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Write a toolbox talk on Welding

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Published by SALUS

Welding Safety ==============

Date: 2026-01-13

Duration: \[DURATION] minutes

Presenter: \[PRESENTER NAME]

Location: \[LOCATION]

Objective

To understand the hazards associated with welding and implement safe work practices to prevent injuries and incidents.

Introduction

Welding involves potential hazards such as fire, explosions, burns, and exposure to fumes and radiation. This toolbox talk will cover key safety measures to protect yourself and others. [1]

Key Points

Inspect Equipment: Before starting any welding task, inspect your equipment to ensure it is in good working condition. Look for damaged cables, loose connections, and any other potential hazards. [1]
Ventilation: Ensure that the welding area is well-ventilated to prevent the build-up of harmful fumes. If natural ventilation is not sufficient, use mechanical ventilation or respiratory protection. [7]
Fire Safety: Keep the welding area clear of flammable materials and have a fire extinguisher readily available. Know the location of emergency exits and fire alarms. [1]
Personal Protective Equipment (PPE): Always wear the appropriate PPE for welding, including a welding helmet, gloves, and fire-resistant clothing. Inspect your PPE before each use to ensure it is in good condition. [7]
Safe Work Practices: Follow safe work practices, such as using proper welding techniques, maintaining a safe distance from others, and avoiding distractions.

Hazard Identification

Welding operations present several hazards that must be understood and controlled to ensure a safe working environment.

Fire and Explosion: Welding sparks can ignite flammable materials, leading to fires and explosions, especially in areas with oil, grease, or combustible materials. [1]
Burns: Exposure to hot sparks, molten metal, and slag can cause severe skin burns. [1]
Eye Injuries: Intense light and radiation from the welding arc can cause eye damage, including burns to the retina. [6]
Inhalation of Fumes and Oxides: Breathing welding fumes can lead to respiratory issues and long-term health problems. [3]
Electric Shock: Contact with electrical components or faulty equipment can result in electric shock. [4]

Control Measures

Remove Fire Hazards: Clear the welding area of all flammable materials within a 35-foot radius. [1]
Use Proper Ventilation: Ensure adequate ventilation to remove welding fumes, or use a respirator if ventilation is insufficient. [7]
Insulate Body from Metal: Insulate your body from the metal you are welding to prevent electric shock. [1]
Ground the Welder: Ensure the welding machine is properly grounded. [1]
Use a Fire Watcher: Designate a fire watcher when welding in areas where major fires can develop. [1]
Inspect Equipment: Regularly inspect welding equipment for damage or defects. [1]

Personal Protective Equipment (PPE) Requirements

Welding Helmet: Always wear a welding helmet with the correct filter shade to protect your eyes and face from radiation, flying particles, and intense light. Use suggested shade numbers instead of minimum shade numbers. [6]

[2]

Gloves: Wear gauntlet-type cuff leather gloves to protect wrists and forearms. Leather is a good electrical insulator if kept dry. [7]
Clothing: Wear fire-resistant clothing made from heavyweight, tightly woven cotton or wool. Long sleeves and pants are essential. Avoid synthetic fabrics. [7]

[5]

Foot Protection: Wear high-top, fully laced boots to prevent sparks from entering. Use fire-resistant boot protectors or spats. [7]

[7]

Respirator: Use a respirator when ventilation is not sufficient to remove welding fumes. Ensure it complies with applicable regulations. [7]

Real-World Example or Case Study

Ben was welding angle iron supports, and welding sparks landed in magnesium shavings, causing a violent fire that engulfed him. He died from severe burns, fire and smoke inhalation, and lack of oxygen. This incident highlights the importance of removing fire hazards from the welding area. [1]

Group Discussion

Discuss the following questions:

What are the potential fire hazards in our welding area?
Have you ever had a near-miss incident while welding? What happened?
What can we do to improve ventilation in our welding area?

Emergency Procedures

In case of fire, use the appropriate fire extinguisher (Class ABC for most welding, Class D for magnesium fires). [1]
For burns, immediately cool the affected area with water and seek medical attention.
In case of electric shock, turn off the power source and administer first aid.

Questions and Answers

Q: What type of clothing is best for welding?

A: Clothing made from heavyweight, tightly woven cotton or wool is best. Avoid synthetic fabrics. [7]

Q: What should I do if my welding helmet is damaged?

A: Replace damaged or defective welding helmets immediately.

Q: How far should flammable materials be from the welding area?

