OSHA

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

WELDING, CUTTING AND BRAZING

SUBPART Q
29 CFR 1910.251 29 CFR 1910.255
INTRODUCTION
Welding is the most common method of joining metals in industry today. When welded,
two pieces of similar metals are fused (melted) together. Once completed, the welded
joint is as strong or stronger than the pieces from which the joint is formed. General
hazards of welding include impact, penetration, harmful dust, smoke, fumes, heat and
light radiation. The proper personal protective equipment can protect you from these
hazards.
TYPES OF WELDING

Gas welding

Arc welding

Oxygen and Arc cutting

Gas welding In gas welding two metals are joined by melting or fusing their adjoining
surfaces. This is done by directing a gas flame over the metals until a molten puddle is
formed. The energy for gas welding comes from the combustion of a fuel with oxygen or
air. A few of the most popular fuels are acetylene, Mapp gas and hydrogen. Since gas
welding is slower and easier to control than electric arc welding, it is often used in
applications such as general maintenance work, brazing and soldering.
Arc welding Arc welding involves a different process-two metals are joined by
generating an electric arc between a covered metal electrode and the base metals. Heat is
produced by the arc which in turn melts the metal and mixes the molten deposits of the
coated electrode. The arc energy is provided by a power supply unit that furnishes direct
or alternating current. The electrodes carry the current to form the arc, producing a gas
that shields the arc from the atmosphere, and add metal to control the weld shape.
When an arc is struck using a coated electrode, the intense heat melts the tip of the
electrode. The drops of metal from the electrode enter the arc stream and are deposited on
the base metal.
The equipment needed for electric arc welding is a power supply, electrode holder,
ground clamp, protective shield, and welders protective clothing.
Oxygen and Arc Cutting Metal cutting in welding is severing or removal of metal by a
flame or arc. The most common cutting processes are:

Oxygen Cutting: Metal is heated by gas flame and an oxygen jet does the
cutting.
M. William

OSHA

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

Arc Cutting: Intense heat of electric arc melts away the metal.

29 CFR 1910.251
DEFINITIONS
Hot Work: Work which may generate heat, flame, or sparks. This may include, but is
not limited to, welding, torch, cuttings, brazing, soldering, and grinding.
Welder and Welding Operator: mean any operator of electric or gas welding and
cutting equipment.
Approved means listed or approved by a nationally recognized testing laboratory.

29 CFR 1910.252
GENERAL REQUIREMENTS:
A.
1.
2.

3.
4.

5.

6.
7.

FIRE PREVENTION AND PROTECTION

If the object to be welded or cut cannot readily be moved, all movable fire hazards
in the vicinity shall be taken to a safe place.
If the object to be welded or cut cannot be moved and if all the fire hazards cannot
be removed, then guards shall be used to confine the heat, sparks, and slag, and to
protect the immovable fire hazards.
If the above requirements cannot be met, then welding and cuttings shall not be
performed.
Suitable fire extinguishing equipment shall be maintained in a state of readiness for
instant use. Such equipment may consist of pails of water, buckets of sand, hose or
portable extinguishers depending upon the nature and quantity of the combustible
material exposed.
Fire watchers are required whenever welding or cutting is performed in locations
where other than a minor fire might develop, or any of the following conditions
exist:
i)
Appreciable combustible materials, in building construction or contents,
closer than 35 feet to the point of operation.
ii)
Appreciable combustibles must than 35 feet away but are easily ignited by
sparks.
A fire watch shall be maintained for at least a half hour after completion of
welding or cutting operations to detect and extinguish possible smoldering fires.
Fire watchers shall have fire extinguishing equipment readily available and be
trained in its use. They shall be familiar with facilities for sounding an alarm in the
event of a fire. They shall watch for fires in all exposed areas, try to extinguish
them only when obviously within the capacity of the equipment available, or

M. William

OSHA
8.

9.

10.

11.

12.

13.

14.

