Plasma cutting uses a high-temperature ionised gas jet to cut electrically conductive metals at speeds significantly faster than oxy-acetylene cutting. The process generates extreme noise levels often exceeding 100 dB(A), dense metal fume, ozone, nitrogen dioxide, and intense UV radiation. When cutting stainless steel, plasma generates chromium VI fume at concentrations that can exceed the incoming WEL of 0.005 mg/m³ within minutes of cutting. Water tables reduce fume and noise but do not eliminate airborne contaminants. This template maps controls to the binding Welding Processes Code of Practice effective 1 July 2026 under Section 26A.
WHS Regulation 2025 Part 7.1 — Hazardous Chemicals and Part 4.3 — Noise
Hot work near flammable atmosphere
Welding Processes, Managing Noise and Preventing Hearing Loss (binding 1 July 2026 under Section 26A)
Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.
| Hazard | Consequence | Likelihood |
|---|---|---|
| Noise exposure exceeding 100 dB(A) during plasma cutting | Permanent noise-induced hearing loss | Almost Certain |
| Metal fume and ozone inhalation from plasma arc | Pulmonary oedema, chronic respiratory disease | Likely |
| Chromium VI fume from cutting stainless steel | Lung cancer, nasal cancer | Likely |
| Intense UV radiation from plasma arc | Severe arc eye, skin burns, skin cancer | Likely |
| Molten metal projection from cutting operation | Burns, eye injuries | Likely |
| Electrical shock from plasma torch and workpiece | Electrocution, cardiac arrest | Unlikely |
Workers exposed to metal fume and dust without adequate ventilation or health monitoring, resulting in occupational lung disease.
2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]
Safety failures during metal fabrication operations resulting in serious worker injuries.
2025 — SafeWork NSW v BI Australia Pty Ltd [2025]
Our WHS consultants build process-specific SWMS that address the extreme noise, fume, and UV hazards of plasma cutting operations.
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