Stick Welding SWMS

Stick welding generates the highest fume emission rates of any common arc welding process. The flux coating on stick electrodes produces a dense fume plume containing iron oxide, manganese, fluoride compounds, and silicates. E7018 low-hydrogen electrodes, the most widely used structural electrode in Australia, contain significant manganese in both the wire core and flux coating. With the manganese WEL dropping to 0.02 mg/m³ in December 2026, stick welding operations will require aggressive fume extraction and respiratory protection to achieve compliance. This template maps controls 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.

Hazards

Hazard	Consequence	Likelihood
High-volume welding fume containing manganese and fluorides	Manganism, fluorosis, chronic lung disease	Almost Certain
Flux fume irritation to eyes and respiratory tract	Chemical conjunctivitis, occupational asthma	Likely
Electric shock from electrode holder and return clamp	Electrocution, cardiac arrest	Unlikely
Burns from slag spatter and hot electrode stubs	Second and third degree burns	Likely
Fire ignition from slag droplets and electrode stubs	Workshop fire, structural damage	Possible
UV radiation and arc flash	Photokeratitis, skin burns	Likely

Controls (Hierarchy of Controls)

Install local exhaust ventilation with at least 0.5 m/s capture velocity at the fume source for all stick welding

Use powered air-purifying respirators for sustained stick welding due to high fume generation rates

Substitute lower-manganese electrode classifications where structural requirements permit

Implement slag disposal procedures to prevent fire ignition from hot slag and electrode stubs

Provide insulated electrode holders in good condition and verify return clamp connections before welding

Use welding screens and curtains to contain UV radiation and protect adjacent workers

Conduct personal exposure monitoring for manganese and fluoride after any process change

Include fluoride biological monitoring in the health surveillance program for regular stick welders

Recent Prosecutions

KML Auto Parts Pty Ltd$375,000

Apprentice suffered severe burns in a welding incident with inadequate training records and supervision for the assigned task.

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

Orica Australia Pty Ltd$1,200,000

Workers exposed to metal fume without adequate ventilation or health monitoring, resulting in occupational lung disease.

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

What Your SWMS Must Include

✓Electrode classification and manganese content for each consumable used

✓LEV specifications and maintenance schedule for stick welding stations

✓RPE selection based on fume generation rate and assigned protection factor

✓Slag and stub disposal procedures to manage fire risk

✓Health surveillance schedule including respiratory function and fluoride biological monitoring

Need a compliant Stick Welding SWMS?

Our WHS consultants build process-specific SWMS that address the high fume generation rates and incoming WEL changes for your stick welding operations.