Baseline Risk Assessment and Risk Matrix (An Example)

Baseline Risk Assessment and Risk Matrix (Example)
WELDING OPERATION
SECTION: WELDING WORKSHOP HIRA NUMBER: DOC. REF
DATE PREPARED / REVISION
RISK/OPERATION IDENTIFIED: Welding Operation 1
REVISED: DATE:
DOCUMENT
DEPARTMENT Mechanical
NUMBER:
DOCUMENT NAME
RISK AREA IDENTIFICATION:
QUESTION
Welded products
What is produced:
None
What raw materials are used:
Steele
What materials are added:
None
What by-products are used solids:
Rods
What by products are used liquids:
What equipment/machinery are Welding machine
involved?
Yes. Refer to waste disposal procedure.
Are wastes controlled, clean up etc?
Element 4.4.6.5 and Element 4.4.6.9
Hard Hats, Overall, Safety Shoes, Leather
Gloves, Hearing Protection, Welding
What PPE is required for this task? Hood, Leather Apron, Respiratory Mask
Page 1 of 8
RISK MATRIX
SEVERITY GUIDLINE:
SEVERITY
SAFETY DAMAGE/FINANCIAL HEALTH ENVIRONMENT

Minor Cost below Environmental Near
1 Near Miss Irritant
1000 Miss
Average Cost
Temporary
2 Minor - First Aid/Minor between 1000 & Minor Env. Impact
Disabled/discomfort
30000
WCL Non Medium Cost Illness leading to
3 Disabling/No shifts between 30000 & Medical Treatment Average Env. Impact
lost 80000 (reversible)
WCL Disabling/Shift High Cost between Illness Leading to
4 Major Impact
lost or 14 + shifts lost 80000 & 200000 disability (irreversible)
Major Cost above Catastrophic
5 Fatality Fatal Illness
200000 occurrences
EXPOSURE AND PROBABILITY GUIDLINE:
EXPOSURE PROBABILITY
(Frequency of occurrence) (Likelihood of occurance)
1 Every second year 1. Rare
2 Once a year 2. Uncommon
3 Twice a year 3. Occassional
4 Four times a year 4. Regular
5 Monthly 5. Frequent
Page 2 of 8
RISK RATING FORMULA:
SEVERITY X EXPOSURE X PROBABILITY = RISK RATING (RR)
RISK RATING RANGES:
Risk Levels
Low Medium High Major
1-6 7 - 15 16 25 >25
RISK ASSESSMENTS AND CONTROLLING METHODS

RISK RATING RISK RATING
HAZARD HIERARCHY OF
WITH TYPE CONTROLS
NO CONTROL
CONTROL
MEASURES
MEASURES
ENVIRONMENTHEALTHDAMAGESAFETY
HAZARD/ ASPECT WHAT IS THE POTENTIAL
TASK/ FATAL RISK INCIDENT, DAMAGE,
ADMIN CONTROL
RISK RATING
RISK RATING
EXISTING CONTROLS
PPE REQUIRED
SUBSTITUTED
PROBABILITY
PROBABILITY
ACTIVITY RISK CATEGORY HEALTH RISK OR
ELIMINATED
RE-DESIGN
EXPOSURE
EXPOSURE
SEVERITY
SEVERITY
IDENTIFIED ENVIRONMENTAL IMPACT
Page 3 of 8
1. Welding operator will be
Metal dust. issued with an adequate
Metal (welding) Hazardous respiratory mask.
Failure of wearing the required
fumes. che 2. Welding operators are
Yes
Yes
Yes
5
No
No
PPE could result in physical or 5 5 5 125 2 2 1 Health
Sparks mic required to wear the
health related injuries
Welding arch als stipulated/recommended PPE as
Hot material noted on page 1
Operator to ensure that the welding

machine earth wire is properly earthed
If the welding machine is to the workbench or to the work piece
Welding machine poorly earthed, it could lead to
Yes
Yes
9
No
No
No
Electrical 5 5 4 100 3 2 2 Safety
poorly earthed. the operator choking against
the steel structure.
General pre
Operators are not permitted to weld in
start checks
wet areas, such as; -
and
Poor floor conditions due to Were floors are wet due to
preparation
rain water or cleaning
Yes
Yes
Yes
3
No
No
before Poor floor condition. Electrical wet floor could lead to trips 5 3 5 75 1 3 Safety
and severe injuries. Outside in the rain
welding
The operator before commencement of

