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Weld shop

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Welding Safety in Welding Shops ===============================

Date: 2025-09-24

Duration: \[DURATION] minutes

Presenter: \[PRESENTER NAME]

Location: \[LOCATION]

Objective

To ensure all personnel understand and follow safe work practices for welding operations, minimizing hazards and preventing accidents in the welding shop.

Introduction

Welding operations present numerous hazards, including exposure to fumes and gases, fire hazards, electrical shock, and potential injuries from equipment. This toolbox talk will cover key safety measures to mitigate these risks and ensure a safe working environment.

Key Points

  • Qualified Personnel: Only qualified personnel should perform welding. [4]

[5] [7] [8]

  • Well Ventilated Area: Be sure to perform welding in a well ventilated and prepared area. [4]

[5] [7] [8]

  • Flammable Objects: Store flammable objects in a safe place before starting welding. [4]

[5] [7] [8]

  • Recheck Area: After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering. [4]

[5] [7] [8]

Hazard Identification

Identifying potential hazards is the first step in preventing accidents. We will discuss common hazards associated with welding and their potential consequences.

  • Exposure to Welding Fumes and Gases: Inhalation of welding fumes and gases can cause respiratory irritation, metal fume fever, lung cancer, and other long-term health issues. Coatings on metals, such as zinc on galvanized steel, can produce toxic fumes when vaporized. [2]

[11]

  • Fire Hazards: Welding generates heat and sparks, which can ignite flammable materials in the vicinity, leading to fires and explosions. [4]

[5] [7] [8]

  • Electrical Shock: Contact with live electrical parts or faulty equipment can result in electrical shock, burns, or electrocution. [11]
  • Eye Injuries: The intense light and radiation produced by welding arcs can cause severe eye damage, including burns to the cornea and retina. Hot slag and metal debris can also cause eye injuries. [1]

[1] [11]

  • Burns: Exposure to hot materials, sparks, and radiation can cause burns to the skin. [11]

Control Measures

  • Use Local Exhaust Ventilation: Install and use local exhaust ventilation systems to remove fumes and gases from the welder's breathing zone. Ensure the ventilation system is properly maintained and used according to manufacturer's instructions. [3]

[9] [11]

  • Remove Coatings and Residues: Prior to welding, remove any coatings, oils, or rust inhibitors from the metal surface to minimize the generation of toxic fumes. Use appropriate stripping products and ensure all residues are removed. [2]

[2] [11]

  • Implement Hot Work Permits: Establish a hot work permit system to ensure that all necessary precautions are taken before welding or cutting in areas where flammable materials may be present. [10]
  • Ensure Proper Grounding: Ground all welding equipment to prevent electrical shock hazards. Regularly inspect grounding connections to ensure they are mechanically strong and electrically adequate. [6]

[6]

  • Use Noncombustible Shields: Use noncombustible or flameproof screens to shield welding operations and protect nearby workers from direct rays of the arc and flying sparks. [12]
  • Avoid Heating Pressurized Lines: Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Install temporary fire-resistant guards to protect hoses or other materials before welding. [4]

[5] [7] [8]

Personal Protective Equipment (PPE) Requirements

  • Welder's Helmet: Always wear a welder's helmet fitted with a filter shade suitable for the type of welding being performed. Inspect the helmet for damage before each use. [1]
  • Safety Glasses with Side Shields or Goggles: Wear safety glasses with side shields or goggles when chipping or grinding a work piece, or when not wearing a welding helmet, to protect against flying debris. [1]
  • Flame-Resistant Clothing: Wear appropriate flame-resistant clothing, such as a welding jacket, gloves, and apron, to protect skin from sparks and burns.
  • Gloves: Wear welding gloves to protect hands from heat, sparks, and electrical shock.
  • Respirator: Use a respirator when ventilation is inadequate to control exposure to welding fumes and gases. Select the appropriate respirator based on the specific hazards present. [9]

Group Discussion

Discuss the following questions:

  1. What are some specific situations in our shop where ventilation is most critical?
  2. Can you share an instance where you identified and mitigated a potential fire hazard during welding?
  3. What are some ways we can improve our housekeeping practices to reduce fire hazards in the welding area?

