TIG Welding SWMS

TIG welding produces cleaner welds than MIG or stick welding but generates significant ozone concentrations, particularly when welding aluminium and stainless steel. The high UV output of the TIG arc drives ozone formation in the surrounding air, creating a respiratory hazard that many fabrication shops underestimate. When welding stainless steel, TIG produces chromium VI and nickel fume at levels that will exceed the incoming December 2026 WELs without dedicated extraction. Tungsten electrode grinding generates fine tungsten dust and potential thorium oxide exposure if thoriated electrodes are used. 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

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
Ozone inhalation from TIG arc UV output	Pulmonary oedema, chronic respiratory disease	Likely
Chromium VI fume from stainless steel TIG welding	Lung cancer, nasal cancer	Likely
Thorium oxide dust from grinding thoriated tungsten electrodes	Radioactive particulate inhalation, lung cancer	Possible
Intense UV radiation causing arc eye and skin burns	Photokeratitis, skin cancer with chronic exposure	Likely
Burns from hot workpieces and filler rod	Second degree burns to hands and forearms	Likely
Argon gas asphyxiation in enclosed areas	Oxygen displacement, loss of consciousness, death	Unlikely

Controls (Hierarchy of Controls)

Install local exhaust ventilation positioned to capture ozone and fume at the weld zone

Substitute ceriated or lanthanated tungsten electrodes for thoriated electrodes to eliminate radioactive dust

Use dedicated tungsten grinding stations with dust extraction fitted with HEPA filtration

Fit-test P2 respirators or powered air-purifying respirators for all TIG welders on stainless steel

Provide shade 10-14 auto-darkening helmets with side shields for UV protection

Monitor argon gas flow rates and ensure adequate ventilation in enclosed welding areas

Implement ozone monitoring during aluminium TIG welding to verify LEV effectiveness

Provide UV-blocking welding curtains around TIG welding stations to protect bystanders

Recent Prosecutions

Orica Australia Pty Ltd$1,200,000

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]

KML Auto Parts Pty Ltd$375,000

Apprentice suffered severe burns during welding operations with inadequate training and supervision.

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

What Your SWMS Must Include

✓Identification of base metals and filler metals with associated fume constituents

✓Ozone monitoring requirements and action levels for TIG welding operations

✓Tungsten electrode type specification prohibiting thoriated electrodes unless risk-assessed

✓LEV specifications for TIG welding stations including capture velocity verification

✓RPE selection and fit-testing schedule for all TIG welders

Need a compliant TIG Welding SWMS?

Our WHS consultants build process-specific SWMS that address ozone, chromium VI, and the incoming WEL changes for your TIG welding operations.