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Perform a risk assessment for welding

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Here is a risk assessment for welding:

Hazards:

Arc Flash and Radiation: Welding produces intense UV and infrared radiation that can cause burns to the skin and eyes 3, 9. Control measures include using appropriate welding helmets with correct filter lenses [1], wearing protective clothing, and using noncombustible screens or shields to protect nearby workers 3, 9. Ensure workers adjacent to welding areas are protected by screens/shields or wear appropriate goggles [1].
Fumes and Gases: Welding can release hazardous fumes and gases, especially when welding materials with coatings or in confined spaces 2, 6. These fumes can cause respiratory irritation, metal fume fever, or long-term health issues. Control measures include providing adequate ventilation, using local exhaust systems, and providing respiratory protection when necessary 2, 6, 20. Monitor exposure levels to ensure they do not exceed occupational exposure limits 2, 7. When welding or cutting stainless steel, ensure mechanical ventilation is used to remove fumes [2].
Fire and Explosions: Welding can create sparks and molten metal that can ignite flammable materials in the vicinity 10, 14. Control measures include removing flammable materials from the work area, using fire-resistant shields, and having a fire watch present 10, 14, 18. Ensure cutting and welding are scheduled so that plant operations that might expose combustibles to ignition are not started during cutting or welding [3]. Also, ensure that cutting or welding is permitted only in areas that are or have been made fire safe [3].
Electric Shock: Welding equipment can pose a risk of electric shock, especially in wet conditions 4, 17. Control measures include ensuring equipment is properly grounded, using insulated electrode holders, and avoiding welding in wet environments 1, 5, 17. Provide special protection against electric shock when arc welding is performed in wet conditions or under conditions of high humidity [2].
Physical Hazards: Welding can involve physical hazards such as burns from hot materials, cuts from sharp edges, and strains from lifting heavy objects. Control measures include wearing appropriate PPE such as gloves and aprons [1], using proper lifting techniques, and ensuring the work area is free from obstructions [1].
Confined Spaces: Welding in confined spaces introduces additional hazards such as limited ventilation and difficulty in rescue 6, 8, 20. Control measures include providing forced ventilation, using supplied-air respirators, stationing an attendant outside the space, and ensuring a preplanned rescue procedure is in place 8, 20. You must adequately vent all welding and cutting operations carried on in confined spaces to prevent the accumulation of toxic materials or possible oxygen deficiency [4].

Risk Assessment:

Assess the likelihood and severity of each hazard based on the specific welding task, environment, and equipment being used.
Consider factors such as the type of materials being welded, the duration of the task, and the proximity of other workers.
Use a risk matrix to prioritize hazards and determine appropriate control measures.

Control Measures (Hierarchy of Controls):

Elimination: If possible, eliminate the hazard by using alternative methods or materials.
Substitution: Substitute hazardous materials with less hazardous alternatives.
Engineering Controls: Use engineering controls such as ventilation systems, machine guards, and welding booths to isolate the hazard 1, 3, 5, 20. Flash welding machines must be equipped with a hood to control flying flash [5].
Administrative Controls: Implement administrative controls such as safe work procedures, training programs, and permit systems to minimize exposure to hazards 2, 10. Ensure that a job hazard analysis is made, by qualified personnel, of the operations to be performed on each welding machine to determine the safeguards and personal protective equipment that must be used for each job [5].
Personal Protective Equipment (PPE): Provide and ensure the use of appropriate PPE such as welding helmets, gloves, aprons, and respirators as a last line of defense 3, 8, 9. Except when engaged in light work, all welders should wear flameproof gauntlet gloves [1].

Monitoring and Review:

Regularly inspect welding equipment and PPE to ensure they are in good working condition.
Conduct air monitoring to assess the effectiveness of ventilation systems.
Review and update the risk assessment as needed based on changes in the work environment or new information about hazards.
Ensure workers are trained on the identified hazards and control measures 2, 14.

Specific Recommendations:

Develop a written welding safety program that includes hazard identification, risk assessment, and control measures.
Provide regular training to welders on safe welding practices and the use of PPE.
Ensure that all welding equipment is properly maintained and inspected.
Establish a permit system for hot work to ensure that fire prevention measures are in place.
Provide first-aid equipment and ensure that employees are trained in first aid [2].
When arc welding is to be suspended for any substantial period of time, such as during lunch or overnight, you must remove all electrodes from the holders and carefully locate the holders so that accidental contact cannot occur and the machine disconnected from the power source 8, 10.
In order to eliminate the possibility of gas escaping through leaks or improperly closed valves, when gas welding or cutting, you must close the torch valves and positively shut off the fuel-gas and oxygen supply to the torch at some point outside the confined area whenever the torch is not to be used for a substantial period of time, such as during lunch hour or overnight 8, 10.

By implementing these control measures and following safe work practices, the risks associated with welding can be significantly reduced.

5 source record(s)

Sources used for this answer

[1] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

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\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ - Note: In gas welding or oxygen cutting where the torch produces a high yellow light, is not desirable to use a filter or lens that absorbs the yellow or sodium line in the visible light of the operation. - (j) All filter lenses and plates must meet the test for transmission of radiant energy prescribed in ANSI Z 87.1-1968--American National Standard Practice for Occupational and Educational Eye and Face Protection. - (3) Protection from arc welding rays . Where the work permits, the welder should be enclosed in an individual booth painted with a finish of low-reflectivity such as zinc oxide (an important factor for absorbing ultraviolet radiations) and lamp black, or must be enclosed with noncombustible screens similarly painted. Booths and screens must permit circulation of air at floor level. You must protect workers or other persons adjacent to the welding areas from the rays by noncombustible or flameproof screens or shields or they must be required to wear appropriate goggles. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), § 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Statutory Authority: RCW 49.17.010, .040, .050. 01-11-038 (Order 99-36), § 296-24-[redacted postal code], filed 05/09/01, effective 09/01/01. Statutory Authority: Order 73-5, 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-[redacted postal code] Protective clothing. - (1) General requirements . You must protect employees exposed to the hazards created by welding, cutting, or brazing operations by personal protective equipment in accordance with the requirements of chapter 296-24 WAC, Part I, and WAC [redacted identifier]. Appropriate prote…

