PIP/Materials/TBT-PIP-007

Steel Pipe Installation and Welding

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Steel Pipe Installation and Welding

Toolbox Talk Record

Ref: TBT-PIP-007  |  Issue: 1  |  Date: March 2026
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What?

  • Steel pipelines are used for water mains, gas transmission, and industrial applications.
  • Installation involves heavy lifting, precise alignment, welding, and NDT of joints.
  • Steel pipes are heavy — a 600mm pipe weighs approximately 140 kg per metre.
  • All welding must be carried out by coded welders working to approved procedures.
  • Welding fumes contain manganese, chromium, and iron oxide harmful to health.
  • COSHH 2002 requires fume extraction or RPE for all pipeline welding.
  • Internal coatings may produce toxic fumes when heated and must be removed first.
  • Pipeline sections must be supported and restrained to prevent movement during welding.
  • Hydrostatic testing of completed sections must follow the safety procedures.
  • The Pressure Equipment Regulations 2016 may apply depending on classification.

Why?

Crush riskHeavy steel pipes require lift plans — dropped pipes cause fatal injuries.
Welding fumeManganese and chromium fumes cause neurological and respiratory disease.
Joint integrityFailed welds on pressurised pipelines cause catastrophic rupture.
Legal complianceCOSHH, LOLER, and pressure regulations all apply to steel pipeline work.
Do Don't
  • Use a lift plan for every pipe handling and positioning operation.
  • Ensure all welders hold valid coding certificates for the procedure.
  • Provide fume extraction at source or suitable RPE for all welding.
  • Remove internal coatings from the weld zone before heating.
  • Support pipe sections to prevent rolling or movement during alignment.
  • Carry out NDT of completed welds as specified in the procedure.
  • Follow the pressure testing method statement for safe hydrostatic testing.
  • Inspect slings, shackles, and pipe hooks before each lift.
  • Brief operatives on the pipe laying sequence and lift plan each day.
  • Barricade the test zone during hydrostatic pressure testing.
  • DON'T lift or position pipes without a planned lift using rated equipment.
  • DON'T allow uncoded welders on structural or pressurised pipelines.
  • DON'T weld without fume extraction or RPE — fumes are harmful.
  • DON'T weld over internal coatings without first removing them.
  • DON'T stand in the line of a pipe end during pressure testing.
  • DON'T enter a pipeline section without treating it as a confined space.
  • DON'T use damaged pipe lifting equipment — replace it immediately.
  • DON'T skip NDT inspections on completed welds.
  • DON'T leave pipe sections unsecured on slopes or unstable ground.
  • DON'T exceed the maximum test pressure specified in the procedure.

See also: Pipeline Safety Awareness | Welding Safety Awareness
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