This Oxy-Acetylene & Plasma Cutting SOP (Safe Operating Procedure) sets out how to carry out oxy-fuel gas cutting and plasma arc cutting of metal safely. It covers clearing or shielding combustibles, fume control, checking cylinders, flashback arrestors and plasma leads, choosing the right tip or consumables, cutting technique, supporting the cut piece so it can't drop or swing, isolating the equipment, and what to do after a flashback, fire or burn. It's written by WHS specialists, aligned to Australian WHS legislation, and fully editable in Microsoft Word.
 
Who it's for
Metal fabricators and welding workshops
Steel and structural fabricators
Mechanical and maintenance fitters
Scrap metal and demolition recyclers
Farm and plant maintenance workshops
 
Use it to
Train and induct workers in exactly how you expect the task to be done
Keep a clear reference at the machine, in the vehicle or on site
Record competency with the built-in sign-off
Show clients, insurers and auditors your safe work methods are written down
 
What this SOP covers
Burns from hot slag, sparks, molten metal and cut edges
Fire or explosion from sparks or hot material reaching combustibles
Cutting fume, including manganese fume and metal fume fever
Eye and skin damage from arc flash, UV, infrared, flame and glare
Noise-induced hearing loss from plasma cutting
Electric shock from the plasma power source, torch or cables
Injuries from cut pieces falling, dropping or swinging
Fire or explosion from damaged or leaking gas cylinders and hoses
Manual handling injuries moving cylinders, equipment or cut material
 
What's included
9 pre-operational checks, from training and combustibles to fire extinguishers, fume control, gas equipment, plasma leads, consumables, PPE and securing the work
A 10-step operating procedure covering marking out, positioning, lighting and pre-heat, standoff distance, travel speed, overhead cutting, supporting the cut piece and coatings
Isolation and energy control for closing cylinder valves, bleeding hoses and isolating the plasma power supply before changing consumables or maintenance
6 shutdown, housekeeping and post-operation steps
Emergency actions for flashback, fires started by sparks or slag, electric shock, burns and eye injuries
PPE checklist and a list of related documents
Competency acknowledgement and worker sign-off
Space for your logo, SOP number, version and review dates
 
Why use this template
Saves hours compared with writing an SOP from a blank page
Written as clear, numbered steps that workers can follow on the job
Fully editable, so you can match it to your equipment, site and how your team works
The competency sign-off gives you a training record from day one
 
How it works
Buy online and download straight away. You'll also get an email with your link.
Add your logo, company name, SOP number and dates.
Check it suits your equipment and site, and edit anything you need to.
Train your workers and have them sign the competency acknowledgement.
 
Need more than one SOP?
This SOP is also included in the Ultimate Steel & Metal Fabrication SOP Bundle. At $197 for the whole bundle, it works out much cheaper than buying SOPs one at a time.
 
Common questions
Does it cover setting up an oxy-acetylene set?
No. General set up, leak checking, lighting and shutdown of an oxy-acetylene set is covered in the Brazing & Oxy-Acetylene Set Use SOP. This SOP covers the cutting technique.
Does it cover MIG, TIG or arc welding?
No. Arc, MIG and TIG welding aren't covered. It covers oxy-fuel and plasma arc cutting of metal only.
Does it address fume from coated metals?
Yes. Workers identify the base metal and any coating, check the SDS, and remove a hazardous coating first where that can be done, with local exhaust ventilation or other fume control in place.
Can I change it?
Yes. It's a Microsoft Word file, so you can add, remove or change any step, check or hazard, and add your own logo and details.
Does it suit my state?
Yes. It's written to the model WHS laws and suits all states and territories, including Victoria under the OHS Act and Regulations.
What if it doesn't suit my work?
You're covered by our 30-day money-back guarantee if it isn't fit for purpose.