Cancer-causing welding fumes, critical controls and noise-induced hearing loss are just some of the big issues Resources Safety and Health Queensland (RSHQ) has been tackling in 2025 and will continue to work on into the new year.
Over recent years RSHQ has been collecting welding fume exposure records from Queensland coal mines after welding fumes were reclassified as a known human carcinogen.
Welding fumes are generated due to intense heat and come from base metals, electrode materials and any contaminants or coatings on the metal being welded. These fumes form tiny particles that can be inhaled into the lungs.
The data collected by RSHQ revealed high exceedance rates and inconsistent control application, including poor compliance and management of the use of respiratory protective equipment (RPE).
Data collected by RSHQ revealed high exceedance rates and inconsistent control application, including poor compliance and management of respiratory protective equipment (RPE).
In response, RSHQ initiated audits and inspections across the state’s coal mines to address these concerns, revealing:
- many coal mines were not adequately managing welding fume exposure.
- personal exposure monitoring was inconsistent, and many sites relied on RPE without robust engineering controls in place.
- significant gaps in welding fume management, including inadequate risk assessments, lack of monitoring, and insufficient training.
The historic data showed that 20% of workers who were exposed to levels above the occupational exposure limit wore no RPE during periods of elevated airborne concentrations.
This is already improving as in more recent years (2024) that number was reduced to 10%. This is an indicator that the message is getting out there and workers are taking action to be better protected.
In response to these findings, RSHQ issued 30 corrective actions across the 25 inspected sites, focusing on:
- improving welding fume management and reducing reliance on RPE.
- prioritising engineering controls such as local exhaust ventilation (LEV) and on-tool extraction systems.
- updating RPE programs to ensure better selection, fit testing, inspection/ maintenance, and training for workers on using powered air-purifying respirators (PAPR).
- the need for comprehensive health risk assessments (HRAs) that account for both full-time employees and contract workers.
Sites were advised to regularly monitor personal exposure, especially during high-risk activities like shutdowns, and to integrate this data and use it in their Safety and Health Management Systems (SHMS).
Improved hot work procedures and education programs were recommended to raise awareness about the health risks associated with welding fume and ensure proper controls are in place.
A new Queensland Guidance Note (QGN) for welding fume management in coal mines is being developed with input from unions and industry experts and will be available soon.
RSHQ’s Chief Inspector of Coal Jacques le Roux said the QGN will provide a detailed framework for monitoring, assessing and controlling welding fume exposure in coal mines.
“The coal mining industry is making significant strides in managing welding fume exposure, with an increasing focus on engineering controls and reducing reliance on RPE,” said Jacques.
“By enhancing monitoring practices, improving risk assessments, and updating training programs, coal mines will be better equipped to protect workers from the health risks associated with welding fumes.”
| Looking ahead to 2026, RSHQ will be working on key projects targeting safety and health in Queensland’s coal industry. To follow updates from RSHQ’s Coal Inspectorate, subscribe to their Safety and Health Alerts. |
