Welding Training School risk assessment (NSW)
55 hazards and 433 controls for vocational colleges, apprentice training bays and commercial training organisations, already identified and rated. Answer Yes, No or N/A online and download a finished Word report.
Tier 2 · Heavy, mobile and process work. 18 activities, 55 hazards, 433 controls.
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The 18 activities in this assessment
Every activity is assessed in three parts — Safety (17 hazards), Process Safety (10) and Occupational Hygiene (28). Untick any activity you do not carry out and it drops out of your assessment.
✓Access to the Welding training school online calculator, tied to the email address used at checkout. Untick any activity you do not carry out and it drops out of your checklist, results and report.
✓A finished Word report (.docx) with every hazard, your answers, the residual risk and your Action Plan already in it — to print, sign and keep with your safety records.
✓The inherent hazard register in Word: every hazard here with what could go wrong, the possible consequence and its starting risk rating, to read before the walk and share with the people you consult.
✓A printable walkthrough checklist for marking by hand on the workshop floor.
What this pack is
Many arcs running at once in shared air, inexperienced operators, and booth extraction and duty of care to students.
Each industry here is a complete risk assessment for one kind of workshop, with the hazards and their starting ratings already identified by a Certified Industrial Hygienist. You answer Yes, No or N/A to the controls, and the calculator works out your residual risk, builds the Action Plan and produces the finished report.
Welding Training School
Workplace risk assessment for vocational colleges, apprentice training bays and commercial training organisations in New South Wales: 18 activities, 55 hazards and 433 controls across safety, process safety and occupational hygiene. Completed in the online calculator, which works out control scores, residual risk and a prioritised Action Plan and produces a finished Word report to print and sign.
- ✓55 hazards across 18 activities, each with its consequences and starting risk already rated
- ✓433 controls listed for you, ranked by the hierarchy of control — you answer Yes, No or N/A
- ✓Colour-coded residual risk and a prioritised Action Plan, worked out for you
- ✓A finished Word report to print and sign
- ✓The inherent hazard register in Word and a printable walkthrough checklist for the workshop floor
Tier 2 · Heavy, mobile and process work. 18 activities, 55 hazards, 433 controls.
Secure checkout via Stripe. Sign in and start as soon as the payment goes through.
Run more than one kind of work? See every industry
The most serious hazards in welding training school
A sample of the 55 hazards in this assessment, each shown with its consequence and the starting risk rating given by a Certified Industrial Hygienist before any controls are counted. The controls themselves are in the calculator.
Everyone in the room receives an exposure to IARC Group 1 fume and to manganese, and the people receiving it without any respiratory protection are the instructor, the waiting students and the visitors. Exposure assessments in training workshops almost always sample the student welding and nobody else. Occupational Hygiene · inherent risk 4D.
The injuries that follow are the predictable ones: arc eye, burns, abrasive wheel injuries, electric shock and eye injury. The business owes a duty to students and visitors as well as to workers, and an inexperienced person cannot be relied on to follow a control they have not understood. Safety · inherent risk 4D.
Zinc fume (metal fume fever), lead from old paint (a lead process with notification and biological monitoring duties), chromate primers containing Cr(VI), cadmium from plating, isocyanates from two-pack coatings. None of these are controlled by the arrangements in a bare mild steel workshop. Occupational Hygiene · inherent risk 4C.
Welding fumes are classified IARC Group 1 (carcinogenic to humans, lung cancer, with limited evidence for kidney cancer). Also occupational asthma, chronic bronchitis and reduced lung function. The exposure standard for welding fumes (not otherwise classified) is 1 mg/m3 as an 8-hour time weighted average, and this figure carries through into the Workplace Exposure Limits that apply from 1 December 2026. Occupational Hygiene · inherent risk 4C.
Crush injuries, multiple fractures, fatality. Vehicle and mobile plant incidents are consistently among the leading mechanisms of work-related fatality in Australia. Safety · inherent risk 4C.
Load dropped onto a person: crush injuries, multiple fractures, fatality. Sling angle is the most common miscalculation, because working load limit falls sharply as the included angle opens up. Safety · inherent risk 4C.
Rapidly developing workshop fire, burns, loss of premises and stock, business interruption. Process Safety · inherent risk 4C.
Workshop fire, flash fire, explosion of a closed vessel, severe burns, fatality, loss of premises and stock. Process Safety · inherent risk 4C.
How one hazard is rated
Hazard S1.1 — manual handling of sections, plate and offcuts — starts at 2D, rated before any controls are counted. The calculator lists 8 controls for it, from elimination and extraction at the source down to PPE, monitoring and emergency arrangements. You answer Yes, No or N/A for each on the floor. Once the last one is answered it works out the control score, applies any severity reduction earned by physical controls, and shows the residual risk as RED, YELLOW or GREEN. Every control you answered No to goes into your Action Plan, most urgent and most effective first, ready for a responsible person and a due date.
