It starts with the real task
MIG on clean 6mm plate at a bench is a different job to gouging galvanised steel in a tank. The process, material, coating, duration, access and who's nearby all change what you write.
Fabora resources
Welding Risk Assessment Template for Steel Fabrication and Site Welding
A welding risk assessment names the hazards, says who could get hurt, sets out the controls, and gets checked before anyone strikes an arc. In a fabrication shop or out on site, it has to match the real bay or work area, the kit, the material and the people around it. A form copied from the last job and left untouched isn't that.
Short answer
A template gives you the bones: the usual hazards and controls. The job is to make it fit: this material, this work area, this kit, these people, these site rules. Do that before it goes out, not after.
- Cover the lot: fume, fire, burns, arc eye, electric shock, gas cylinders, grinding, cutting, PPE, COSHH and what happens in an emergency.
- Shop welding and site welding rarely need the same controls: ventilation, permits and who's nearby all change once you leave the workshop.
- It should tie into the method statement, the hot works permit and the wider RAMS pack, not float on its own.
- Fabora RAMS gives you reusable hazards, controls, PPE, COSHH and equipment to edit around the job. The final review still sits with you.
General guidance, not legal advice. It doesn't replace a competent job-specific risk assessment, COSHH review, site rules, client requirements or your own sign-off.
Practical summary
What to take from this page
A template gives you the bones: the usual hazards and controls. The job is to make it fit: this material, this work area, this kit, these people, these site rules. Do that before it goes out, not after.
General guidance, not legal advice. It doesn't replace a competent job-specific risk assessment, COSHH review, site rules, client requirements or your own sign-off. For official detail, use the source links later on this page.
Free download
Download the free template
Editable and free, with no signup. Fill it in for your job, then keep it for the next one.
Stop re-typing it every job
The template is a good start. Fabora RAMS turns it into reusable, editable RAMS you build in minutes — saved hazard, COSHH and PPE libraries, branded PDF export and revisions, instead of editing the same Word file every time.
Plain English answer
What is a welding risk assessment?
It's the document that names the hazards in a welding job, says who could be harmed, and lists the controls that need to be in place before work starts.
It names who's at risk
Not just the welder. The labourer holding the steel, the next bay along, other trades, the client walking through, the public on the far side of a hoarding: anyone the fume, sparks or UV can reach.
It sets controls people can actually use
A supervisor should be able to read it and know what's expected: the PPE, the fume control, the fire precautions, the equipment checks, the exclusion zone, and when to stop.
It feeds the RAMS
The risk assessment usually sits inside the RAMS pack, next to the method statement that spells out the working sequence.
Hazards
Common welding hazards
Most welding jobs share the same handful of hazards. The template should prompt them, but no two jobs are identical, so don't treat the list as the whole assessment.
Fume and gases
Mild steel fume is a known carcinogen (HSE STSU1-2019), so this isn't optional. Think process, material, coatings, duration, extraction or ventilation, RPE, and who's stood downwind. Galvanising, paint and primers make it worse.
Fire and hot works
Sparks travel further than people expect, up to ten metres, and they drop through gaps onto whatever's below. Check combustibles, hidden voids, the gap under the floor, and do a proper end-of-job check before you leave.
Burns, arc eye and UV
Hot steel and spatter cause most burns; arc eye usually catches the person who glanced over from the next bay. Screens protect them as much as the welder.
Electric shock and gas kit
Damaged leads, dodgy return clamps, wet conditions and generators on the electrical side. On the gas side: securing cylinders, checking hoses and regulators, flashback arrestors, and keeping oxy and fuel apart.
Grinding, cutting and prep
The bit either side of welding adds its own list (abrasive wheels, flying particles, noise, hand-arm vibration and dust) and often needs different PPE to the welding itself.
Handling and nearby people
Frames, plates, gates and secondary steel are heavy, sharp and awkward to move. And other trades, workshop staff or the public nearby may need screens, exclusion zones, signs or timing controls.
Controls
Welding safety controls
Controls only count if they're specific and tied to the work area. "Use PPE" tells nobody anything. "Shade 11 lens, FR jacket, screens up before the arc strikes" does.
Competent people and supervision
Who's welding, whether they're coded or trained for it, who's supervising, who briefs the team, and who has the authority to stop the job when something changes.
PPE and RPE
Welding mask with the right shade, gauntlets, FR clothing, safety boots, ear defenders for the grinding, and RPE where the fume control on its own won't cut it.
Fume control
LEV at source where you can, general ventilation, weld position, and RPE to back it up. Then sanity-check it actually matches the material: galvanised or painted steel needs more than clean mild steel.
Hot works precautions
Permit if the site runs one, combustibles cleared or covered, extinguisher and fire blanket to hand, and a fire watch that stays after the welding stops. Smouldering fires often start an hour later.
Equipment checks
Eyeball the welding set, leads, return clamp, plugs, grinders, hoses, regulators, cylinders and cable routes before you start. Damaged leads come out of use, not back in the van.
