is required in confined spaces or for prolonged operations. Review the electrode SDS for specific fume hazards. Position the welder's head to the side of the fume plume, not directly above it. Monitor air quality where exposure to manganese or hexavalent chromium is possible. | Moderate | Welder / Safety Officer |
| Fire from welding spatter landing on combustibles | High | Issue a hot work permit before commencing in areas with fire risk. Remove or protect all combustibles within 5 metres. MMA welding generates significant spatter — fit a spatter guard to the work area and direct the weld away from combustibles where possible. Post a fire watcher during the operation and for 30 minutes after completion. Ensure a serviceable fire extinguisher is within 5 metres. Inspect the area for smouldering material after each session. | Moderate | Welder / Fire Watcher |
4.Slag removal and weld inspection
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Eye injury from flying slag during chipping operations | High | Always wear a full-face shield or safety glasses when chipping slag from welds. Allow the weld to cool to a safe handling temperature before chipping. Use a proper chipping hammer and wire brush — never use screwdrivers, chisels, or improvised tools. Position the body so that slag chips are directed away from the face. Ensure other workers in the vicinity also wear eye protection during chipping operations. Dispose of slag chips in a metal waste bin. | Low | Welder |
5.Hot work area shutdown and fire watch
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Smouldering fire igniting after work is complete | High | Post a dedicated fire watch for a minimum of 30 minutes after all welding is completed, or longer if the fire risk warrants it. The fire watcher must inspect all surfaces, crevices, and areas below the work where spatter or slag may have settled. Remove hot stubs of used electrodes using pliers and place them in a steel electrode stub bin — never discard on the ground. Confirm with a thermal camera or touch test that no hot spots remain. Sign off the hot work permit to confirm the area has been cleared. | Low | Welder / Fire Watcher / Site Supervisor |
Relevant Codes of Practice
Worker Acknowledgement
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