Emergency Procedures

  1. In case of fire, activate the fire alarm and evacuate the area immediately. Use a fire extinguisher to put out small fires if it is safe to do so.
  2. In case of electrical shock, immediately turn off the power supply and provide first aid. Seek medical attention as soon as possible.
  3. For eye injuries, flush the eyes with water for at least 15 minutes and seek medical attention.

Questions and Answers

  • Q: What should I do if I feel unwell while welding?

A: Stop welding immediately and move to an area with fresh air. Report your symptoms to your supervisor and seek medical attention if necessary.

  • Q: How often should I inspect my welding equipment?

A: Inspect your welding equipment before each use to ensure it is in good working condition. Report any defects to your supervisor immediately.

Summary

Recap of main points:

  • Always use appropriate PPE, including a welding helmet, safety glasses, gloves, and flame-resistant clothing.
  • Ensure adequate ventilation to minimize exposure to welding fumes and gases.
  • Follow safe work practices, including hot work permits and proper grounding procedures.
  • Know the emergency procedures in case of fire, electrical shock, or eye injury.

Report all hazards, near-misses, and incidents to your supervisor immediately.

Safety powered by SALUS

12 source record(s)

Sources used for this answer

[1] Cal/OSHA Hazard Alert - Engineered Stone Countertop Fabrication

Page 2

Open source document

Source excerpt

# Engineered Stone Countertop Fabrication (cont.) ## How to prevent overexposures to workers? The best way is keep the dust out of the air by using: • Water when cutting, grinding, and shaping, whenever possible. • Local exhaust ventilation at the source generating the airborne dust. The types of controls used for cutting or grinding natural stone countertops can usually be effectively used for engineered stone. No matter which controls are used, it is very important that they be properly: • Designed, as most homemade or aftermarket controls do not work as well as those designed by the manufacturer of the machine. - Maintained. - Used according to the manufacturer instructions, including using the required amounts of exhaust ventilation or water. ## Respirators should only be used: - As a last resort for protection when local exhaust ventilation or water controls are not feasible or do not adequately control employee airborne exposures. - Where exposures exceed the permissible exposure limit (50 µg/m3, 8-hour TWA) while installing or implementing feasible engineering and work practice controls. • When the employee is in a regulated area. Housekeeping methods such as dry sweeping and using compressed air can result in high dust exposures and must be avoided, where feasible. Use water or a properly filtered vacuum. ## What are the Cal/OSHA regulatory requirements? Respirable Crystalline Silica Standards - Important Update outlines the relevant Title 8, California Code of Regulations requirements: • 5204: Countertop manufacturing • 1532.3: Construction • 5155: Permissible Exposure Levels Besides silica, a number of other hazards may be present in an engineered stone countertop fabrication workplace, including: • Other hazardous materials, such as granite, resins, solvents, and coatings. • Machine and electrical hazards. • Noise. • Back and other musculoskeletal injuries from lifting heavy countertops. • Crushing hazards from working arou…

[2] Hitachi ZAXIS 17U-2 Hydraulic Excavator Operator's Manual

Page 36

Open source document

Source excerpt

# SAFETY ## PRECAUTIONS FOR WELDING AND GRINDING • Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. - Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. • Grinding on the machine may create a fire hazard. Store flammable objects in a safe place before starting grinding. • After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering. ## AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. • Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other materials before engaging in welding, soldering, etc. ## AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids. • Remove flammable fluids thoroughly with nonflammable solvent before welding or flame cutting pipes or tubes that contained flammable fluids. SA-818 SA-030 S-27

[3] Hitachi ZAXIS 110, 110M, 120, 130, 130LCN, 125US, 135US, 135UR Excavator Workshop Manual

Page 33

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Source excerpt

# SAFETY ## PRECAUTIONS FOR WELDING AND GRINDING • Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. • Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. • Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. • After finishing welding and grinding, recheck that there are no abnormalities such as the area sur- rounding the welded area still smoldering. 523-E01A-0818 ## AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. - Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.. ## AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids. - Clean them thoroughly with nonflammable solvent before welding or flame cutting them. 510-E01B-0030 SA-818 SA-030 SA-27

