Risk Assessment: Electrofusion & Butt Fusion Welding¶
Document Information
| Field | Value |
|---|---|
| Document Reference | RA17 |
| Issue Number | 2 |
| Issue Date | 1 June 2026 |
| Next Review | 1 June 2027 |
| Prepared By | Sean Ashton |
| Approved By | Aaron Mason, Director |
Risk Assessment Table¶
| Activity/Process | Hazard | Who/What Affected | Existing Controls | Pre-Control Risk (S/L/R) | New Controls Required | Post-Control Risk (S/L/R) |
|---|---|---|---|---|---|---|
| Jointing PE pipes using electrofusion/butt fusion equipment | Physical injury when using the equipment | Site personnel - cuts, bruises, serious injuries from improper use | • All operatives trained in equipment use and familiar with specific model • Personnel with pacemakers kept away from electrofusion operations • Butt fusion equipment has audible alarms and emergency stop button |
3/2/6 (Moderate) | • Ensure annual refresher training • Maintain log of trained personnel • Supervisors check competency cards before work Supervisor, ongoing |
3/1/3 (Low) |
| Preparing pipe ends by scraping/trimming | Eye injuries from flying particles | Site personnel - eye injuries from particles or hot PE from coupling | • Safety eyewear mandatory during all preparation and fusion activities | 3/2/6 (Moderate) | • Implement mandatory eye protection checks • Consider safety glasses with side protection Site Supervisor, immediate |
3/1/3 (Low) |
| Operating welding equipment | Equipment failure leading to electric shock or fire | Site personnel - electric shocks or burns from faulty equipment | • Equipment checked before use • All equipment within inspection date • Maintained per manufacturer's regime • Defective equipment removed immediately • Fire extinguishers available |
4/2/8 (Moderate) | • Implement formal pre-use inspection checklist • Establish quarterly equipment audit • Tag and remove defective equipment immediately Health & Safety Manager, within 1 month |
4/1/4 (Low) |
| Moving and positioning equipment | Manual handling of heavy equipment | Site personnel - musculoskeletal injuries from handling heavy equipment | • All personnel have manual handling training • Mechanical aids provided where practicable • Team lifting for heavier items |
3/2/6 (Moderate) | • Review equipment weights • Mark items requiring 2+ person lift Site Supervisor, within 1 month |
3/1/3 (Low) |
| Working with hot equipment | Contact with hot PE pipe causing burns | Site personnel - burns from hot equipment or molten PE | • First aid trained team member present • Equipment never left unattended when hot • Heat resistant gloves provided |
3/2/6 (Moderate) | • Provide dedicated heat-resistant gloves • Add visible warning signs to hot equipment • Consider cool-down period before handling Supervisor, immediate |
3/1/3 (Low) |
| Setting up equipment | Equipment falling due to incorrect positioning | Site personnel - injuries from falling equipment, especially near excavations | • Equipment placed on firm stable ground • Adequate working space maintained • Not positioned close to excavation edges |
3/2/6 (Moderate) | • Develop minimum distance guidance from excavation edges • Provide level bases where necessary Site Supervisor, within 1 month |
3/1/3 (Low) |
| Working in adverse weather | Electrical hazards from water ingress | Site personnel - electric shock from water in electrical equipment | • All equipment 110v or RCD protected • Shelter/tent provided for wet weather operations |
4/2/8 (Moderate) | • Provide additional weather protection kits • Formalise pre-work weather assessment Site Supervisor, immediate |
4/1/4 (Low) |
| Using generator power source | Carbon monoxide exposure | Site personnel - CO poisoning if generators used in confined spaces | • Work planned to avoid equipment in excavations/enclosed spaces | 4/2/8 (Moderate) | • Provide CO detectors for teams using generators • Enhance training on generator positioning Health & Safety Manager, within 1 month |
4/1/4 (Low) |
| Refuelling generators | Fire/explosion when refuelling | Site personnel - burns or respiratory issues from fuel fires | • See RA - portable petrol driven equipment for detailed controls | 4/2/8 (Moderate) | • Provide spill kits with generators • Reinforce hot work permit system Site Supervisor, immediate |
4/1/4 (Low) |
| Preparing coiled PE pipe | Impact injuries from stored energy in coiled pipe | Site personnel - struck by pipe when cutting restraining straps | • Coiled pipe restrained in purpose-made trailer/cage • For smaller pipes (≤63mm), operative stands within coil when cutting straps |
3/2/6 (Moderate) | • Review and update training on handling coiled pipe • Provide visual guidance in vehicles and trailers Leanne Mason, within 2 months |
3/1/3 (Low) |
Key:¶
- S = Severity (1-5 scale)
- L = Likelihood (1-5 scale)
- R = Risk Rating (S × L)
- Risk Levels:
- Low (1-3)
- Moderate (4-8)
- High (9-15)
- Very High (16-25)