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Welding and Fabrication Risk Assessment

Free Risk Assessment template · Category: ManufacturingView all Risk Assessment templates
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Risk Assessments

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Risk Assessment Matrix

Risk Assessment Matrix

Likelihood

  • 5 = Certain
  • 4 = Likely
  • 3 = Possible
  • 2 = Unlikely
  • 1 = Remote

Severity

  • 5 = Fatality
  • 4 = Major Injury
  • 3 = Lost Time Injury
  • 2 = Minor injury
  • 1 = Trivial Injury

Risk Rating [L x S]

1-5 = Low
6-12 = Medium
13-25 = High

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Risk Assessment Description:

This free welding and fabrication risk assessment template is designed for manufacturing plant managers, production supervisors and skilled operatives who need a quick, compliant way to assess the hazards associated with welding and metal fabrication in a factory setting. Whether you’re performing MIG/TIG welding on assembly lines, cutting and grinding components, or fitting structural steel in a workshop, this welding and fabrication risk assessment example provides pre‑filled hazards and control measures you can customise.

The template covers all key risks for welding and fabrication, including exposure to hazardous fumes, arc‑eye, burns, electric shock, fire, noise, vibration, manual handling, confined‑space asphyxiation, and gas cylinder hazards. It also addresses common manufacturing‑specific issues such as machine guarding, LOTO isolation, and slip/trip hazards on oily floors.

Use this template for:

  • Pre‑task risk planning – identify and control welding‑related hazards before work starts.
  • Worker briefings – provide clear, actionable controls to the welding crew.
  • Compliance documentation – demonstrate adherence to PUWER 1998 (Reg 5‑7), COSHH 2002 (Reg 5‑6) and relevant HSE manufacturing guidance.

Each hazard includes suggested control measures covering local exhaust ventilation, respiratory protection, eye and skin PPE, equipment guarding, isolation procedures, and safe storage of gases, all drawn from HSE guidance on welding risks and controls[[1]](https://www.hse.gov.uk/welding/health-risks-welding.htm),[[2]](https://www.hse.gov.uk/welding/welding-controls.htm).

Fully editable and shareable – customise hazards, add site‑specific risks, adjust control measures to match your conditions, and download as a PDF for records or share with your team.

Compliant with: Provision and Use of Work Equipment Regulations 1998 (PUWER), Control of Substances Hazardous to Health Regulations 2002 (COSHH), and HSE manufacturing welding guidance.

Sample PDF Document Image:

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Risks covered in this Welding and Fabrication Operatives risk assessment

This Welding and Fabrication Operatives risk assessment template covers 15 assessed hazards, each scored before and after control measures on a 5×5 HSE risk matrix.

HazardInitial riskControlled risk
Fire and explosion from flammable materials2010
Exposure to welding fumes and metal dust168
Burns from hot metal, spatter and slag168
Electric shock from welding equipment1510
Confined‑space asphyxiation during welding1510
Gas cylinder handling and storage hazards1510
Inadequate hot‑work permit and fire‑watch procedures155
Arc flash hazard when welding on live equipment155
Arc‑eye and ultraviolet radiation exposure128
Manual handling of heavy components126
Noise‑induced hearing loss96
Hand‑arm vibration from grinding and hand‑held tools96
Slip, trip and fall on oily or metallic floors96
Exposure to ozone and nitrogen oxides from welding fumes93
Heat stress during prolonged welding in hot environments93

Frequently asked questions

Are these risk assessment templates really free to download?

Yes — completely free. Over 1900 free UK risk assessment templates, free to use forever, no signup required for guests, no paywall. Customise to your workplace and download as a professional HSE-compliant PDF in minutes.

Can I download risk assessment templates in PDF or Word format?

Risk assessments download as a professional, HSE-compliant PDF — ready to print and file as-is. Word (.docx) export is not available for risk assessments, but you can fully customise every hazard, control measure, persons-at-risk entry and rating online before you download.

Are the risk assessment templates HSE-compliant?

Yes. Every template aligns with HSE guidance and the HSE 5-Step Risk Assessment process. They cover the requirements of the Management of Health and Safety at Work Regulations 1999, COSHH 2002, Manual Handling Operations Regulations 1992, Work at Height Regulations 2005, and other relevant UK regulations.

What industries do the risk assessment templates cover?

Over 1900 templates across every UK industry — painting, electrical, HVAC, plumbing, carpentry, concrete, solar panel installation, asbestos, scaffolding, working at height, manual handling, fall protection, hot works, confined space entry, lifting operations, kitchen fitting, plumbing, drywall, tiling, plastering, and many more.

What's the difference between a risk assessment form and a risk assessment template?

A risk assessment form is the blank document; a risk assessment template is a pre-filled form ready to customise. Our generator gives you both — a free interactive form you fill in plus over 1900 pre-written templates you can customise to your specific workplace.

Do I need to create an account to use the risk assessment templates?

No — guests can generate and download risk assessments for free without signing up. Register a free account if you want to save documents to your dashboard, edit them later, or share them for digital signatures.

Can I customise the risk assessment templates to my workplace?

Yes — fully. Edit hazards, control measures, persons at risk, likelihood and severity ratings, PPE requirements, and review schedules. Each template is a starting point you tailor to your specific operation.

How many risks can I add to a single risk assessment?

The number of risks (hazards) you can include in one assessment depends on your plan: guests get unlimited risks, Free accounts unlimited risks, Standard unlimited risks, Pro unlimited risks, and Enterprise unlimited risks per assessment. You can add and preview every risk in a template, then tick the ones to include up to your plan limit — upgrade any time for more. See our pricing page for the full plan comparison.

Are these risk assessment templates valid for UK construction work?

Yes. Our construction-specific risk assessment templates align with HSE construction guidance, the Construction (Design and Management) Regulations 2015 (CDM 2015), and the Work at Height Regulations 2005. Templates cover scaffolding, working at height, concrete pouring, excavation, roofing, electrical installation, and more.

How often should I update my risk assessment?

Whenever there is reason to believe the assessment is no longer valid — after workplace changes, near-misses, accidents, new equipment, new substances, or new processes. HSE guidance recommends an annual formal review at minimum.

What is the HSE 5-step risk assessment process?

Step 1: Identify the hazards. Step 2: Decide who might be harmed and how. Step 3: Evaluate the risks and decide on precautions. Step 4: Record findings and implement them. Step 5: Review the assessment and update if necessary. Our interactive generator walks you through all 5 steps.

Can I use these risk assessment templates for self-employed work?

Yes. Self-employed workers are required to assess risks to themselves and anyone affected by their work. Our templates are suitable for sole traders, contractors, and small businesses.

Do you have RIDDOR-aligned risk assessment templates?

Yes. Several templates cover RIDDOR (Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 2013) requirements — including accident reporting and investigation risk assessments. All RA templates support incident logging and review.