Area control and emergencies
Exclusion zone, screens, signs, decent housekeeping, first aid, the site fire arrangements, and a clear line on what makes everyone down tools.
Template checklist
What a welding risk assessment template should capture
Six headings to fill in before the document goes out. It still needs a competent person to edit it for the job and sign it off.
Job and work area
Company, job reference, customer, the bay or site area, scope, dates, review date, revision number and who approved it. Get the dates and contacts right. Stale ones are the giveaway that it was copied.
Process and people
Welding or hot work type, who's doing it, who's at risk, supervision, competence, nearby trades, public exposure and the site contact.
Materials, kit and COSHH
Steel and its condition, coatings, consumables, gases, the welding set, grinders and cutting tools, plus the COSHH items and the safety data sheets behind them.
Fume, ventilation and fire
Fume controls, extraction, ventilation, RPE, permit needs, fire risk, extinguishers, fire watch and the end-of-job check.
PPE, access and position
Welding PPE, RPE, ear protection, screens, access equipment, work at height, awkward positions, manual handling and exclusion zones.
Emergencies and review
Emergency arrangements, stop-work triggers, first aid, fire response, incident reporting, permit close-out, the approval route and the revision history.
Workshop example
Workshop welding: the order it usually runs in
A worked example of how a shop weld gets reviewed start to finish. It's a guide to the order, not a finished assessment for your job.
01. Check the bay and set up
Bench or booth, screens, extraction point, access route, who's nearby, housekeeping. Sort the combustibles before the leads come out.
02. Check materials and consumables
Steel condition, coatings, contamination, wire or rods, gas, sprays and cleaners, plus the COSHH info behind anything that needs it.
03. Inspect the kit
Welding set, return lead, cables, plugs, gas, extraction, RPE and PPE. Anything damaged comes out of use.
04. Confirm fume control
LEV, ventilation, RPE and weld position suit the material and how long the run is. Galvanised or painted steel needs more.
05. Weld to the agreed controls
PPE, fume control, fire precautions and supervision as set out. Manage hot offcuts, spent consumables and sparks as you go.
06. Check the work and log anything
Inspect the weld and the area, then record damaged kit, fume concerns, missing PPE or anything to fix before the next job.
Site example
Site welding: the order it usually runs in
Site welding needs more thought job-to-job: permits, ventilation, access and other trades change every time you turn up somewhere new.
01. Sign in and get inducted
Site access, welfare, emergency arrangements, the site contact, local rules, and any restriction that bites on the welding.
02. Confirm the area and the permit
Exact work area, hot works permit route and timing, nearby materials and services, access and escape routes.
03. Re-read the RAMS against what's in front of you
Brief the RAMS, check the permit conditions, and make sure the risk assessment still matches the live location, not the one you imagined in the office.
04. Get kit and cylinders in safely
Agreed access route, cylinders secured, manual handling managed, walkways and escape routes kept clear.
05. Set up controls before the arc
Screens, signs, barriers, extinguisher, fire blanket, fume control and ventilation in place. Recheck height, platform and combustibles for anything that's changed since the RAMS were written.
06. Weld, fire-watch, hand back, record
Work to the agreed controls, hold the fire watch for the agreed period, clear leads, cylinders, offcuts and screens, then log permit close-out, defects, photos and any follow-up before you leave.
RAMS connection
How the risk assessment fits the rest of the pack
The risk assessment is the hazards and controls. The method statement is the sequence: how the work actually gets done. RAMS bring them together so the whole job reviews as one. Our method statement template for steelwork covers the sequence side, and the toolbox talk topics guide further down turns the key points into a short team briefing.
The risk assessment side
Fume, fire, burns, arc eye, electric shock, gases, grinding, manual handling, nearby people, PPE, COSHH and emergencies.
The method statement side
Arrive, set up, check permits, move kit, weld, fire-watch, clear up, record. The order the job runs in.
Permits and COSHH
It should hook into the hot works permit, the COSHH info, the fume controls, the equipment checks and the PPE you've chosen.
The wider steelwork job
On site, the weld doesn't sit alone: access, lifting, other trades and the public all feed into how it affects the install.
Fabora RAMS
Where Fabora RAMS saves you time
It speeds up the drafting and keeps your content consistent. What it doesn't do is sign the job off. That stays with you.
Your company details, saved
Company info, customers, sites and contacts are held once, so a welding RAMS doesn't start life as last month's file with the names changed.
Reusable hazards and controls
Pull welding hazards, fume controls, hot works precautions, PPE, COSHH and equipment from your libraries, then edit them around the job in front of you.
PDF export and share links
Export the reviewed pack as a PDF, send it to whoever needs it, and keep a cleaner revision trail as the job moves.
You still sign it off
It gives you structure, speed and consistency. It doesn't replace a competent risk assessment, the client's rules, site acceptance or your approval.
Copied templates
Where copied welding risk assessments fall down
A copied form can look complete and still miss the controls that matter. These are the ones that catch a weak template before it goes out.
