Metal Fabrication

WHS Management for Aluminium Fabrication

Aluminium dust is combustible and aluminium welding fume demands specific RPE and ventilation controls.

Aluminium fabrication involves cutting, welding, machining, and finishing aluminium alloys for architectural, marine, transport, and aerospace applications. The primary hazards differ from steel fabrication in important ways. Aluminium dust generated during grinding, sanding, and machining is combustible and can cause a dust explosion if allowed to accumulate in extraction systems or on surfaces. Aluminium welding fume contains aluminium oxide and ozone, both of which require specific extraction and RPE controls. TIG welding of aluminium generates significantly more ozone than steel welding due to the high UV output of the aluminium arc.

Key Hazards

Combustible aluminium dust accumulation and explosion riskAluminium welding fume and ozone exposureNoise exposure from cutting and grinding aluminiumBurns from molten aluminium spatter during weldingManual handling injuries from large aluminium extrusionsEye damage from high UV output during aluminium TIG welding

Regulatory Requirements

HRCW Categories

Hot work, work near combustible dust atmosphere

Section 26A Codes (binding 1 July 2026)
Welding ProcessesHazardous ChemicalsNoisePlantManual Tasks

SWMS Required

Tig WeldingMig WeldingGrindingSpray Painting MetalPress Brake

Related Sectors

Sheet MetalStainless SteelStructural Steel

Need Help with Aluminium Fabrication WHS?

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