Oxy-Acetylene Cutting SWMS

Oxy-acetylene cutting uses a fuel gas flame to preheat steel to ignition temperature and then introduces a high-pressure oxygen jet to oxidise and blow away the molten metal. The process generates iron oxide fume, significant fire risk from molten slag projections, and explosion risk from flashback into gas supply lines. When cutting coated, painted, or galvanised steel, toxic fume from zinc, lead, cadmium, and chromate primers adds to the respiratory hazard. Gas cylinder handling, storage, and flashback arrestor maintenance are critical safety elements. This template maps controls to the binding Welding Processes Code of Practice effective 1 July 2026.

Legal Requirements

regulation

WHS Regulation 2025 Part 7.1 — Hazardous Chemicals and Part 4.7 — Plant

hrcw category

Work in or near a contaminated or flammable atmosphere

code of practice

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

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Fire from molten slag and sparks during cutting	Workshop fire, burns, property destruction	Likely
Flashback and explosion in gas supply hoses or regulators	Fatal explosion, severe burns, shrapnel injuries	Unlikely
Iron oxide and metal fume inhalation	Siderosis, metal fume fever, chronic respiratory disease	Likely
Toxic fume from cutting coated or galvanised steel	Metal fume fever, lead poisoning, cadmium poisoning	Possible
Oxygen enrichment of clothing and immediate area	Rapid fire propagation, severe burns	Possible
Gas cylinder fall or valve damage	Projectile cylinder, gas release, explosion	Unlikely

Controls (Hierarchy of Controls)

Install and maintain flashback arrestors on both the torch and regulator ends of each hose

Conduct pre-use inspection of all hoses, connections, regulators, and flashback arrestors

Establish a fire-free zone of at least 10 metres around the cutting area and assign a fire watch

Provide LEV or natural ventilation to remove metal fume from the cutting zone

Identify coatings on material before cutting and implement coating-specific controls

Store gas cylinders upright, secured, separated by fuel type, and away from ignition sources

Prohibit oxygen use for cooling, cleaning, or pressurising and prevent oxygen enrichment of clothing

Fit-test P2 respirators for all oxy-cutting operators and upgrade to PAPR for coated materials

Recent Prosecutions

BI Australia Pty Ltd$400,000

Crane incident during steel fabrication operations resulting in serious worker injuries due to inadequate lift planning and safety controls.

2025 — SafeWork NSW v BI Australia Pty Ltd [2025]

Orica Australia Pty Ltd$1,200,000

Workers exposed to metal fume and dust without adequate ventilation or health monitoring.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

What Your SWMS Must Include

✓Gas equipment inspection checklist including flashback arrestor testing dates

✓Fire prevention and fire watch procedures for every oxy-cutting location

✓Coating identification procedure for materials to be cut

✓Cylinder storage, handling, and transport procedures

✓Emergency procedures for flashback, gas leak, and fire events

Related SWMS

Plasma Cutting →Hot Work →Grinding →

Need a compliant Oxy-Cutting SWMS?

Our WHS consultants build process-specific SWMS that address fire risk, flashback prevention, and fume controls for your oxy-acetylene cutting operations.