A: Remove all potential fire hazards from the welding area for at least 35 feet. [1]

Summary

Recap of main points:

Always wear appropriate PPE, including a welding helmet, gloves, and fire-resistant clothing.
Remove all flammable materials from the welding area. [1]
Ensure proper ventilation and use a respirator if needed. [7]
Inspect welding equipment before use. [1]

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

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7 source record(s)

Sources used for this answer

[1] Welding - Personal Protective Equipment and Clothing

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# Welding - Personal Protective Equipment and Clothing (cont.) ## What type of PPE is available when welding? (cont.) <table><tr><th colspan="5">Welding - Personal Protective Equipment</th></tr><tr><td>Body Part</td><td>Equipment</td><td></td><td>Illustration</td><td>Reason</td></tr><tr><td>Eyes and face</td><td>Welding helmet, hand shield, or goggles</td><td>Helmet</td><td></td><td>Protects from: radiation flying particles, debris hot slag, sparks intense light irritation and chemical burns Wear fire resistant head coverings under the helmet where appropriate</td></tr><tr><td>Lungs (breathing)</td><td>Respirators</td><td></td><td></td><td>Protects against: fumes and oxides</td></tr></table> Welding - Personal Protective Equipment and Clothing CCOHS

[2] Welding - Personal Protective Equipment and Clothing

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# Welding - Personal Protective Equipment and Clothing (cont.) ## What type of PPE is available when welding? (cont.) <table><tr><th colspan="4">Welding - Personal Protective Equipment</th></tr><tr><td>Body Part</td><td>Equipment</td><td>Illustration</td><td>Reason</td></tr><tr><td>Exposed skin (other than feet, hands, and head)</td><td>Fire/Flame resistant clothing and aprons</td><td>Heat resistant jacket No cuffs</td><td>Protects against: heat, fires burns radiation Notes: pants should not have cuffs, shirts should have flaps over pockets or be taped closed</td></tr><tr><td>Ears - hearing</td><td>Ear muffs, ear plugs</td><td>Ear protection</td><td>Protects against: noise Use fire resistant ear muffs where sparks or splatter may enter the ear, rather than plugs.</td></tr><tr><td>Feet and hands</td><td>Boots, gloves</td><td>Insulated Rubber-soled gloves safety shoes Steel</td><td>Protects against: electric shock heat burns fires</td></tr></table> Welding - Personal Protective Equipment and Clothing CCOHS

[3] Toolbox Talk: Arc Welding and Fire Safety

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Construction Toolbox Talk Arc Welding and Fire Safety NIOSH CPWR [● If properly inspected and used, the arc welder is safe. If used improperly, it can expose welders to fire, explosion, and burns to the retina (lining of the eye). ## Ben's Story Ben was welding angle iron supports to a steel joist. There were magnesium shavings and cuttings on the ground in his work area. Welding sparks and slag from the welding landed in the shavings, causing a violent fire that engulfed Ben. He died from severe burns, fire and smoke inhalation, and lack of oxygen. - What caused this incident? *How could this have been prevented? *Have you ever been injured while welding, or do you know someone who was injured or killed while welding? If so, what happened? ## Remember This Before starting work: • Inspect the arc welder. • Read all warning labels and instruction manuals for the welder. ## How can we stay safe today? What will we do at the worksite to prevent injuries from arc welding and fire hazards? • Insulate your body from the metal you are welding. • Ground the welder case. CD C National Insund Health NIOSH CENTERS FOR DISEASE CONTROL AND PREVENTION • Avoid fire hazards such as oil, grease, and flammables. • Remove all potential fire hazards from the welding area, for at least 35 feet. ## While working: • Wear dry gloves in good condition and the right footwear and clothes (long sleeves and pants) to protect from hot sparks, molten metal, and slag. • Do not strike an arc without putting on proper eye protection. • Have the proper class of fire extinguisher (employer provided) nearby, ready for use. - For most welding, it is best to use a combination fire extinguisher (Class A, B, C). - For magnesium fires, use a Class D fire extinguisher or cover the fire with sand or magnesium foundry flux. • Have a designated fire watcher when you weld or cut in areas where major fires can develop (such as combustible materials or materials closer than 35 feet to …

[4] Welding - Personal Protective Equipment and Clothing

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# Welding - Personal Protective Equipment and Clothing (cont.) ## What else should you know about eye protection? (cont.) - Protect the shade lens from impact and sudden temperature changes that could cause it to crack. - Use a cover lens to protect the filter shade lens. Replace the cover lens if it gets scratched or hazy. - Make sure to replace the gasket periodically if your helmet uses one. - Replace the clear retaining lens to protect your eyes from broken pieces. - Clean lenses periodically. - Discard pitted, cracked or damaged lenses. ## What should you know about filter shade selection? For Arc welding, the correct filter shade is selected according to the welding process, wire diameter, and operating current. The table below gives the correct shade numbers for different situations. ALWAYS use suggested shade numbers instead of minimum shade numbers. The values below are samples from CSA Standard W117.2-19 Safety in welding, cutting and allied processes. Other processes are listed in the Standard. Shade Numbers for Selected Arc Processes (from CSA W117.2) <table><tr><th>Process</th><th>Electrode Diameter (mm)</th><th>Current (Amperes)</th><th>Minimum Shade</th><th>Suggested Shade</th></tr><tr><td rowspan="4">SMAW</td><td>< 2.5</td><td>< 60</td><td>7</td><td>-</td></tr><tr><td>2.5 4</td><td>60 - 160</td><td>8</td><td>10</td></tr><tr><td>4- 6.4</td><td>160 -250</td><td>10</td><td>12</td></tr><tr><td>> 6.4</td><td>250 - 550</td><td>11</td><td>14</td></tr><tr><td rowspan="4">GMAW FCAW MCAW</td><td rowspan="4"></td><td>< 60</td><td>7</td><td>-</td></tr><tr><td>60 -160</td><td>10</td><td>11</td></tr><tr><td>160 -250</td><td>10</td><td>12</td></tr><tr><td>250 -500</td><td>10</td><td>14</td></tr><tr><td rowspan="3">Air Carbon Arc Cutting light heavy</td><td></td><td></td><td></td><td></td></tr><tr><td></td><td>< 500</td><td>10</td><td>12</td></tr><tr><td></td><td>500 -1000</td><td>11</td><td>14</td></tr></table> *In the United States u…

