Welding, Cutting & Fabrication
Arc welding, oxy-fuel cutting and fabrication, where fire, fume, arc radiation, shock and compressed gas share one workspace.
Welding and fabrication put several serious hazards in a small space: sparks and slag that can start fires, a fume plume of metal oxides, an arc bright enough to injure the eyes of people nearby, and an electrical circuit the welder is part of. How much each matters depends on the process, the base metal and the surroundings.
Hot work creates hazards that travel. Sparks and slag can land well beyond the weld cell and smolder in hidden combustibles after the torch is off, which is why OSHA (US federal) requires a fire watch, where one is needed, to stay for at least half an hour after welding or cutting ends. Fume carries metals such as manganese and hexavalent chromium into the breathing zone, and the arc's ultraviolet and infrared radiation can injure the eyes and skin of anyone nearby, not only the welder.
Because these hazards overlap in one workspace, controls work best chosen as a system. A hot-work permit and fire watch cover the whole job, source-capture ventilation and the right filter shade protect the welder, screens protect bystanders, and cylinder discipline keeps stored pressure and fuel gas contained. In arc processes, equipment condition and the welder's insulation from the work matter as much as the weld itself.
The main hazards and the controls that reduce them
Work down the hierarchy of controls: remove or substitute the hazard where you can, then use engineering and administrative controls. PPE is the last line of defense, not a substitute for the controls above it.
Hot-work ignition from sparks and slag
Sparks and molten slag bounce, roll through floor and wall openings, and can land in combustibles out of the welder's sight.
- Move work to a designated welding area where possible
- Relocate combustibles at least 35 feet from the work, or protect them with flame-resistant covers
- Use flame-resistant curtains and guards to confine sparks and slag
- Issue a hot-work permit for work outside designated areas
- Post a trained fire watch with an extinguisher during the work and for at least 30 minutes after (OSHA, US)
Welding fume and respiratory exposure
Mild-steel fume carries manganese, which can affect the nervous system, and stainless-steel fume adds hexavalent chromium, a recognized lung carcinogen. Source-capture ventilation removes fume before it reaches the welder's breathing zone.
- Choose processes and consumables that generate less fume
- Provide source-capture local exhaust ventilation at the arc
- Use fume-extraction guns and keep the head out of the plume
- Monitor exposure against OSHA's hexavalent chromium limit (US) or the provincial limit (Canada)
- Supply respiratory protection where ventilation does not control the exposure
Arc radiation and shade selection
The arc's ultraviolet and infrared radiation can cause arc eye (photokeratitis) and skin burns to the welder and to people nearby. Screens protect bystanders; the correct filter shade for the process and current protects the welder.
- Set up welding screens and curtains to protect bystanders
- Select filter shade by process and amperage
- Use auto-darkening helmets certified to ANSI/ISEA Z87.1 (US) or CSA Z94.3 (Canada)
- Cover skin against ultraviolet and wear a cap under the helmet
- Wear safety glasses under the helmet for chipping and grinding
Electric shock in arc welding
In arc welding the operator is part of a live electrical circuit, and shock risk rises in damp conditions and against grounded steel. Primary-voltage contact during setup and repair is the most dangerous exposure.
- Ground the machine frame and connect the work lead as the manufacturer specifies
- Insulate the welder from the work and grounded steel with dry insulating mats or boards
- De-energize and lock out before opening equipment for repair
- Inspect cables, holders, and connections; remove damaged gear from service
- Keep the work area dry and wear dry, undamaged welding gloves
Compressed-gas cylinder handling
Cylinders store energy as pressure and, for fuel gases, as flammability. A broken valve can release that pressure at once, and oxygen stored beside fuel gas feeds any fire that starts.
- Secure cylinders upright, with valve caps on when not in use
- Store oxygen at least 20 feet from fuel gas, or behind a 5-foot noncombustible barrier rated for half an hour (OSHA, US)
- Move cylinders with carts; never lift by the valve cap
- Leak-test connections and never use acetylene above 15 psig (OSHA, US)
- Store away from heat, ignition sources, and electrical circuits
The core safety programs for this work
Hot-work permit and fire watch
Outside a designated area, no arc is struck or torch lit until a permit confirms that combustibles are cleared or protected, a fire watch is posted, and the area will be checked after the job ends. OSHA (US federal) requires the person authorizing the work to inspect the area first and prefers a written permit; NFPA 51B sets out the permit and fire watch process in detail.
Ventilation-first fume control
Source-capture local exhaust comes before respirators. Respiratory protection covers the residual exposure, and exposure monitoring confirms the controls are working against the hexavalent chromium and manganese in the fume.
Cylinder storage discipline
Keep cylinders upright, secured and capped, with oxygen separated from fuel gas, and include cylinder storage and carts in routine shop inspections.
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Safety Assessment
Check the program behind your shop, from hazard identification and controls to training and emergency planning, in 20 questions with recommendations for low-scoring areas.
Start the assessment →Welding and fire safety articles
Articles on welding PPE, ventilation and fire protection, fire prevention planning, and respiratory protection.
Browse the articles →OSHA standards shown are federal; states with their own OSHA-approved plans can set different or stricter requirements. Consensus standards and NIOSH guidance are recommendations unless a regulation adopts them. Confirm the rules that apply to your site.