welding will ensure ; -
1. Tools and equipment that is
Poor housekeeping could lead not used are stored in it intended
Yes By Cleaning
to: toolboxes
Tripping over 1. Tripping hazards. 2. Area around workbench and
Yes
Yes
8
No
No
material or objects Housekeeping 2. Misplacing of items. 5 5 5 125 machine will be kept clear of 2 4 1 Safety
around the machine. 3. Slip and falls leading material.
to injury. 3. No flammable chemicals are
4. Fire in the area were welding sparks
could ignite the chemical
4. Fire equipment is available
for emergency purposes
Page 4 of 8
HAZARD HIERARCHY OF
UN- TYPE CONTROLS
CONTROLLED
CONTROLLED
ADMIN CONTROL
RISK RATING
PPE REQUIRED
EXISTING CONTROLS
SUBSTITUTED
PROBABILITY
RISK RATING
ELIMINATED
RE-DESIGN
EXPOSURE
SEVERITY
SEVERITY
No
N/A
Yes
Yes
Yes - Maintenance
Starting the Electrical faults Electrical Electrical faults or tampering 5 4 5 100 1. Machinery will 5 1 2 10 Safety
welding on machinery or could lead to;- be checked monthly for electrical Damage
process cables. Fire faults during the maintenance cycle.
Tampering with Electrocution of operator 2. Welding cables,
electrical Malfunction/damage of be it positive or negative will not be
equipment. machinery joined. Burnt cables or damaged
cables will be replaced completely.
3. No operator will
be permitted to carry on with work
(on faulty equipment) should a fault
be detected.
4. Six monthly
observations conducted.
5. No person other
than the maintenance department or
electrician will be permitted to
conduct repairs on electrical
equipment and no persons will
tamper with electrical equipment if
he is not authorised/qualified.
Page 5 of 8
1. Operator to
ensure that machine is pre-checked
before use.
2. Continuous
Overheated machinery could
awareness to check machine for
Overheating of lead to severe financial
Yes
Yes
5
No
No
No
Machinery 3 5 5 75 overheating to be done by operator 1 5 1 Damage
machinery. implications, should it be
and any defects reported to
repaired or replaced.
maintenance immediately.
3. Maintenance of
the machine will be done as per
maintenance schedule.
1. The operator will be issued
with a set of leather gloves, and he
is required by standard to wear
these gloves whilst handling welded
Contact with hot
Material materials.
material. Hot material could lead to
han 2. The SHE reps will inspect
Yes
Yes
9
No
No
No
severe burns on the operators 5 5 5 125 3 3 1 Safety
dlin whether al operators are wearing
Sharp edges of hands.
g their PPE as required.
material.
3. Random inspections to be
conducted by the supervisor.
4. Damaged PPE will be replaced
immediately.

