Welding & Fabrication Risk Assessment Template 2026
OHSA-compliant hazard identification and risk assessment (HIRA) for welding & fabrication work. Covers Burns from hot metal and sparks, Eye damage from UV radiation, Inhalation of welding fumes, and more.
Instant Generation
AI creates your complete welding & fabrication HIRA in under 2 minutes.
OHSA Compliant
Meets Construction Regulations 2014 requirements for risk assessments.
Risk Matrix Included
Automated risk scoring with likelihood × severity calculations.
Welding & Fabrication HIRA Categories
Hazard Categories Covered
- Hot Work Hazards
- Fume and Gas Hazards
- UV Radiation
- Fire and Explosion
- Electrical Hazards
Specific Hazards Addressed
- Burns from hot metal and sparks
- Eye damage from UV radiation
- Inhalation of welding fumes
- Electric shock
- Fire and explosion
- Noise exposure
- Musculoskeletal strain
- Confined space hazards
Risk Matrix Methodology
Our welding & fabrication HIRA uses a 5×5 risk matrix combining likelihood and severity to calculate risk scores. The AI automatically applies hierarchy of controls to reduce residual risk.
High Risk (15-25)
Work cannot proceed. Immediate controls required.
Medium Risk (8-14)
Additional controls needed before work starts.
Low Risk (1-7)
Work may proceed with standard precautions.
Key Welding & Fabrication Risks & Controls
Weld defects and structural failure
Our AI applies hierarchy of controls: elimination, substitution, engineering controls, administrative controls, and PPE.
Fire from hot work
Our AI applies hierarchy of controls: elimination, substitution, engineering controls, administrative controls, and PPE.
Fume inhalation health effects
Our AI applies hierarchy of controls: elimination, substitution, engineering controls, administrative controls, and PPE.
Material damage from distortion
Our AI applies hierarchy of controls: elimination, substitution, engineering controls, administrative controls, and PPE.
Required PPE for Welding & Fabrication Work
Welding & Fabrication Risk Assessment Requirements in South Africa
Welding and fabrication in South Africa is governed by SANS 2001-CS1 (structural steelwork), SANS 44 (welder qualification), and the OHSA General Machinery Regulations for pressurised equipment. Government tenders for structural steel, pipeline, and pressure vessel work require detailed Welding Procedure Specifications (WPS) qualified per SANS 44 or AWS D1.1, along with proof that all welders hold valid coded welder certificates. The South African Institute of Welding (SAIW) is the primary certification body, and SAIW qualifications are referenced in most government tender requirements. CIDB classes CS (Structural Steelwork) and ME (Mechanical Engineering) cover different welding applications. Non-Destructive Testing (NDT) must be performed by SANAS-accredited operators per SANS 17024. For pressure equipment, the Pressure Equipment Regulations under OHSA require that all welding is pre-qualified and that NDT is performed per the applicable vessel code (SANS 347 for classification, ASME VIII Div 1 or PD 5500 for design).
Key Risk Assessment Focus Areas for Welding & Fabrication
Focus 1: UV radiation and arc eye from welding — specify minimum shade numbers per process (Shade 10-12 for MIG, 12-14 for arc), welding curtains for bystander protection
Focus 2: Fume exposure: manganese, hexavalent chromium (stainless), and zinc (galvanised) fumes. Specify local exhaust ventilation requirements and RPE per OHSA HCS Regulations
Focus 3: Fire and explosion from hot work near flammable materials — require hot work permits, fire watch for 30 minutes after welding, and gas testing in classified areas
Focus 4: Compressed gas hazards: cylinder storage (upright, chained, separated), flashback arrestors on oxy-fuel equipment, and leak testing procedures
Focus 5: Electric shock from welding equipment: specify RCD protection for welding machines, dry conditions requirements, and insulated work platforms for confined space welding
Common Mistakes in Welding & Fabrication Risk Assessments
Using a WPS that hasn't been qualified with a PQR for the actual material combination and thickness range used on the project
Not verifying welder certifications cover the required welding positions — a welder coded for flat (1G) cannot weld overhead (4G)
Omitting preheat requirements for thick sections or high-strength steel — this causes hydrogen-induced cracking that may not show up until weeks later
Using generic NDT acceptance criteria instead of the standard specified in the contract (SANS 11666 vs AWS D1.1 have different acceptance levels)
Failing to maintain weld maps and NDT traceability — every weld must be uniquely numbered and traceable to the welder, WPS, and NDT report
Key Legislation for Welding & Fabrication Risk Assessments
| Regulation / Standard | Requirement |
|---|---|
| SANS 2001-CS1 | Structural steelwork fabrication and erection — covers welding procedures, welder qualification, NDT requirements (Table E.1), tolerances, and material specifications for SA construction. |
| SANS 44 (ISO 9606-1) | Qualification testing of welders — defines test requirements for manual and semi-automatic welding by process, material, thickness, and position. Certificates valid for 2 years with continuous employment. |
| Pressure Equipment Regulations (OHSA) | All welding on pressure equipment must use pre-qualified WPS. NDT per the applicable vessel code. SANAS-accredited inspection body must approve the manufacturer's quality plan. |
| SANS 347 | Categorisation and conformity assessment of pressure equipment — classifies equipment into hazard categories determining the level of third-party inspection and certification required. |
Welding & Fabrication Risk Assessment FAQ
What is the difference between WPS and PQR?
Do all welders need coded certificates for government tenders?
What NDT is required for structural steel connections?
What CIDB class covers welding and fabrication?
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