[2] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

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\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ toxicity of flammability, you must follow appropriate precautions such as manufacturer's instructions. - (2) Degreasing . You must locate degreasing or other cleaning operations involving chlorinated hydrocarbons so that no vapors from these operations will reach or be drawn into the atmosphere surrounding any welding operation. In addition, trichloroethylene and perchlorethylene should be kept out of atmospheres penetrated by the ultraviolet radiation of gas-shielded welding operations. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), § 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Order 73-5, 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-[redacted postal code] Cutting of stainless steels. You must ensure that oxygen cutting, using either a chemical flux or iron powder or gas-shielded arc cutting of stainless steel, is done using mechanical ventilation adequate to remove the fumes generated. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), § 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Order 73-5, 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-[redacted postal code] First-aid equipment. You must ensure that first-aid equipment is available at all times. On every shift of welding operations there should be present employees trained to render first aid. You must report all injuries as soon as possible for medical attention. You must render first aid until medical attention can be provided. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), §…

[3] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 343

Open source document

Source excerpt

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ - (1) Hoods . Freely movable hoods intended to be placed by the welder as near as practicable to the work being welded and provided with a rate of airflow sufficient to maintain a velocity in the direction of the hood of 100 linear feet per minute in the zone of welding when the hood is at its most remote distance from the point of welding. The rates of ventilation required to accomplish this control velocity using a 3-inch wide flanged suction opening are shown in the following table: - (2) Fixed enclosure . A fixed enclosure with a top and not less than 2 sides which surround the welding or cutting operations and with a rate of airflow sufficient to maintain a velocity away from the welder of not less than 100 linear feet per minute. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), § 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Order 73-5, 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-[redacted postal code] Ventilation in confined spaces. - (1) Air replacement . You must adequately vent all welding and cutting operations carried on in confined spaces to prevent the accumulation of toxic materials or possible oxygen deficiency. This applies not only to the welder but also to helpers and other personnel in the immediate vicinity. All air replacing that withdrawn must be clean and respirable. - (2) Airline respirators . In such circumstances where is not impossible to provide such ventilation, you must use airline respirators or hose masks approved for this purpose by the National Institute for Occupational Safety and Health (NIOSH) under 42 CFR Part 84. - (3) Self-contained units . In areas immediately hazardou…

[4] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 334

Open source document

Source excerpt

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ - (iii) See that cutting and welding are so scheduled that plant operations that might expose combustibles to ignition are not started during cutting or welding. - (d) Must secure authorization for the cutting or welding operations from the designated management representative. - (i) Must determine that the cutter or welder secures their approval that conditions are safe before going ahead. - (ii) Must determine that fire protection and extinguishing equipment are properly located at the site. - (iii) Must ensure fire watches are available at the site when required. - (15) Fire prevention precautions . You must permit cutting or welding only in areas that are or have been made fire safe. Within the confines of an operating plant or building, cutting and welding should preferably be done in a specific area designed for such work, such as a maintenance shop or a detached outside location. Such areas should be of noncombustible or fire-resistive construction, essentially free of combustible and flammable contents, and suitably segregated from adjacent areas. When work cannot be moved practically, as in most construction work, you must make the area safe by removing combustibles or protecting combustibles from ignition sources. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 18-03-159 (Order 17-24), § 296-24-[redacted postal code], filed 01/23/2018, effective 02/23/2018. Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), § 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Statutory Authority: Chapter 49.17 RCW. 94-15-096 (Order 94-07), 296-24-[redacted postal code], filed 7/20/94, effective 9/20/94; Order 73-5, 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, 296-24-[redacted…

[5] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 330

Open source document

Source excerpt

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ ## WAC 296-24-[redacted postal code] Portable welding machines. - (1) Counter-balance . All portable welding guns must have suitable counter-balanced devices for supporting the guns, including cables, unless the design of the gun or fixture makes counterbalancing impractical or unnecessary. - (2) Safety chains . All portable welding guns, transformers and related equipment that is suspended from overhead structures, eye beams, trolleys, etc., must be equipped with safety chains or cables. Safety chains or cables must be capable of supporting the total shock load in the event of failure of any component of the supporting system. - (3) Clevis . When trolleys are used to support portable welding equipment, they must be equipped with suitable forged steel clevis for the attachment of safety chains. Each clevis must be capable of supporting the total shock load of the suspended equipment in the event of trolley failure. - (4) Switch guards . All initiating switches, including retraction and dual schedule switches, located on the portable welding gun must be equipped with suitable guards capable of preventing accidental initiation through contact with fixturing, operator's clothing, etc. Initiating switch voltage must not exceed 24 volts. - (5) Moving holder . The movable holder, where it enters the gun frame, must have sufficient clearance to prevent the shearing of fingers carelessly placed on the operating movable holder. - (6) Grounding . The secondary and case of all portable welding transformers must be grounded. Secondary grounding may be by center tapped secondary or by a center tapped grounding reactor connected across the secondary. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), § 296-24-[redacted postal…

Publication receipt

Publisher: SALUS
Final reviewer: Francis Langlois
Original answer: Jun 14, 2025

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Topics

Confined spaces Electrical safety Emergency response Equipment safety Ergonomics Fire prevention Hazard assessment Personal protective equipment Safety training

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