HAZARD HIERARCHY OF
UN- TYPE CONTROLS
CONTROLLED
CONTROLLED
ADMIN CONTROL
RISK RATING
PPE REQUIRED
EXISTING CONTROLS
SUBSTITUTED
PROBABILITY
RISK RATING
ELIMINATED
RE-DESIGN
EXPOSURE
SEVERITY
SEVERITY
Page 6 of 8
Flying objects such as: 1. Operator to ensure
The work piece dislodging work piece is properly secured
from the table wise clamp before starting the welding process
Material 2. Eye protection is
Starting the table could cause injury.
han
Yes
Yes
compulsory even when chipping
No
No
No
welding Flying objects. Sparks could result in 5 5 5 125 2 2 2 8 Safety
dlin welding flux from the work piece.
process injury or severe burns.
g
Flying flux chipped from
welding could enter
operators eyes.
1. According to
Steeledale.ARC policies, no person
will be permitted to use homemade
Using tools tools.
Using defective tools could
incorrectly or Tools & 2. The operator will
lead to:
Chipping of unsafely. Equi ensure that the welding hammer is
Yes
Yes
Yes
5
No
No
Injury of operator. 5 5 5 125 1 1 5 Safety
welding flux pme in good condition and that no burs
Further damage to
Using homemade nt are forming alongside the
tools or equipment.
tools. hammering side of the tool
3. SHE reps will also
conduct monthly inspections on all
tools.
Untrained or unable personnel 1. No person will be permitted to
could lead to: operate a machine or equipment if
1. The operator being he has not been authorised to do
injured due to no so.
knowledge of the 2. Adequate SWP training will be
machine or operation. conducted with the operator
Unauthoris
2. Damage to the machine annually.
ed or untrained
due to not educating the 3. The supervisor will conduct follow-
operators
Training & operator regarding the up job observations twice a year.
General Incorrect
Awa controls. Deviations will be noted and
Yes
Yes
Yes
6
No
No
Machine person for the 5 5 4 100 3 1 2 Safety
rene 3. Legal implication on both retraining will be done should it be
Operation job
ss the operator and the required.
Poor company in the event of 4. The production Manager or
awareness an accident. Supervisor will conduct on-the-job
campaign. 4. Operator unfit for work training,
could result in injury 5. Pre-placement criterias will be
5. Failure to be able to, of conducted to see if the person is
failure to wear PPE as a able and medically fit
result of knowledge could
cause health implications.
TASK/ HAZARD/ ASPECT FATAL RISK WHAT IS THE POTENTIAL EXISTING CONTROLS HAZARD HIERARCHY OF
ACTIVITY CATEGORY INCIDENT, DAMAGE, RISK RATING RISK RATING TYPE CONTROLS
RISK HEALTH RISK OR
UN- CONTROLLED
CONTROLLED
Page 7 of 8
ADMIN CONTROL
RISK RATING
PPE REQUIRED
SUBSTITUTED
PROBABILITY
RISK RATING
ELIMINATED
RE-DESIGN
EXPOSURE
SEVERITY
SEVERITY
1. Emergency switches
are included in the machine
maintenance checks.
Machinery & Failure of emergency switches
2. Operator will inspect
Failure of Elec could result in injury to Safety
N/A
N/A
Yes
Yes
9
No
5 5 5 125 the operation of the emergency stop 3 1 3
emergency switches tricit operator or damage to Damage
and start switches when conducting
y machinery.
his daily pre-start inspection.
General 3. Any defects will be
Machine reported and repaired immediately.
Operation Leaving the machine 1. No person will leave a machine
unattended whilst running or at or operation unattended whilst the
Leaving the machine any stage during a power machine is in operation.
unattended. failure could: 2. The operator will unplug the
N/A
Yes
5
No
No
No
Machinery 5 3 5 75 5 1 1 Safety
Result in injury to machine as to prevent positive and
Power failure. fellow workers or visitors. negative wiring of the welding
Damage to product machine coming in contact with
or machinery. each other.
RESPONSIBLE 16(2) OPS & MAINT.

PREPARED BY:
APPOINTEE: MANAGER
SIGNATURE: SIGNATURE: SIGNATURE
DATE: DATE: DATE
Page 8 of 8

Baseline Risk Assessment and Risk Matrix (An Example)

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Baseline Risk Assessment and Risk Matrix (An Example)

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Baseline Risk Assessment and Risk Matrix (Example)

RISK AREA IDENTIFICATION:

SAFETY DAMAGE/FINANCIAL HEALTH ENVIRONMENT

EXPOSURE AND PROBABILITY GUIDLINE:

1 Every second year 1. Rare

2 Once a year 2. Uncommon

3 Twice a year 3. Occassional

4 Four times a year 4. Regular

SEVERITY X EXPOSURE X PROBABILITY = RISK RATING (RR)

RISK RATING RANGES:

RISK ASSESSMENTS AND CONTROLLING METHODS

Operator to ensure that the welding

The operator before commencement of

RISK RATING RISK RATING

RESPONSIBLE 16(2) OPS & MAINT.

SIGNATURE: SIGNATURE: SIGNATURE

DATE: DATE: DATE

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