[4] Safety and Health Regulations for Construction (OSHA 29 CFR 1926) - 1926.351 - Arc welding and cutting

Page 4

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Source excerpt

# Occupational Safety and Health Administration (cont.) ## 1926.351(d) (cont.) Any faulty or defective equipment shall be reported to the supervisor. 1926.351(d)(5) See $1926.406(c) for additional requirements. 1926.351(e) Shielding. Whenever practicable, all arc welding and cutting operations shall be shielded by noncombustible or flameproof screens which will protect employees and other persons working in the vicinity from the direct rays of the arc. [44 FR 8577, Feb. 9, 1979; 44 FR [redacted postal code], Apr. 6, 1979, as amended at 51 FR [redacted postal code], July 11, 1986] Scroll to Top + OSHA Standards Enforcement Topics Media Center Contact Us UNFARTMENT OF LABOR UNITED STATES OF Submit Feedback U.S. DEPARTMENT OF LABOR Occupational Safety and Health Administration [redacted street address] NW Washington, DC [redacted postal code] 1-800-321-OSHA 1-[redacted phone] www.osha.gov FEDERAL GOVERNMENT+ OCCUPATIONAL SAFETY & HEALTH - White House - Benefits.gov Frequently Asked Questions - A- Z Index - Coronavirus Resources Freedom of Information Act - - OSHA

[5] Welding - Overview of Types and Hazards

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Open source document

Source excerpt

# Welding - Overview of Types and Hazards (cont.) ## Is there more than one type of welding process? There are over 70 different welding processes. The type of welding process used is related to the specific application. The most common processes are: - Shielded Metal Arc Welding (SMAW), also known as Manual Metal Arc Welding, MMAW. - Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas (TIG) Welding. - Flux Cored Arc Welding (FCAW). - Gas Metal Arc Welding (GMAW), also known as Metal Inert Gas (MIG) Welding or hard wire welding. - Plasma Arc Welding (PAW), Plasma Arc Cutting (PAC) and Gouging - Submerged Arc Welding (SAW) - Resistance Spot Welding (RSW) or spot welding. - Air Carbon Arc Cutting (CAC-A) and Air Carbon Arc Gouging (CAG) - Oxyfuel Gas Welding (OFG), Cutting and Heating (oxygen-acetylene [oxyacetylene] (OAW) or oxygen-propane [oxy-propane] mixtures are the most common fuel mixtures used). ## What, in general, are the hazards associated with welding? Health hazards associated with welding, cutting, and brazing operations will depend on the composition and exposure level to welding fumes and gases, and to ultraviolet (UV) radiation. Health risks include respiratory irritation, metal fume fever, lung cancer, skin cancer, damage to the nervous system, asphyxiation, and other health risks. Safety hazards associated with these processes include burns, eye damage, electrical shock, cuts, injury to toes and fingers. Fires and explosions may also occur. Many of these hazards can be controlled with elimination and substitution controls (e.g., eliminate need for welding or using a using lower fume-generating welding process), engineering controls (e.g., local exhaust ventilation), work practices (e.g., remove coatings before welding, and worker training), and personal protective equipment (PPE)(e.g., respiratory protection). Risk assessments and occupational hygiene air sampling can be performed to determine health and safety risks and worker exp…

[6] Hitachi ZAXIS 75US-7, 85USB-7 Hydraulic Excavator Operator's Manual

Page 52

Open source document

Source excerpt

# SAFETY ## Precautions for Welding and Grinding • Welding may generate gas and/or small fires. - Be sure to perform welding in a well ventilated and prepared area. Store flammable materials in a safe place before starting welding. . Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. . Turn the battery disconnect switch to the OFF position before performing welding on the machine. • Grinding on the machine may create fire hazards. Store flammable materials in a safe place before starting grinding. SA-818 ja • After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering. ## Avoid Heating Near Pressurized Fluid Lines • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. - Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc. SA-030 ja ## Avoid Applying Heat to Lines Containing Flammable Fluids • Do not weld or cut pipes or tubes that contain flammable fluids. • Clean pipes and tubes thoroughly with non-flammable solvent before welding or cutting. ENMDEW-NA1-3 S-36