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

otherwise sound the alarm. A fire watch shall be maintained for at least a half hour
after completion of welding or cutting operations to detect and extinguish possible
smoldering fires.
Floors. Where combustible materials such as paper clippings, wood shavings, or
textile fibers are on the floor, the floor shall be swept clean for a radius of 35 feet
(10.7m). combustible floors shall be kept wet, covered with damp sand, or
protected by fire-resistant shields. Where floors have been wet down, personnel
operating arc welding or cutting equipment shall be protected from possible shock.
Cutting or welding shall not be permitted in the following situations:

In areas not authorized by management.

In sprinklered buildings while such protection is impaired.

In the presence of explosive atmospheres (mixture of flammable gases,

vapors, liquids, or dusts with air), or explosive atmospheres that may develop
inside uncleaned or improperly prepared tanks or equipment which have
previously contained such materials, or that may develop in areas with an
accumulation of combustible dusts.
Welding or Cutting Containers
No welding, cutting, or other hot work shall be performed on used drums, barrels,
tanks or other containers until they have been cleaned so thoroughly as to make
absolutely certain that there are no flammable materials present or any substances
such as greases, tars, acids, or other materials which when subjected to heat, might
produce flammable or toxic vapors. Any pipe lines or connections to the drum or
vessel shall be disconnected or blanked.
Confined Spaces:
When arc welding is to be suspended for any substantial period of time, such as
during lunch or overnight, all electrodes shall be removed from the holders and the
holders carefully located so that accidental contact cannot occur and the machine
be disconnected from the power source.
In order to eliminate the possibility of gas escaping through leaks or improperly
closed valves, when gas welding or cutting, the torch valves shall be closed and the
gas supply to the torch positively shut off 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. Where practicable, the torch and hose shall also be
removed from the confined space.
Combustible walls. Where cutting or welding is done near walls, partitions, ceiling
or roof of combustible construction, fire-resistant shields or guards shall be
provided to prevent ignition.
Noncombustible walls. If welding is to be done on a metal wall, partition, ceiling
or roof, precautions shall be taken to prevent ignition of combustibles on the other
side, due to conduction or radiation, preferably by relocating combustibles. Where
combustibles are not relocated, a fire watch on the opposite side from the work
shall be provided.

M. William

OSHA
B.

PROTECTION OF PERSONNEL
1.

2.
3.

4.

5.
6.

7.

8.

9.
10.

C.

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

A welder or helper working on platforms, scaffolds, or runways shall be

protected against falling through the use of railings, safety belts, life lines, or
some equally effective safeguards.
Welding cable. Welders shall place welding cable and other equipment so
that it is clear of passageways, ladders, and stairways.
Helmets or hand shields shall be used during all arc welding or arc cutting
operations, excluding submerged arc welding. Helpers or attendants shall be
provided with proper eye protection.
Helmets and hand shields shall be made of a material which is an insulator
for heat and electricity. Helmets, shields and goggles shall not be readily
flammable and shall be capable of withstanding sterilization.
Helmets and hand shields shall be arranged to protect the face, neck and ears
from direct radiant energy from the arc.
Welders should always select clothing materials which will provide
maximum protection from sparks and hot metal. Protective eyewear, safety
shoes, fire-resistant clothing, and fire-resistant gauntlet gloves are
recommended. Additionally, the shirt should have full sleeves, no pockets
and should be worn outside the trousers with collar buttoned. The trousers
should have no cuffs and should extend well down to the safety shoes.
Goggles or other suitable eye protection shall be used during all gas welding
or oxygen cutting operations. Spectacles without side shields, with suitable
filter lenses are permitted for use during gas welding operations on light
work, for torch brazing or for inspection.
All operators and attendants of resistance welding or resistance brazing
equipment shall use transparent face shields or goggles, depending on the
particular job, to protect their faces or eyes, as required.
Helmets shall be provided with filter plates and cover plates designed for
easy removal.
Protective clothing General requirements. Employees exposed to the
hazards created by welding, cutting, or brazing operations shall be protected
by personal protective equipment in accordance with the requirements of
1910.132. Appropriate protective clothing required for any welding
operation will vary with the size, nature and location of the work to be
performed.

