Welding — Auto Body SWMS

Welding in auto body workshops involves MIG, spot, and occasionally gas welding on panels that are coated, galvanised, or painted, generating toxic metal fumes containing zinc, manganese, and chromium compounds. The confined workshop environment concentrates fume exposure far more rapidly than open-air welding operations. Welding fume is now classified as IARC Group 1 carcinogenic to humans, and welding fume exposure limits were tightened in November 2025. This template covers all auto body welding operations with controls mapped to the binding Welding Processes Code of Practice effective 1 July 2026.

Legal Requirements

regulation

WHS Regulation 2025 Part 7.1 — Hazardous Chemicals; Part 4.4 — Hot Work

hrcw category

Hot work near flammable materials

code of practice

Welding Processes (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — Welding Processes code binding July 2026. Non-compliance is a standalone offence.

Hazards

Hazard	Consequence	Likelihood
Welding fume inhalation from coated and galvanised panels	Metal fume fever, lung cancer (IARC Group 1), manganism	Likely
Fire from welding sparks contacting flammable materials	Workshop fire, burns, property damage	Possible
UV radiation from welding arc	Arc eye (photokeratitis), skin burns, long-term skin cancer risk	Likely
Electric shock from faulty welding equipment	Electrocution, cardiac arrest	Unlikely
Burns from hot metal and spatter	Thermal burns to skin and through clothing	Likely

Controls (Hierarchy of Controls)

Provide local exhaust ventilation (extraction arm or on-gun extraction) positioned within 300 mm of weld zone

Remove all coatings, paint, and galvanising from weld area before welding to eliminate toxic fume sources

Provide P2 respiratory protection minimum for all auto body welding tasks

Maintain minimum 3-metre fire-free zone around welding operations with fire extinguisher and fire blanket

Require welding helmet with minimum shade 10 filter and full-body welding PPE

Inspect welding equipment daily including earth clamp, cable insulation, and gas connections

Assign fire watch for 30 minutes after hot work completion near combustible materials

Recent Prosecutions

SafeWork NSW v Workshop Operator$95,000

Worker suffered metal fume fever after MIG welding galvanised panels without fume extraction or RPE. Workshop had no welding fume controls despite daily welding operations.

2024 — SafeWork NSW Prosecution Database

What Your SWMS Must Include

✓Fume extraction requirements for each welding process and location

✓Pre-weld coating removal procedure for painted and galvanised surfaces

✓RPE selection based on welding process and base metal coating

✓Fire prevention controls including fire-free zone and fire watch duration

✓Welding equipment inspection and maintenance schedule

Need a compliant Auto Body Welding SWMS?

Our WHS consultants develop welding SWMS with fume extraction specifications and controls mapped to the binding Welding Processes code.