[7] Hitachi ZAXIS 160LC, 180LC, 180LCN Excavator Workshop Manual

Page 31

Open source document

Source excerpt

# SAFETY ## PRECAUTIONS FOR WELDING AND GRINDING • Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. • Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. • Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. • After finishing welding and grinding, recheck that there are no abnormalities such as the area sur- rounding the welded area still smoldering. 523-E01A-0818 ## AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. - Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.. ## AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids. - Clean them thoroughly with nonflammable solvent before welding or flame cutting them. 510-E01B-0030 SA-818 SA-030 SA-27

[8] Welding - Fumes And Gases

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Source excerpt

# How do coatings affect the composition of welding fumes? Vapours or fumes can come from coatings and residues on metal being welded. Some ingredients in coatings can have toxic effects. These ingredients include: - metal working fluids, oils, and rust inhibitors - zinc on galvanized steel (vaporizes to produce zinc oxide fume) - cadmium plating - chromates - vapours from paints and solvents - lead oxide primer paints - plastic coatings Metal Coatings - A Source of Hazardous Fumes ## How do I remove the coatings? - Remove coatings from the weld area to minimize the fume. The removal of coating will also improve weld quality. - Use stripping products to remove coatings. Make sure to remove any residues before welding. - Use wet slurry vacuum removal techniques for removing very toxic coatings. - Do not grind coatings. Grinding dust may be toxic. - Follow appropriate safety procedures and use the necessary personal protective equipment during the coating removal process, which will be based on risk assessments, manufacturer's instructions, and potential exposures. Welding - Fumes And Gases CCOHS

[9] Welding - Ventilation

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CCOHS CCHST Canadian Centre for Occupational Health and Safety Centre canadien d'hygiène et de sécurité au travail Welding # Welding - Ventilation On this page Where can I find some general guidelines for welding ventilation? What types of ventilation can be used to remove air contaminants from a welder's breathing zone? What are some examples of Local Exhaust Ventilation? ## Where can I find some general guidelines for welding ventilation? Ventilation is used for three general purposes: - Remove air contaminants from a worker's breathing zone and work area, - Prevent the accumulation of flammable or combustible gases or vapours; and, - Prevent oxygen rich or oxygen deficient atmospheres. For processes such as welding, brazing, soldering, and torch cutting, the primary purpose of ventilation is to remove air contaminants from the worker's breathing zone. Different ventilation strategies may be needed in each case to remove air contaminants from the welder's breathing zone. General guidelines have been published in the CSA standard W117.2:19 (R2023) Safety in welding, cutting, and allied processes, and the ANSI (American National Standards Institute) standard Z49.1-2021 Safety in Welding, Cutting and Allied Processes. Whenever ventilation is used as a means of worker protection, the ventilation system should be used and maintained in accordance with acceptable procedures. Where ventilation alone cannot adequately protect the welder, personal protective equipment (respirators) may also be used. Select the appropriate respirator according to the hazards present, any applicable legislation, and/or to the CSA standard Z94.4:18 (R2023) Selection, Use and Care of Respirators. Welding - Ventilation CCOHS

[10] Safety and Health Regulations for Construction (OSHA 29 CFR 1926) - 1926.351 - Arc welding and cutting

