Construction & Trade
Welding and Metal Fabrication Risk Assessment Template
The complete guide to creating professional risk assessments for welding work.
Free to use Instant PDF download Updated February 2026
The essential guide to welding safety
Welding involves joining metals using intense heat, creating unique hazards including fire, fumes, UV radiation, and electrical risks. From MIG and TIG to arc and oxy-acetylene, each process requires specific safety controls.
This guide covers everything you need to create a thorough welding risk assessment—from fume extraction and fire prevention to eye protection and hot work permits.
Trade & Construction
Trade & Construction
Activity Benefits
Why professional welding matters
Strong Joints
Creates strong, permanent metal joints.
Manufacturing
Essential for manufacturing and construction.
Repair
Enables repair and restoration of metal items.
Fabrication
Allows custom metal fabrication work.
Risk Identification
Key hazards & control measures
Welding FumesHigh Risk
Potential Harm
Respiratory disease, lung cancer, metal fume fever, asthma.
Control Measures
- Use local exhaust ventilation at source
- Wear appropriate respiratory protection
- Work in well-ventilated areas
- Health surveillance for regular welders
Fire & BurnsHigh Risk
Potential Harm
Burns from sparks, molten metal, hot surfaces; fire from combustibles.
Control Measures
- Obtain hot work permit before starting
- Clear area of combustible materials
- Keep fire extinguisher within reach
- Wear flame-resistant clothing and gloves
UV RadiationMedium Risk
Potential Harm
Arc eye (welder's flash), skin burns, long-term eye damage.
Control Measures
- Use correct shade welding lens for process
- Screen work area to protect others
- Wear long sleeves and covered skin
- Auto-darkening helmets where appropriate
Electric ShockMedium Risk
Potential Harm
Electric shock, electrocution from welding equipment.
Control Measures
- Inspect equipment before use
- Use dry, undamaged gloves
- Avoid wet conditions
- Insulate from workpiece
This guide covers the most common hazards. Our risk assessment wizard includes 34 hazards and 80+ control measures for Welding and Metal Fabrication, sourced from industry guidance — create your assessment in minutes.
Safety Checklist
Welding safety checklist
Hot Work Permit
- Permit obtained and displayed
- Area inspected before work
- Combustibles removed
- Fire watch assigned
PPE
- Welding helmet with correct shade
- Leather gauntlets worn
- Flame-resistant clothing
- Safety boots with caps
Ventilation
- LEV positioned at source
- Extraction working correctly
- RPE available if needed
- Natural ventilation adequate
Equipment
- Welding set inspected
- Cables undamaged
- Earth lead secure
- Gas bottles secure and upright
Ready to create your welding risk assessment?
Use our step-by-step wizard to generate a professional risk assessment in minutes.