HEALTH PROTECTION AND VENTILATION

1.

M. William

Mechanical ventilation is required when welding or cutting is done with

materials not specifically mentioned in this section. These materials
fluorine compounds, zinc, lead, beryllium, cadmium, mercury, cleaning
compounds, and stainless steel are partially hazardous and have specific
control requirements.
4

OSHA
2.

3.

4.

5.

6.

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

Screens. When welding must be performed in a space entirely screened on

all sides, the screens shall be so arranged that no serious restriction of
ventilation exits. It is desirable to have the screens so mounted that they are
about 2 feet (0.61m) above the floor unless the work is performed at so low
a level that the screen must be extended nearer to the floor to protect nearby
workers from the glare of welding.
Maximum allowable concentration. Local exhaust or general ventilating
systems shall be provided and arranged to keep the amount of toxic fumes,
gases, or dusts below the maximum allowable concentration as specified in
1910.1000 of this part.
Mechanical ventilation shall be provided:

In a space of less than 10.000 cubic feet (284 m3) per welder.

In a room having a ceiling height of less than 16 feet (5m)

Minimum rate. Such ventilation shall be at the minimum rate of 2.000 cubic
feet (57m3) per minute per welder, except where local exhaust hoods and
booths, or airline respirators approved by the U.S. Bureau of Mines for such
purposes are provided. Natural ventilation is considered sufficient for
welding or cutting operations where restrictions are not present.
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 air-flow
sufficient to maintain a velocity in the direction of the hood of 100 linear
feet (30m) 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 (7.6 cm) wide flanged
suction opening are shown in the following table:

Minimum air flow

Welding Zone
(1) cubic feet/
minutes
4 to 6 inches from arc or torch .
150
6 to 8 inches from arc or torch .
275
8 to 10 inches from arc or torch .
425
10 to 12 inches from arc or torch
600
.
7.

8.
D.

Fixed enclosure. A fixed enclosure with a top and not less than two 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 (30 m) per minute.
Oxygen for ventilation. Oxygen shall never be used for ventilation.

HOT WORK PERMIT

M. William

Duct
diameter,
inches (2)
3
3
4
5

OSHA

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

A written permit must be obtained prior to starting any welding, cutting or hot
work operations. Ensuring that all safety precautions have been taken.

29 CFR 1910.253
Gas Welding and Cutting
A.
1.

2.
3.

4.

5.

6.

7.

B.

GENERAL REQUIREMENTS:
Maximum pressure. Under no condition shall acetylene be generated, piped
(except in approved cylinder manifolds), or utilized at a pressure in excess of 15
psig (pounds per square inch gauge) or 30 psia (pounds per square inch absolute) .
Apparatus. Only approved apparatus such as torches, regulators or pressurereducing valves, acetylene generators, and manifolds shall be used.
Using acetylene at pressures in excess of 15 psi gauge pressure (or about 30 psi
absolute pressure) is a hazardous practice. Free gaseous acetylene is potentially
unstable at pressures above 15 psig and could decompose with explosive violence.
Experience indicates that 15 psig is generally acceptable as a safe upper pressure
limit.
The decomposition characteristics of acetylene gas are avoided by keeping the gas
in liquid solution and storing it in cylinders of unique construction. Internally,
acetylene cylinders are not designed like other kinds of compressed gas cylinders.
Acetylene cylinders are never hollow. These cylinders contain a porous, calcium
silicate filler and a suitable solvent, usually acetone, because, under pressure,
acetylene by itself is unstable. Acetone is used because it has the ability to absorb
over 400 times its own volume of acetylene at 70 F.
Millions of microscopic pores make up the calcium silicate filler. Although it
appears to fill the steel shell, approximately 90 percent of the fillers volume
consists of pore space for holding and evenly distributing the acetylene/acetone
solution.
When absorbed in this filler, the acetylene is divided into such small units that,
should acetylene decomposition take place in one pore, the heat released is not
enough to raise the temperature of the acetylene in surrounding pores to the point
where it, too, will decompose.
Acetylene is usually supplied in cylinders which have a capacity of up to 300 cubic
feet of dissolved gas under pressure of 250 psig at 70 F.
CYLINDERS AND CONTAINERS:

M. William

OSHA
1.