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Source excerpt

# Occupational Safety and Health Administration (cont.) ## 1926.351(c) (cont.) point shall cause rejection of the structures as a ground circuit. ## 1926.351(c)(4) When a structure or pipeline is continuously employed as a ground return circuit, all joints shall be bonded, and periodic inspections shall be conducted to ensure that no condition of electrolysis or fire hazard exists by virtue of such use. - 1926.351(c)(5) The frames of all arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current. Grounding circuits, other than by means of the structure, shall be checked to ensure that the circuit between the ground and the grounded power conductor has resistance low enough to permit sufficient current to flow to cause the fuse or circuit breaker to interrupt the current. - 1926.351(c)(6) All ground connections shall be inspected to ensure that they are mechanically strong and electrically adequate for the required current. ## 1926.351(d) Operating instructions. Employers shall instruct employees in the safe means of arc welding and cutting as follows: - 1926.351(d)(1) When electrode holders are to be left unattended, the electrodes shall be removed and the holders shall be so placed or protected that they cannot make electrical contact with employees or conducting objects. - 1926.351(d)(2) Hot electrode holders shall not be dipped in water; to do so may expose the arc welder or cutter to electric shock. - 1926.351(d)(3) When the arc welder or cutter has occasion to leave his work or to stop work for any appreciable length of time, or when the arc welding or cutting machine is to be moved, the power supply switch to the equipment shall be opened. 1926.351(d)(4) Submit Feedback

[11] Welding - Personal Protective Equipment and Clothing

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# Welding - Personal Protective Equipment and Clothing (cont.) ## Why is eye protection important? Eye injury can occur from the intense light and radiation that a welding arc can produce. Eye injury can also occur from hot slag and other metal debris that can fly off from the weld during cooling, chipping or grinding. - Protect your eyes from welding light by wearing a welder's helmet fitted with a filter shade that is suitable for the type of welding you are doing. - ALWAYS wear safety glasses with side shields or goggles when chipping or grinding a work piece if you are not wearing a welding helmet. ## What type of eye and face protection is appropriate for my welding task? The various types of eye protection are broken down into classes in the CSA standard Z94.3- 20 "Eye and face protectors". Each class is designed for a specific use. Eye and face protectors should have distinctive markings to identify the manufacturer and their class. Classifications of common protectors for welding operations are listed below: - Class 2C — direct / non-ventilated goggles with non-ionizing radiation protection - Class 3 - welding helmets - Class 4 - welding hand shields - Class 6 - face shields for non-ionizing radiation protection - Class 7 - respirator facepiece for non-ionizing radiation protection The following operations require full face protection by using either a welding helmet or a hand shield: - arc welding, - plasma arc cutting, gouging or welding, and - air carbon arc cutting. For gas cutting, welding, or brazing, the intensity of the light is much less than from arc welding, cutting or gouging processes. Lighter shade filter lenses can be used with goggles in place of a helmet. More information can be found in the OSH Answers on Eye and Face Protectors. What are the various components of welding hand shields and helmets? Welding - Personal Protective Equipment and Clothing CCOHS

[12] Welding - Hot Work

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CCOHS CCHST Canadian Centre for Occupational Health and Safety Centre canadien d'hygiène et de sécurité au travail Welding # Welding - Hot Work ## On this page What is hot work? What is a hot work management program? Can hot work be avoided? Before performing hot work, what are some general good practices? ## What is hot work? Working with ignition sources near flammable materials is referred to as "hot work." Welding, soldering, and cutting are examples of hot work. Fires are often the result of the "quick five- minute" job in areas not intended for welding or cutting. Getting a hot work permit before performing hot work is just one of the steps involved in a hot work management program that helps to reduce the risk of starting a fire by hot work in areas where there are flammable or combustible materials. The 2024version of NFPA (National Fire Protection Association) Standard 51B "Fire Prevention During Welding, Cutting and Other Hot Work," serves as the basis for many current fire prevention practices adopted by industry. CSA standard W117.2-12 (R2017) - Safety in welding, cutting, and allied processes and ANSI (American National Standards Institute) standard Z49.1: 2021Safety in Welding, Cutting and Allied Processes were created to protect persons and property from injury, illness, and damage from fire and explosions that may occur from these processes. ## What is a hot work management program? Hot work management programs are put in place to control or eliminate hot work hazards and their risks. Programs include the development of policies, procedures, and the assignment of responsibilities and accountabilities for all aspects of hot work. A program includes: 1. Policies a. Where hot work is permitted b. When hot work is permitted Welding - Hot Work CCOHS

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