Brazing and Soldering — Safe Work Method Statement
Safe Work Method Statement for torch brazing and soldering of copper pipe and fittings in plumbing, gas fitting, refrigeration and air conditioning work, covering fire prevention in buildings, gas cylinders, fumes, nitrogen purging and burns.
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Brazing and soldering copper pipe is everyday work for plumbers, gas fitters and refrigeration mechanics, and it is one of the most common causes of fires on building sites and in occupied homes. The flame gets into wall cavities, roof spaces and subfloors where it can ignite timber framing, insulation, sarking and dust, and the fire may smoulder unseen for an hour or more before it breaks out. Brazing and soldering on their own are not High Risk Construction Work, so a SWMS is not legally required for this task alone. It is good practice, and most principal contractors will ask for one. If the work is done at height above 2 metres, near energised electrical services, in a confined space, or in an area that may have a flammable atmosphere, it becomes HRCW and a SWMS is required.
Fumes are the hidden hazard. Some silver brazing alloys contain cadmium, and cadmium fume can cause serious lung damage from a single exposure; use cadmium-free alloys and check the SDS. Fluoride-based fluxes produce irritating fumes, and lead-based solders must not be used on drinking water pipes. Work in a ventilated area, keep your head out of the fume plume, and use extraction in enclosed areas.
In refrigeration and air conditioning work, nitrogen is commonly flowed through pipework while brazing to prevent oxide scale. Nitrogen displaces oxygen and can create an asphyxiation risk in small rooms, plant rooms or ceiling spaces, so control the flow rate and ventilate. Refrigerant must be recovered from a system by someone holding the appropriate refrigerant handling licence before the pipework is opened, because heating refrigerant can produce toxic decomposition products. Gas cylinders (oxygen, acetylene, LPG or MAPP-type gases) must be secured upright with flashback arrestors fitted where required.
Plumbing, gas fitting and refrigeration work must be done by workers holding the licence required in your state or territory. Check your state or territory regulator.
Customise this template with the location of the work, the gas and torch type, the brazing alloy and flux (with SDS references), the hot work permit reference if the site uses one, the combustibles near the joints and how they will be protected, the fire extinguisher type and location, the fire watch period, and the nitrogen purge set-up if used.
Personal Protective Equipment
Risk Assessment
1.Planning the work and checking the area
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Fire in wall cavity, roof space or subfloor | High | Inspect behind and around each joint for timber, insulation, sarking, plastic and dust. Remove combustibles or protect them with a heat-resistant mat or shield. Pre-fabricate and braze assemblies in the open where possible so fewer joints are made in place. Obtain a hot work permit where the site requires one. | Low | Plumber / Refrigeration Mechanic |
| Fire extinguisher not available | Moderate | Suitable fire extinguisher within reach of the work area. Water spray bottle or wet rag available for small flare-ups. | Low | Plumber / Refrigeration Mechanic |
2.Gas cylinders and torch set-up
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Gas leak or flashback causing fire or explosion | High | Secure cylinders upright with chain or in a trolley. Fit flashback arrestors where required for the gas set. Leak test connections with soapy water. Inspect hoses for cracks and burns before use. Close valves and bleed lines at the end of each job. | Low | Plumber / Refrigeration Mechanic |
| Gas build-up in vehicles or enclosed areas | High | Transport cylinders upright and ventilated, never in a closed car boot. Do not store cylinders in roof spaces, subfloors or small enclosed rooms. | Low | Worker |
3.Preparing pipework (refrigerant recovery and nitrogen purge)
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Toxic decomposition of refrigerant when heated | High | Refrigerant recovered by a licensed refrigerant handler before pipework is opened or heated. Confirm system is at zero pressure. | Low | Licensed Refrigeration Mechanic |
| Asphyxiation from nitrogen in small enclosed areas | High | Use a flow regulator set to the lowest flow that protects the joint. Vent the purge outlet to outside or a ventilated area. Ventilate the work area. Use an oxygen monitor in small plant rooms or ceiling spaces. | Low | Refrigeration Mechanic |
4.Brazing and soldering joints
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Cadmium, flux or lead fume inhalation | High | Use cadmium-free brazing alloys and lead-free solder on drinking water lines. Read the SDS for each alloy and flux. Work with ventilation or fume extraction; keep your head out of the plume. P2 respirator with fume rating in enclosed areas. | Low | Plumber / Refrigeration Mechanic |
| Burns from flame, hot pipe or molten filler | Moderate | Leather gloves. Point flame away from body and others. Mark freshly brazed joints as hot. Allow to cool before handling. | Low | Worker |
| Eye damage from glare | Moderate | Wear brazing goggles or a face shield with the correct filter shade for the flame size. | Low | Worker |
| Fall from ladder while brazing overhead | Moderate | Use a platform ladder or mobile scaffold for overhead joints. Keep both feet on the platform. Do not hold the torch and lean beyond the ladder. | Low | Worker |
5.Fire watch and pack-up
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Smouldering fire after work finishes | High | Check behind and around each joint after brazing, including inside the cavity where possible. Fire watch for at least 30 minutes after the last joint, or longer if the site hot work permit requires. Re-check before leaving site. | Low | Plumber / Refrigeration Mechanic |
| Gas left in hoses during transport | Moderate | Close cylinder valves, bleed hoses and remove regulators where required before transport. | Low | Worker |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.