This example risk assessment has been prepared using the
F-HS20 General Risk Assessment form template - a purpose-built template designed to focus entirely on what matters: identifying hazards, rating risk and recording controls, without any unnecessary fields getting in the way.
The file is supplied in fully editable MS Word format and can be easily customised and saved to Google Docs format if required. The document uses pre-defined style formatting throughout with styles to match the risk-ratings which are input using select boxes pre-populated with all possible risk ratings. All text is in Calibri font for improved readability.
The following document labelling is included in the footer:
- Form number and title
- Information-classification
- Version
- Page number / total pages
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Welding Operations Risk Assessment
This fully completed welding operations risk assessment example has been prepared by a qualified health and safety professional. It covers a typical range of hazards, risks and associated control measures for MIG, TIG, MMA and gas welding, together with associated surface preparation, grinding and finishing activities and can be used as a starting point when developing your own risk assessment documentation.
What Does This Welding Operations Risk Assessment Cover?
This risk assessment identifies the key hazards associated with welding operations including;
- General welding operations — UV/IR radiation burns, fume inhalation, electric shock, fire and hot metal burns from arc and gas welding
- Electrical hazards — electrocution risk from incorrect earthing, damaged connections and inadequate circuit rating
- Use of power tools and portable electrical equipment — cuts, abrasions and electric shock from grinders, drills and finishing tools
- Manual handling — sprains and musculoskeletal disorders from lifting welding equipment, materials and gas cylinders
- Noise — long-term hearing loss and tinnitus from arc welding equipment, angle grinders and fabrication tools
Each hazard includes an inherent risk rating ranging from Moderate to Substantial, and a comprehensive listing of applicable control measures covering areas such as;
- Competent operatives, welding masks (BS EN 175) and correct shade lenses for the welding process
- Welding screens, local exhaust ventilation (LEV) and Respiratory Protective Equipment (RPE)
- Heat-resistant gloves, flame-retardant clothing and hot work permits outside designated welding bays
- Correct earthing, open circuit voltage limits and inspection of all electrical connections before use
- PAT testing, RCD protection and eye/hand protection for grinding and cutting
- Noise assessments, hearing protection zones and audiometry health surveillance
A residual risk rating is then assigned to each hazard, demonstrating how effective risk management reduces overall risk to a tolerable level.
A Professional, Easy-to-Use Risk Assessment Template
This document uses colour-coded header styles matched to risk ratings, making it quick to read and easy to communicate during toolbox talks and worker training. A built-in risk rating matrix supports consistent evaluation of likelihood and consequence, and hazard pictograms using internationally recognised ISO warning symbols are included alongside relevant hazard entries — improving clarity and helping to highlight risks and mandatory controls.
The result is a completed risk assessment that looks professional, reads clearly, and demonstrates a structured and effective approach to risk management.
Who Is This Risk Assessment Template Suitable For?
This welding operations risk assessment template is suitable for health and safety advisers, health and safety managers, production supervisors, welding operatives and any employer with a duty to assess risks associated with welding and fabrication activities. It can be implemented as a standalone document or as part of a broader occupational health and safety management system aligned with ISO 45001.
Note: This example risk assessment is supplied for use as guidance only and should be reviewed and completed by a competent person.