BSBOHS403A I DENTIFY HAZARDS AND ASSESS OHS RISKS Element 4 Risk assessment - Case s tudy welding

Risk assessment - M IG Welding in open workshop

Risk factors
People
exposed
Duration &
Exposure
3 tradespersons
inv olved in
design and
f abrication
Duration and
exposure varies
with the
demands of the
tasks but often
more than 30
mins/day
Risk f actors

Physical
env ironment
Open workshop
Concretef loor
No f lammable
materials in
vicinity
No water in
vicinity
General
ventilation

Equipment

Procedures

Portable MIG
welder that
meets AS
requirement
and has
required
maintenance
by qualif ied
persons
ELCB and
electrical
testing and
tagging

Duration and
exposure
variable. Likely
to exceed that
recommended
when only
general
ventilation
No screens
No established
work welding
bay

Organisational
and
management
environment

People

Small
workshop with
each person
being
responsible for
their own work

Trade
qualif ications
including
welding training

No
documented
procedures
Compliance
with
procedures
may be an
issue

Effectiv eness of risk controls

Note for effectiveness of controls:
3 = very effective reliable, 2 = some controls, medium reliability, reasonably vigilant, 1 = minimal controls,
some monitoring, 0 = no controls in place
Identified
Potential for
Existing control measures
Effectiv eness
Further action
hazard
inj ury w ith no
of controls
recommended
controls
?
Eli minati on
Electricity
HIGH
2-3
Substit ution
(Death)
YES
Engineering

Admi nistration

Radiation

PAGE 1

MEDIUM
(Temporary or
permanent eye
damage)

PPE
Eli minati on
Substit ution
Engineering
Admi nistration
PPE

Type of equipment
ELCB
Equipment
chec ks(infor mal)
Dry environment
Single welder in
area
Testing and
tagging
Safet y f oot wear

Effectiv e reliable

Must do

1
YES
Eye and fac e
protecti on
Cotton overalls

SAFETYLINE INSTITUTE

Minimal control
No screens

Should do

JULY 2005

BSBOHS403A I DENTIFY HAZARDS AND ASSESS OHS RISKS Element 4 Risk assessment - Case s tudy welding

Identified
hazard
T hermal

Potential for
inj ury w ith no
controls
MEDIUM
(Burns to
skin/face)

HIGH
(Fire)

Existing control measures

Eli minati on
Substit ution
Engineering
Admi nistration
PPE
Eli minati on
Substit ution
Engineering
Admi nistration

Hazardous
substances

MEDIUM
(Ill-health from
fumes)

HIGH
(Asphyxiation)

T ripping
hazard

Manual
handling/
postures

LOW
Multiple
(Fracture,
sprain/strain,
burn)
LOW
Sprain/strain,

PPE
Eli minati on
Substit ution
Engineering
Admi nistration
PPE
Eli minati on
Substit ution
Engineering
Admi nistration
PPE
Eli minati on
Substit ution
Engineering
Admi nistration
PPE
Eli minati on
Substit ution
Engineering
Admi nistration
PPE

Effectiv eness
of controls
3=
2
Some controls

Cotton overalls
Face pr otecti on
Welders gloves
No flammable
mat erials in area
Inert gas
Design of
equipment
Chec king
surrounding area
for flammable
mat erials
Fire extinguisher
Low level of fumes
from MIG c/f other
types of wel ding
General ventilation

Inert gas
Control val ves
Equipment c hec ks
(informal)

No leather
clothing

Further action
recommended
?
YES
Could do

3
Effectiv e reliable

1
YES
Minimal
controls

Must do

3
Effectiv e reliable

1
YES
Empl oyee
awareness

Minimal
controls

Should do

1
Placement of wor k
Empl oyee
awareness

Minimal
controls

YES
Must do

Prioritisation of risks
Risks that must be addressed:

Risk of electrocution due to equipment checks not alw ays occurring

Ill-health from hazardous substances

Sprain/strain from fixed postures

Risks that should be addressed:

Eye damage to other w orkers or by-standers

Tripping hazard from trailing leads and cables

Risks that could be addressed:

Burns to skin and clothing as a result of not w earing appropriate protection

PAGE 2

SAFETYLINE INSTITUTE

JULY 2005

BSBOHS403A I DENTIFY HAZARDS AND ASSESS OHS RISKS Element 4 Risk assessment - Case s tudy welding

As the m ust do risks have to be addressed there are 3 tasks that requir e further prioritisation.
1
2
3

Eye injury to other w orkers and by-standers as a result of screens not being used
Thermal burns to the skin w hen w earing cotton overalls but no leather clothing.
Tripping hazard from cables and leads .

AS/NZS 4360 1999 Appendix

Risk
scenario

Likelihood

Consequence

LEV EL OF RISK

Likely (B)

Moderate (3)

HIGH

Possible (C)

Minor (2)

MODERATE

Likely (B)

Insignificant (1)

MODERATE

Kinney and Wiruth - nomogram

1
2

PAGE 3

SAFETYLINE INSTITUTE

JULY 2005