Steel Cutting on Site

Steel cutting on site uses disc cutters, oxy-fuel torches, plasma cutters, and reciprocating saws.
Hot cutting methods (oxy-fuel, plasma) require hot works permits and fire prevention controls.
Cold cutting with disc cutters generates sparks, noise, and metal dust that travel significant distances.
Sparks from steel cutting can ignite combustible materials up to 10 metres from the cutting point.
Metal dust and fume from cutting galvanised or coated steel are harmful and require extraction or RPE.
Disc cutters create extreme noise levels exceeding 100 dB — hearing protection is mandatory.
Off-cuts of steel can fall unpredictably during cutting — exclusion zones must be maintained below.
COSHH 2002 applies to fume exposure and PUWER 1998 applies to the safe use of cutting equipment.
Thermal cutting of painted or coated steel may release lead, zinc, or chromium fumes.
Cut edges are razor-sharp — immediate deburring or marking is required to prevent lacerations.

Fire risk	Sparks from steel cutting travel far and ignite combustible materials causing site fires.
Fume hazard	Cutting coated or galvanised steel releases toxic metal fumes that damage lungs.
Laceration danger	Cut steel edges are extremely sharp and cause deep wounds on contact.
Noise exposure	Disc cutters exceed safe noise limits within seconds of starting.

Do

Don't

Obtain a hot works permit before using any thermal cutting method on site.
Clear combustible materials within 10 metres of the cutting location.
Wear hearing protection, eye protection, and RPE during all steel cutting.
Use fume extraction when cutting galvanised, painted, or coated steel.
Maintain an exclusion zone below and around the cutting area for falling off-cuts.
Deburr or mark cut edges immediately to prevent laceration injuries.
Inspect disc cutters and abrasive wheels before every use.
Maintain a fire watch for 60 minutes after completing any hot cutting.
Secure the steel member to prevent movement during the cutting operation.
Have a fire extinguisher immediately available at the cutting location.

DON'T cut steel using thermal methods without a hot works permit in place.
DON'T cut galvanised or painted steel without fume extraction or RPE.
DON'T allow sparks to reach combustible materials — clear or protect them first.
DON'T leave cut steel edges unprotected — they cause deep lacerations.
DON'T use a disc cutter without hearing and eye protection.
DON'T cut steel with anyone standing below where off-cuts may fall.
DON'T use damaged or expired abrasive discs — they shatter at high speed.
DON'T cut into structural members without the engineer's written approval.
DON'T store oxy-fuel gas cylinders near the cutting area during operations.
DON'T skip the fire watch after hot cutting — fires start hours later.

See also: Steel Erection Safety | Grinding and Cutting Safety

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