3 Potential Welding Safety Hazards to Avoid
Welding can be performed safely when hazards are identified and the correct controls are in place. Three major risks deserve particular attention: welding fumes and gases, electrical shock, and inadequate personal protective equipment. Employers and welders should understand each hazard before work begins.
Why Is Welding Safety Important?
Welding, cutting and brazing expose workers to several potential hazards. OSHA identifies health hazards such as metal fumes and ultraviolet radiation, along with safety hazards including burns, eye injuries, electrical shock and other physical injuries.
Many of these risks can be reduced through appropriate engineering controls, safe work practices and personal protective equipment.
Before using welding equipment, workers should:
- Read and understand the manufacturer's instructions.
- Review the applicable safety information and safety data sheets.
- Follow the employer's established welding and hot-work procedures.
- Inspect the work area and equipment before beginning work.
- Understand what ventilation and PPE are required for the application.
Source: OSHA Welding, Cutting and Brazing: Hazards and Solutions
Hazard 1: Welding Fumes and Gases
Welding can generate a complex mixture of airborne metal particles and gases. The exact contaminants depend on the welding process, base metal, electrode or wire, surface coatings and other materials involved.
Welding fumes can contain metallic oxides and other substances such as manganese, chromium, nickel, zinc and additional contaminants depending on the application. Welding can also generate gases such as ozone, carbon monoxide and nitrogen oxides.
The health risk depends on what contaminants are present, their concentration in the breathing zone, and the duration of exposure.
How Can Welding Fume Exposure Be Reduced?
Local exhaust ventilation is one method used to capture contaminated air close to the welding operation. General ventilation may also be required depending on the work area, materials and applicable exposure limits.
Confined spaces require particular attention. OSHA states that ventilation is a prerequisite for welding and cutting work in confined spaces.
For applications where source capture is appropriate, an extraction arm or welding fume extractor can collect fumes before they disperse through the shop.
Learn more in What Is a Welding Fume Extractor? and Guide to Welding Fume Extraction Systems .
Sources: OSHA 29 CFR 1910.252 and CDC/NIOSH Welding Fumes and Manganese
Hazard 2: Electrical Shock
Electrical shock is one of the most serious hazards associated with arc welding. Welding equipment uses electrical energy capable of causing serious or fatal injury when workers contact energized components or become part of an electrical circuit.
The severity of an electrical injury cannot be judged from voltage alone. Factors such as the amount of current passing through the body, the path it takes, the length of exposure, skin condition and moisture all affect the outcome.
Wet or high-humidity conditions can increase electrical risk. OSHA specifically requires additional protection, such as insulating rubber pads or boots, when arc welding is performed in wet or high-humidity conditions in covered maritime operations.
How Can Welders Reduce Electrical Shock Risk?
- Inspect welding leads, electrode holders and equipment before use.
- Do not use damaged cables or exposed electrical connections.
- Keep gloves, clothing and the work area as dry as practicable.
- Use appropriate insulation when working in damp or conductive environments.
- Follow equipment lockout and de-energization procedures where applicable.
- Do not make unauthorized repairs to energized welding equipment.
Source: OSHA Welding, Cutting and Brazing Hazards
Hazard 3: Inadequate Personal Protective Equipment
PPE is an essential part of welding safety, but the correct equipment depends on the specific hazard. OSHA requires employees exposed to welding, cutting or brazing hazards to be protected with appropriate PPE.
Appropriate protection may include:
- A welding helmet with the correct filter shade
- Safety glasses or goggles
- Welding gloves
- Protective footwear
- Appropriate protective clothing
- Hearing protection when required
- Respiratory protection when required by the exposure assessment
OSHA notes that appropriate protective clothing varies with the size, nature and location of the welding work being performed.
What Clothing Should Welders Wear?
Welding clothing should protect the worker from heat, sparks, molten metal and other hazards identified in the workplace assessment.
Leather gloves and other suitable protective clothing are commonly used because they provide protection against sparks, heat and abrasion.
Where workers are exposed to flash fire or short-duration flame hazards, OSHA expects employers to select clothing that provides suitable protection.
Clothing should also be selected so that it does not increase the severity of an injury if exposed to flame or an electrical arc.
Sources: OSHA 29 CFR 1910.252 and OSHA Guidance on Flame-Resistant Clothing for Welders
What Other Welding Hazards Should You Consider?
Fumes, electrical shock and PPE are only three areas of welding safety. A complete hazard assessment may also need to consider:
| Hazard | Typical Concern |
|---|---|
| Fire and explosion | Sparks, hot metal and nearby combustible materials |
| UV and infrared radiation | Eye injuries and skin burns |
| Noise | Hearing damage from welding, grinding and fabrication activity |
| Confined spaces | Fume accumulation, oxygen deficiency and difficult emergency access |
| Hot surfaces and sparks | Burns and ignition hazards |
How Do You Build a Safer Welding Environment?
Welding safety works best when controls are selected according to the hierarchy of controls rather than relying on PPE alone.
Depending on the hazard, this can include:
- Eliminating or reducing the hazard where practicable.
- Using engineering controls such as local exhaust ventilation.
- Establishing safe work practices and procedures.
- Training workers to recognize welding hazards.
- Using appropriate PPE for hazards that remain.
For welding fume specifically, source capture can help remove airborne contaminants close to where they are generated.
If you are reviewing welding-fume controls for your facility, use our Which Fume Extractor Do I Need? guide as a starting point.
Frequently Asked Questions
What are the three major welding hazards?
Three important welding hazards are exposure to welding fumes and gases, electrical shock, and injuries caused by inadequate personal protective equipment. Welding work can also involve fire, radiation, noise and confined-space hazards.
Are welding fumes dangerous?
Yes. Welding fumes may contain hazardous metal particles and gases. The actual risk depends on the welding process, materials, contaminant concentration and duration of exposure.
How can welding fumes be controlled?
Local exhaust ventilation can capture contaminated air near the welding source. General ventilation, work practices and respiratory protection may also be required depending on the application.
Why is electrical shock dangerous during welding?
Arc welding equipment uses electrical energy that can cause serious or fatal injury. Risk increases when damaged equipment, exposed conductors, moisture or conductive surfaces are present.
What PPE should welders use?
PPE should be selected based on the hazards present. Typical welding PPE can include a welding helmet, eye protection, suitable gloves, protective clothing, footwear, hearing protection and respiratory protection when required.
Related Reading
- Welding Fume Facts: What It Is and What It Does to You
- Welding Fume Health Hazards
- What Is a Welding Fume Extractor?
- Health Risks Associated With Inhalation of Fume Particles
Need Help Controlling Welding Fume?
Tell us about your welding process and work area. We can help narrow down the extraction options that fit your application.
Find the Right System
