Plasma Cutting — Safe Work Method Statement
Safe Work Method Statement for plasma arc cutting operations including equipment setup, active cutting, and post-work procedures, in compliance with Australian WHS legislation and relevant Australian Standards.
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Plasma arc cutting uses a high-velocity jet of ionised gas at temperatures exceeding 20,000°C to cut electrically conductive metals with speed and precision. It is used across construction, fabrication, and maintenance industries for cutting mild steel, stainless steel, aluminium, copper, and other conductive materials. Plasma cutting is not classified as High Risk Construction Work under the model WHS Regulations in itself, but on construction sites it is frequently performed in conjunction with HRCW activities, and a hot work permit must be issued whenever it is performed outside a dedicated cutting bay.
Electric shock from the plasma cutting torch is the primary acute hazard. Plasma cutting systems operate at open-circuit voltages of 200–400 V DC, substantially higher than MMA welding machines, and are capable of delivering lethal shocks if the operator contacts the torch nozzle while it is energised. Plasma torches must never be touched while the machine is energised, and the machine must be switched off before any torch maintenance or tip replacement is performed. In wet or damp conditions, the electrocution risk is elevated and additional insulation precautions are mandatory.
Plasma cutting generates UV radiation from the cutting arc that can cause arc eye (photokeratitis) and skin burns with brief unprotected exposure. The UV intensity from a plasma cutter is broadly similar to MIG welding and requires a welding filter shade of at least shade 9 (for currents below 100A) in the cutting helmet or shield. Bystanders within line-of-sight of the arc must also be protected by welding screens. Metal fume and toxic gas generation during plasma cutting of coated, painted, or plated metals requires local exhaust ventilation; cutting galvanised steel generates zinc oxide fume at concentrations that can cause metal fume fever, and cutting cadmium-plated or beryllium-containing alloys generates immediately dangerous-to-life fumes requiring respiratory protection and specialist advice.
Customise this template by documenting the metals to be cut and any coatings or platings present, the plasma cutter rated current and open-circuit voltage, the fume extraction method, the hot work permit reference, and the fire watch duration and extinguisher type.
Personal Protective Equipment
High Risk Construction Work Types
- •Work in an area that may have a contaminated or flammable atmosphere
Risk Assessment
1.Plasma cutter setup and consumable inspection
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Electric shock from high-voltage plasma cutting circuit | High | Plasma cutters operate at open-circuit voltages up to 400 V. Inspect the machine, torch leads, power cable, and plug before each use. Remove from service any equipment with cracked torch bodies, damaged leads, or faulty pilot arc circuits. Connect via an RCD-protected outlet. Ensure the work clamp has a firm, low-resistance connection to the workpiece. Never change consumables (nozzle, electrode, shield cup) with the machine energised — isolate and wait 5 seconds before touching the torch tip. Wear dry leather gloves during setup. | Low | Operator |
| Compressed air failure causing arc instability and torch damage | Moderate | Check that the air supply pressure meets the manufacturer's specification (typically 5.5–6.9 bar / 80–100 PSI). Drain the air compressor tank of moisture before commencing. Check the inline moisture separator/filter and drain if required. Test pilot arc and cutting arc before production cutting. Ensure hose connections are secure and free from leaks. Keep the air supply hose clear of the cutting area and heat sources. | Low | Operator |
2.Active plasma cutting operations
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Fire from plasma sparks and molten metal stream | Catastrophic | Issue a hot work permit. The plasma arc creates a high-velocity stream of molten metal that can travel up to 5 metres. Remove all combustibles within a 5-metre radius or shield with fire-resistant welding blankets. Position the cut so the molten stream is directed downward or into a non-combustible catcher. Never plasma cut over or near flammable liquids, gases, or vapours. Post a fire watch during cutting and for 30 minutes after completion. Position a serviceable fire extinguisher within immediate reach. | Moderate | Operator / Fire Watcher |
| Arc flash causing eye and skin injury to operator and bystanders | High | The operator must wear an auto-darkening welding helmet set to shade 8 for currents below 100 A and shade 10 for 100–200 A. Erect opaque welding screens or flash curtains around the cutting area to prevent arc flash exposure to other workers. Ensure all bystanders maintain a minimum 5-metre exclusion zone or wear appropriate eye protection. Never look at the plasma arc directly, even for a moment. Inspect helmet lens condition before every use. | Low | Operator / Site Supervisor |
| Fume and ozone inhalation from plasma cutting process | High | Plasma cutting produces ozone, nitrogen oxides, and metal-specific fumes at high concentrations. Ensure adequate ventilation or install LEV at the source. For stainless steel, galvanised, or coated materials, a supplied-air respirator is required; a minimum P2 respirator is required for mild steel in well-ventilated conditions. Review the SDS for the base material. Monitor air quality in confined or semi-enclosed areas. Do not cut materials with unknown coatings without first identifying the coating chemistry. | Moderate | Operator / Safety Officer |
| Hearing damage from plasma cutter noise (95–110 dB(A)) | High | Plasma cutting typically generates 100–110 dB(A). Mandatory hearing protection (minimum SLC80 20 earmuffs or earplugs) must be worn by the operator and all workers within 5 metres. Limit continuous plasma cutting to 30-minute intervals. Schedule high-noise cutting during low-occupancy periods where practicable. Erect acoustic barriers for prolonged operations in occupied areas. | Low | Operator / Site Supervisor |
3.Handling cut material and waste disposal
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Burns and lacerations from hot cut edges and offcuts | Moderate | Allow cut material to cool before handling. Plasma-cut edges can reach temperatures above 300°C immediately after cutting. Wear leather welding gauntlets when handling cut pieces. Mark hot material with chalk. Use tongs or a magnetic lifter for small offcuts. Dispose of metal offcuts in a designated metal waste skip. Ensure offcuts cannot fall on personnel below the working level; use drop-containment trays or barriers. | Low | Operator / Labourer |
Relevant Codes of Practice
Worker Acknowledgement
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