MIG Welding SWMS

MIG welding is the most widely used welding process in Australian metal fabrication, accounting for the majority of production welding on carbon steel, stainless steel, and aluminium. The process generates significant quantities of welding fume containing manganese, iron oxide, and depending on the base metal, chromium VI and nickel. With manganese limits dropping 98 per cent to 0.02 mg/m³ in December 2026, every MIG welding operation must be reassessed for fume extraction adequacy. This template covers controls mapped to the binding Welding Processes Code of Practice effective 1 July 2026 under Section 26A.

Legal Requirements

regulation

WHS Regulation 2025 Part 7.1 — Hazardous Chemicals

hrcw category

Hot work near 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.

hrwl required

Not required for standard MIG welding; required for crane-assisted component positioning

Hazards

Hazard	Consequence	Likelihood
Inhalation of welding fume containing manganese and iron oxide	Manganism (neurological damage), siderosis, lung cancer	Almost Certain
Chromium VI fume from stainless steel MIG welding	Lung cancer, nasal cancer, kidney damage	Likely
UV radiation and arc eye from welding arc	Photokeratitis, retinal burns, skin cancer	Likely
Burns from molten spatter and hot workpieces	Second and third degree burns	Likely
Fire from spatter igniting combustible materials	Workshop fire, property damage, fatalities	Possible
Electrical shock from welding equipment	Electrocution, cardiac arrest	Unlikely

Controls (Hierarchy of Controls)

Install local exhaust ventilation at every MIG welding station with capture velocity of at least 0.5 m/s at the fume source

Use fume extraction guns for semi-automatic MIG welding where fixed LEV is impractical

Fit-test P2 or powered air-purifying respirators to AS/NZS 1715 for all MIG welders

Substitute lower-fume welding consumables where joint design permits

Enclose welding cells with mechanical ventilation to contain fume and protect bystanders

Implement a hot work permit system for MIG welding outside designated welding areas

Provide welding curtains or screens to protect adjacent workers from UV radiation

Train all MIG welders in fume hazard awareness including the IARC Group 1 carcinogen classification

Recent Prosecutions

Orica Australia Pty Ltd$1,200,000

Workers exposed to cobalt dust and metal fume without adequate ventilation or health monitoring, resulting in occupational lung disease across multiple workers.

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

KML Auto Parts Pty Ltd$375,000

Apprentice suffered severe burns in a welding incident where training records were absent and supervision was inadequate for the task assigned.

2022 — SafeWork NSW v KML Auto Parts Pty Ltd [2022]

What Your SWMS Must Include

✓Identification of all materials being MIG welded and the fume constituents generated

✓LEV specifications including capture velocity, extraction rate, and maintenance schedule

✓RPE selection based on assigned protection factor matching the exposure level

✓Health surveillance schedule for welders including respiratory function and biological monitoring

✓Emergency procedures for fume overexposure and fire ignition

Need a compliant MIG Welding SWMS?

Our WHS consultants build process-specific SWMS that address the incoming WEL changes and protect your welders from Australia's most significant fume exposure challenge.