Twenty arcs in one room of shared air
A training workshop is the one place where many arcs run at once in the same air. Ten or twenty booths strike together, and the fume that escapes each one accumulates in the general atmosphere. Welding fume is IARC Group 1, with an exposure standard for welding fumes not otherwise classified of 1 mg/m3 as an 8-hour time weighted average. Manganese is normally the first limit exceeded, and from 1 December 2026 its limit tightens tenfold for inhalable and fiftyfold for respirable.
The liability here falls on people who are not welding. The instructor moves between booths all day without a helmet, students wait their turn, and visitors, assessors and maintenance staff walk in unprotected. Exposure assessments in training workshops almost always sample the student at the arc and nobody else, so the heaviest unprotected dose is often the one never measured.
What makes a school different from a production shop is who is holding the torch. Students strike their first arc with limited instruction, use grinders and cut-off saws for the first time, and some are minors or have limited English. The injuries are predictable, arc eye, burns, abrasive wheel injuries, electric shock, and the business owes a duty to students and visitors as well as to its workers.
What an inspector asks a training provider to show
The assessment puts supervision first, and every one of these is a gate. Is there a documented induction covering every hazard in the room, signed before the first arc, in a form the student can understand? Is a maximum supervision ratio set in writing and enforced for live arc and abrasive wheel work? Is competency checked before a student uses a grinder, cut-off saw or cutting equipment unsupervised? Is power isolated when the room is unattended so no arc can be struck without an instructor? Are there extra arrangements for students under 18 and those with limited English, and is PPE issued and fitted to each student, with fit testing where tight-fitting respirators are used?
Beyond supervision it checks booth extraction and whether it has been tested, the guards and emergency stops on shared machines to AS/NZS 4024, work rests to AS/NZS 1788, and whether exposure has been measured for the instructor and the room as well as the booth.
Where a training workshop usually stands after the first pass
Most schools answer Yes on booth screens, helmets and gloves, and No on the room. Booth extraction was designed for one arc and now serves a full class. Filters are changed when someone notices. The induction is a verbal talk on day one. Nobody has asked what the instructor breathes across a full teaching day, and machines are left powered between sessions.
The top-tier answers that move ratings to green are the ones a student cannot undo: a fixed cut-off saw or bandsaw for straight cuts in place of a hand-held grinder, guards that are never removed, RCD protection on all portable equipment, and barriers between walkways and the areas where stock is delivered and moved.
NOT RATED appears when a student can walk in and strike an arc alone. If you answer No to equipment locked out or power isolated when the room is unattended, the duty-to-students hazard is not scored. The report prints NOT RATED and puts isolation first on the Action Plan, because every other supervision control assumes an instructor is in the room.
How your controls are scored
Not generic advice — the specific, hierarchy-of-controls measures written into the pack, matched to how these assets actually fail.
Built for the people who do this work
If you operate, maintain or contract to these assets in NSW, this pack is written for your duties.
- ✓Vocational colleges, apprentice training bays and commercial training organisations
- ✓Owners and managers who need a risk assessment that stands up to a SafeWork NSW visit
- ✓Safety coordinators covering several workshops or several trades
- ✓Workshops whose insurer, principal contractor or client has asked for a documented assessment
- ✓Trainers and supervisors inducting apprentices onto workshop hazards
Authored to the codes and the law
The Codes of Practice and Australian Standards these documents are measured against, and the legislation behind them.
- §Work Health and Safety Act 2011 (NSW)
- §Work Health and Safety Regulation 2025 (NSW)
- §Workplace exposure standards for airborne contaminants (Safe Work Australia)
- §AS 1674.1 and AS 1674.2 — Safety in welding and allied processes
- §AS/NZS 1715 and AS/NZS 1716 — Selection, use and maintenance of respiratory protective equipment
Frequently asked questions
Add an in-house CIH risk assessment review
Complete your risk assessment using our digital engine, then have our in-house Certified Industrial Hygienist (CIH) and Full Member of the Australian Institute of Occupational Hygienists (MAIOH) review your specific results to ensure bulletproof compliance.
Post-completion expert review
Not sure if you categorised your site’s controls correctly? Complete your online assessment and send us the generated report. Our in-house experts will review your residual risk scores, validate your “N/A” selections, and ensure your action plan adequately addresses your highest liabilities (like hexavalent chromium or LEL environments) before you sign off.
- Scope
- Remote CIH and MAIOH review of your completed calculator report and hazard register.
- Turnaround
- 3–5 business days.
- Pricing
- Remote review is billed at an hourly rate of $250 AUD/hour (total quote based on the number of sections reviewed).
Walk it, answer it, sign it.
The calculator generates a finished, fully formatted .docx record with your Action Plan already inside it. Print it, sign it off, and you are audit-ready for this workshop.
Price in AUD, no GST charged · Jurisdiction: New South Wales — WHS Act 2011, WHS Regulation 2025 and SafeWork NSW Codes of Practice applied
This is a generic risk assessment for a typical workshop of this kind, to support your due diligence — completing it is not compliance in itself. You must answer it for your own site, consult your workers, put the missing controls in place, and get competent advice where it says so — exposure monitoring, for example, is work for an occupational hygienist. The limits are set out at the front of every report.