TIG Welding — Safe Work Method Statement
Safe Work Method Statement for Tungsten Inert Gas (TIG) welding operations, including setup, operation, and post-work procedures in compliance with Australian WHS regulations.
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TIG (GTAW) welding is a precision welding process used for stainless steel, aluminium, titanium, and other non-ferrous metals requiring the highest weld quality. Like MIG welding, TIG welding is not inherently classified as High Risk Construction Work under the model WHS Regulations, but it generates a specific hazard profile that differs materially from other welding processes and requires careful management under the model WHS Act's duty to eliminate or minimise risks so far as is reasonably practicable.
No specific licence is required to perform TIG welding, but structural TIG welders must be qualified to AS/NZS 2980 for the specific base materials, filler metals, and joint configurations. For pressure equipment, pipelines, and critical aerospace or medical components, additional qualification standards apply. The tungsten electrode used in TIG welding historically contained thorium oxide (a radioactive material); while thoriated electrodes are still available, safer alternatives including ceriated and lanthanated tungsten electrodes are preferred and should be substituted where technically feasible.
The primary health hazard unique to TIG welding of stainless steel and chromium alloys is hexavalent chromium (Cr(VI)) in the welding fume. The workplace exposure standard for Cr(VI) compounds is 0.01 mg/m³ TWA — one of the lowest WES values in the WHS Regulations — reflecting its potency as a respiratory carcinogen and skin sensitiser. Local exhaust ventilation positioned at the weld zone and a P2 or P3 respirator with appropriate cartridges is required for stainless steel TIG welding in enclosed spaces. Ozone is also generated in significant quantities during TIG welding due to the UV radiation from the arc interacting with atmospheric oxygen; the WES for ozone is 0.1 ppm, easily exceeded in poorly ventilated workshops.
Customise this template by documenting the base metals, filler metals, and electrode type; the fume extraction method; the hot work permit reference; the welder's qualifications for the material and joint type; and the specific ventilation requirements for chromium alloy welding.
Personal Protective Equipment
High Risk Construction Work Types
- •Work involving the use of explosives
- •Work in an area that may have a contaminated or flammable atmosphere
Risk Assessment
1.Pre-work area preparation and inspection
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Fire and explosion from flammable materials near welding area | Catastrophic | Conduct a hot work permit assessment before commencing. Remove all flammable and combustible materials within a 3-metre radius of the welding area, or shield them with fire-resistant blankets. Inspect the area for fuel sources including solvents, oils, and gases. Ensure a minimum 9kg dry powder or CO2 fire extinguisher is immediately accessible and the operator is trained in its use. Post a fire watch during welding and for 30 minutes after completion. Check that fire suppression systems are operational and not isolated. | Moderate | Site Supervisor / Welder |
| Inadequate ventilation leading to toxic fume inhalation | High | Assess the workspace for adequate natural or mechanical ventilation before commencing. For enclosed or semi-enclosed spaces, install local exhaust ventilation (LEV) positioned within 150–300mm of the welding arc to capture fumes at the source. When welding stainless steel, galvanised, or coated materials, mandatory P2 or supplied-air respiratory protection must be worn due to hexavalent chromium or zinc oxide fume hazards. Check the SDS for base and filler materials. Monitor oxygen levels in confined spaces using a gas detector. | Low | Welder / Safety Officer |
2.TIG welding equipment setup and gas cylinder handling
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Compressed gas cylinder falling and causing physical injury or gas release | High | Secure all gas cylinders (argon shielding gas) in an upright position using a dedicated cylinder trolley with chain restraints, or chain/strap them to a fixed wall bracket. Never leave cylinders unsecured or laid on their side. Transport cylinders only on approved trolleys with regulators removed and valve caps fitted. Inspect cylinders for damage, correct labelling, and current test dates before use. Store cylinders away from heat sources and direct sunlight. | Low | Welder |
| Electric shock from TIG welding equipment | High | Inspect the welding unit, leads, and torch before each use. Tag-out and remove from service any equipment with damaged insulation, frayed leads, or defective connectors. Ensure the welding unit is connected to a residual current device (RCD). Never change tungsten electrodes while the unit is energised. Wear dry leather welding gloves at all times. Ensure the work clamp is securely connected as close as practicable to the weld area. In damp or wet conditions, cease welding operations until conditions improve. | Low | Welder |
| UV/IR radiation causing eye and skin burns (arc eye) | High | Use an auto-darkening welding helmet with a minimum shade 10 lens for TIG welding. Ensure all personnel within a 5-metre radius wear appropriate eye protection (minimum shade 5 safety glasses or welding screens). Erect opaque welding screens or curtains to prevent arc flash exposure to other workers. Cover all exposed skin with flame-resistant clothing. Inspect the helmet lens for cracks or damage before use and replace if compromised. | Low | Welder / Site Supervisor |
3.Active TIG welding operations
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Burns from contact with hot work piece or spatter | Moderate | Allow welded components to cool before handling; use thermal chalk or temperature-indicating stickers to confirm safe handling temperature. Mark hot work pieces with chalk or a "HOT METAL" sign. Wear leather welding gauntlets and flame-resistant jacket at all times during welding and immediately after. Do not place hot components on flammable surfaces. Use insulated tongs or clamps to handle hot material. | Low | Welder |
| Musculoskeletal strain from awkward welding postures | Moderate | Set up the workpiece at a comfortable working height using adjustable welding tables or stands to minimise bending, twisting, and overhead welding where possible. Rotate tasks to reduce sustained static postures. Use welding positioners or jigs to reposition the workpiece rather than repositioning the welder. Take regular breaks every 45 minutes when performing sustained welding in awkward positions. Conduct a manual task risk assessment for repetitive welding operations. | Low | Welder / Site Supervisor |
4.Post-weld inspection and cleanup
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Contact with hot slag or metal particles during cleaning | Moderate | Allow welds and parent material to cool adequately before inspection and cleaning. Wear leather gauntlets, safety glasses, and face shield when chipping or brushing welds. Ensure grinding and brushing activities are performed away from combustible materials. Dispose of metal waste in a designated fire-resistant metal waste bin. Never use compressed air to blow metal particles as this creates projectile hazards. | Low | Welder |
| Improper gas cylinder shutdown creating leak hazard | High | Follow the standard shutdown procedure: close the cylinder valve first, then purge residual gas from the regulator and hoses by holding the torch trigger, then close the regulator. Inspect all fittings, hoses, and connections for leaks using an approved leak detection solution (never a naked flame). Store cylinders in a cool, dry, well-ventilated area with valve protection caps fitted. Record cylinder contents and report any cylinder damage to the supplier. | Low | Welder |
Relevant Codes of Practice
Worker Acknowledgement
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