[5] Welding - Personal Protective Equipment and Clothing

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# What should you know about using respirators when welding? Respiratory protection is needed when ventilation is not sufficient to remove welding fumes or when there is risk of oxygen deficiency. Select and use respirators in compliance with applicable regulations. Seek expert advice, conduct a hazard assessment, and initiate an appropriate respiratory protection program. For more information on selecting the appropriate respirators, see the OSH Answers on Respirator Selection. The process of selecting appropriate respiratory protection is also outlined in CSA standard Z94.4 and ANSI (American National Standards Institute) standard Z88.2 "Respiratory Protection". ## What are some tips to know when using protective clothing? DO - Wear clothing made from heavyweight, tightly woven, 100% wool or cotton to protect from UV radiation, hot metal, sparks and open flames. - Keep clothing clean and free of oils, greases and combustible contaminants. - Launder flame retardant fabrics according to the manufacturer's instructions. Some products such as chlorine bleach or hydrogen peroxide may damage the fabric or its properties. - Wear long-sleeved shirts with buttoned cuffs and a collar to protect the neck. Dark colours prevent light reflection. - Tape shirt pockets closed to avoid collecting sparks or hot metal or keep them covered with flaps. - Pant legs must not have cuffs and must cover the tops of the boots. Cuffs can collect sparks. - Repair all frayed edges, tears or holes in clothing. - Wear high-top boots fully laced to prevent sparks from entering into the boots. - Use fire-resistant boot protectors or spats strapped around the pant legs and boot tops, to prevent sparks from bouncing in the top of the boots. - Remove all ignition sources such as matches and butane lighters from pockets. Hot welding sparks may light the matches or ignite leaking lighter fuel. - Wear gauntlet-type cuff leather gloves or protective sleeves of similar material, to prot…

[6] 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

[7] Welding - Personal Protective Equipment and Clothing

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Source excerpt

# Welding - Personal Protective Equipment and Clothing (cont.) ## What should you know about filter shade selection? (cont.) - Do not use gas welding goggles for arc welding. - Do not substitute modified glasses, sunglasses, smoked plastic or other materials for proper welding lenses. The recommended shade numbers for oxygen cutting are shown in the table below. Shade Numbers for Cutting (from CSA W117.2) <table><tr><th>Process</th><th>Plate Thickness (in mm)</th><th>Minimum Shade #</th><th>Suggested Shade #</th></tr><tr><td rowspan="3">Light Medium Heavy</td><td>< 25</td><td>3</td><td>4</td></tr><tr><td>25 150</td><td>4</td><td>5</td></tr><tr><td>> 150</td><td>5</td><td>6</td></tr></table> * In the US use ANSI/AWS Standard F2.2 for selecting filter lens shade. ## Can you wear contact lenses when welding? The CSA Standard W117.2 states that contact lenses should not be worn by welders and welding personnel because foreign bodies (objects) in the eye can cause excessive irritation. Contact lenses do not provide protection from ultraviolet radiation and flying objects. All workers in proximity to welding procedures must wear appropriate eye protection according to the circumstances. The OSH Answers document Contact Lenses at Work discusses how dust particles or chemicals can irritate the eyes. Note that in Canada, Prince Edward Island's Occupational Health and Safety Act General Regulations Section 45.11 specifically bans wearing contact lenses while welding. ## What measures can protect skin from welding radiation? - Wear tightly woven work-weight fabrics to keep UV radiation from reaching your skin. - Button up your shirt to protect the skin on the throat and neck. - Wear long sleeves and pant legs. - Cover your head with a fabric cap to protect the scalp from UV radiation. - Protect the back of your head by using a hood. - Protect your face from UV radiation by wearing a tight-fitting, opaque welder's helmet. - Make sure that all fabric …

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Publisher: SALUS
Final reviewer: Francis Langlois
Original answer: Jan 13, 2026

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