Last job's details
Old site name, wrong dates, a contact who left, a supervisor who's on another job. If the header's wrong, nobody trusts the rest.
Hazards with no specifics
It lists "welding fume" and "fire" but never says what's being welded, where, how it's ventilated or who's nearby. That's a list, not an assessment.
Fume treated as a tick-box
Extraction, ventilation, RPE, the fume path and the material all matter. A generic "adequate ventilation" line on a galvanised job won't survive a second look.
Thin on hot works
Fire watch, extinguishers, combustibles, hidden voids, permit conditions and the end-of-job check get skipped when the template was written for a clean bench weld.
No review when the job changes
Different material, coating, location, duration, access or trades nearby: any of those should trigger a fresh look, not a reused PDF.
Paperwork instead of a plan
Pages of generic wording aren't the same as a usable control plan. The good ones make the real hazards, controls and who's responsible easy to find.
Official guidance
Relevant official sources
These links point to the underlying official material. This page is a practical summary, not a replacement for those sources, competent review, or legal advice.
HSE: Health risks from welding
Useful HSE context on welding fume, gases, noise, vibration and other health risks linked to welding.
HSE: Safety risks from welding
Useful HSE context on fire, explosion, burns, electric shock, compressed gases and other welding safety risks.
HSE: Controlling the risks from welding
Useful HSE guidance on welding risk assessment, fume control, ventilation, RPE and protecting nearby workers.
HSE: COSHH essentials for welding
Useful HSE welding COSHH guidance for fumes, gases, cutting and related process-generated exposure.
FAQ
Common questions
Short answers on practical use, review expectations, and where this guidance stops.
Important note
Final review, suitability, and approval still remain with the customer's business and the people responsible for the job.
What is a welding risk assessment?
It's the document that names the hazards in a welding job, says who could be harmed, and sets out the controls needed for that actual workshop or site task before work starts.
What hazards should a welding risk assessment include?
Usually fume and gases, fire, burns, arc eye and UV, electric shock, gas cylinders, grinding and cutting, noise, hand-arm vibration, manual handling, slips and trips, nearby people, PPE, COSHH and emergency arrangements. Pick the ones that apply to the job rather than listing all of them every time.
What controls are usually used for welding?
Competent welders and supervision, a task briefing, the right PPE, fume extraction or ventilation, RPE where it's needed, a hot works permit if the site runs one, extinguishers and a fire watch, equipment checks, screens, exclusion zones and clear emergency arrangements.
Does welding need a COSHH assessment?
Yes. Welding fume is hazardous to health (HSE classes mild steel fume as a carcinogen), and jobs often involve gases, consumables, cleaners or sprays too. The COSHH review usually sits inside the wider welding risk assessment and RAMS pack.
Is a welding risk assessment the same as a method statement?
No. The risk assessment covers the hazards, who's at risk and the controls. The method statement explains the sequence: how the welding actually gets done. RAMS bring the two together.
Can I use the same welding risk assessment for every job?
You can start from a company template, but it has to be edited for the job. Material, coating, process, ventilation, access, who's nearby, permits and kit all change, and a copied one that ignores that won't stand up.
Related reading
Continue from here
These links keep the topic moving, either into related guidance or into the Fabora RAMS product pages.
Fabora RAMS
See how Fabora RAMS helps steelwork teams prepare editable welding RAMS and risk assessment content faster.
Pricing
Compare the Fabora RAMS plans if you prepare welding RAMS, risk assessments and method statements regularly.
RAMS Template UK
Useful if you need the broader RAMS structure around a welding risk assessment and method statement.
Method statement template for steelwork
Useful if you need a practical welding or steelwork method statement sequence alongside the risk assessment.
Toolbox Talk Topics for Welding and Steelwork
Useful if you need practical briefing topics that connect welding hazards, controls, PPE, fumes and fire risk to the job.
Toolbox Talk Generator
Create a practical toolbox talk outline from welding hazards, controls, PPE, fumes and fire-risk briefing points.
Welding Risk Assessment Checklist
Use the free checklist tool to review welding hazards, fumes, hot works, PPE, COSHH, equipment and job-specific controls before drafting RAMS.
RAMS Checklist Generator
Useful when welding risk assessment content needs to sit inside a wider RAMS pre-issue review before the pack goes out.
Site welding RAMS guide
Useful if your welding risk assessment needs to sit inside a wider site welding RAMS pack.
Hot works permits and site welding controls
Useful where welding risk assessment controls need to connect with permits, fire watch and close-out checks.
COSHH and welding consumables
Useful where welding fumes, gases, consumables and COSHH items need clearer supporting review.
Welding fume control and LEV
Useful background for fume control, extraction, ventilation and RPE decisions in fabrication workshops.
Types of welding explained
Useful if the welding process itself affects the hazards, fume controls, consumables or PPE selection.
Hot works permit generator
Use the free Fabora tool when a hot works permit needs to sit alongside welding RAMS and risk assessment review.