HSE Knowledge Network
Saddle Welding at Petrol Station Risk Assessment
Here’s a Risk Assessment for welding a pipe saddle on a metal strip near the wall of a petrol station:
Title: Risk Assessment for Pipe Saddle Welding Near Petrol Station
Location: [Specify Location]
Date: [Insert Date]
Prepared By: [Your Name or Designation]
Risk Residual
S/N Hazards Hazard Effects Controls Action to be Taken
Evaluation Risk
Conduct gas testing for
Use fire-resistant Likelihood:
Likelihood: 4 flammable vapors.
Presence of screens to isolate 1
Impact: 5 Ensure all welding
1 flammable Fire or explosion the work area. Impact: 5
Risk: 20 activity is at least 15
vapors Assign a fire watch Risk: 5
(High) meters away from fuel
during the activity. (Low)
sources.
Remove combustible Provide fire Likelihood:
Likelihood: 3
Hot work Fire spreading to materials within a 10- extinguishers at the 1
Impact: 4
2 sparks and nearby flammable meter radius. worksite. Impact: 4
Risk: 12
heat materials Use welding blankets to Ensure hot work Risk: 4
(Medium)
cover nearby surfaces. permit is obtained. (Low)
Use proper ventilation
Likelihood:
Likelihood: 3 or local exhaust Monitor air quality.
Welding Health issues such as 2
Impact: 3 systems. Ensure welders have
3 fumes and respiratory problems Impact: 2
Risk: 9 Provide welding adequate PPE and
gases or eye irritation Risk: 4
(Medium) helmets with proper training.
(Low)
filters and respirators.
Inspect welding Conduct toolbox Likelihood:
Likelihood: 3
machines for faults. talks on electrical 1
Electrical Shock or burns from Impact: 4
4 Ensure proper safety. Impact: 4
hazards welding equipment Risk: 12
grounding and Provide insulated Risk: 4
(Medium)
insulation. gloves and boots. (Low)
Use noise-reducing Limit exposure Likelihood:
Likelihood: 3
Noise from Hearing damage or equipment. duration. 1
Impact: 2
5 welding disturbance to Provide hearing Inform nearby Impact: 2
Risk: 6
activity nearby workers protection like earplugs workers before the Risk: 2
(Medium)
or earmuffs. activity. (Low)
Maintain clear access Conduct a site Likelihood:
Likelihood: 2
Difficulty in routes at all times. inspection before 1
Restricted Impact: 4
6 evacuation or fire Use barriers to and after work. Impact: 4
access to site Risk: 8
response demarcate the work Provide emergency Risk: 4
(Medium)
area. response training. (Low)
Notes:
1. Hot Work Permit: Obtain prior approval and adhere to the petrol station's hot work permit requirements.
2. Continuous Monitoring: Assign a safety officer to monitor the activity and ensure compliance.
3. Emergency Preparedness: Keep fire-fighting equipment readily available and ensure the team is trained
in emergency response.
Preventive Recommendations for Pipe Saddle Welding Near Petrol Station
To ensure safety during the welding activity, the following preventive measures are recommended:
1. Pre-Work Preparations
Risk Assessment: Conduct a detailed risk assessment before starting the activity to identify and mitigate
potential hazards.
Hot Work Permit: Obtain a hot work permit from the petrol station management and follow all specified
guidelines.
Site Inspection: Inspect the work area for flammable materials, vapors, or leaks. Ensure the area is free of
ignition sources and properly ventilated.
Fire Watch: Assign a trained fire watch to monitor for sparks or fire throughout the activity and during the
cooling period afterward.
2. Worksite Controls
Safety Barriers: Install fire-resistant screens or barriers around the welding area to contain sparks and
protect nearby personnel and property.
Distance from Fuel Sources: Maintain a safe distance (minimum 15 meters) from fuel storage or
dispensing areas.
Removal of Combustibles: Clear all flammable materials within a 10-meter radius of the worksite. Cover
nearby surfaces with fire blankets if removal is not possible.
Continuous Monitoring: Use gas detectors to monitor for the presence of flammable vapors in the air
during the activity.
3. Personal Protective Equipment (PPE)
Welders: Provide welders with appropriate PPE, including fire-resistant clothing, welding helmets with
face shields, insulated gloves, and respiratory protection.
Other Personnel: Equip all personnel in the vicinity with basic PPE, such as safety goggles, gloves, and
hearing protection.
4. Equipment and Tools
Welding Machine Inspection: Ensure all welding equipment is inspected for faults and properly grounded
before use.
Fire Extinguishers: Keep fire extinguishers (CO₂, foam, or dry chemical types) easily accessible at the
worksite.
Ventilation: Use local exhaust ventilation or fans to disperse welding fumes and prevent the accumulation
of flammable gases.
5. Emergency Preparedness
Evacuation Plan: Develop and communicate an evacuation plan to all personnel, including assembly
points and emergency contacts.
Training: Conduct toolbox talks and ensure all workers understand the hazards and emergency response
procedures.
First Aid Readiness: Keep a first aid kit nearby and ensure personnel trained in first aid are available on-
site.
6. Post-Work Activities
Cooling Period Monitoring: After completing the welding, monitor the area for a sufficient cooling period
to ensure no smouldering materials remain.
Area Inspection: Perform a thorough inspection of the site to confirm that no residual hazards exist.
Documentation: Record the activity and observations in the logbook, including any incidents or
deviations.
Implementing these preventive measures will significantly reduce the risk of accidents during the
welding activity and ensure compliance with HSE standards.
By: Misbah Ul Haq Labeed