2.

3.
4.
5.

6.
7.

8.

9.
10.

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

All portable cylinders used for the storage and shipment of compressed gases shall

be constructed and maintained in accordance with the regulations of the U.S.

Department of Transportation.
Compressed gas cylinders shall be legibly marked, for the purpose of identifying
the gas content, with either the chemical or trade name of the gas. Such marking
shall be by means of stenciling, stamping, or labeling, and shall not be readily
removable. Whenever practical, the marking shall be located on the shoulder of the
cylinder.
Cylinders shall be kept away from radiations and other sources of heat.
Inside of buildings, cylinders shall be stored in a well-protected, well-ventilated,
dry location, at least 20 feet (6.1 m) from highly combustible materials.
Cylinders should be stored in definitely assigned places away from elevators,
stairs, or gangways, or other areas where they might be knocked over or damaged
by passing or falling objects, or subject to tampering.
Empty cylinders shall have their valves closed.
Valve protection caps, where the cylinder is designed to accept a cap, shall always
be in place, hand-tight, except when cylinders are in use or connected for use. The
valve protection cap is designed to take the blow in case the cylinder falls.
Inside a building, cylinders, except those in actual use or attached ready for use,
shall be limited to a total gas capacity of 2,000 cubic feet (56 m3) or 300 pounds of
liquefied petroleum gas.
Acetylene cylinders shall be stored valve end up. If the cylinder is on its side,
acetone may leak out and create a dangerous condition.
Oxygen cylinders in storage shall be separated from fuel-gas cylinders or
combustible materials (especially oil or grease), a minimum distance of 20 feet
(6.1 m) or by a non-combustible barrier at least 5 feet (1.5 m) high having a fireresistance rating of at least one-half hour. This requirement is intended to reduce
the possibility of any fire support when a fire occurs among the fuel gas storage.
This is illustrated in the figure below:

M. William

OSHA

11.

12.
13.
14.

15.

16.

17.

18.

19.
20.

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

Cylinders, cylinder valves, couplings, regulations, hose and apparatus shall be kept
free from oily or greasy substances. Oxygen cylinders or apparatus shall not be
handled with oily hands or gloves. A jet of oxygen must never be permitted to
strike an oily surface, greasy clothes, or enter a fuel oil or other storage tank.
Valve-protection caps shall not be used for lifting cylinders from one vertical
position to another.
Before a regulator is removed from a cylinder valve, the valve shall be closed and
the gas released from the regulator.
An acetylene cylinder valve shall not be opened more than one and one-half turns
of the spindle. This permits adequate flow of acetylene and allows ready closing of
the valve in an emergency situation. Do not remove the cylinder wrench from the
cylinder.
All cylinders with a water weight capacity of over 30 pounds (13.6 kg) shall be
equipped with means of connecting a valve protection cap or with a collar or recess
to protect the valve.
Fuel-gas cylinder storage. Inside a building, cylinders, except those in actual use or
attached ready for use, shall be limited to a total gas capacity of 2,000 cubic feet
(56 m (3)) or 300 pounds (135.9 kg) of liquefied petroleum gas.
For storage in excess of 2,000 cubic feet (56 m(3)) total gas capacity of cylinders
or 300 pounds (135.9 kg) of liquefied petroleum gas, a separate room or
compartment conforming to the requirements specified shall be provided, or
cylinders shall be kept outside or in a special building. special buildings, rooms or
compartments shall have no open flame for heating or lighting and shall be well
ventilated. They may also be used for storage of calcium carbide in quantities not
to exceed 600 (271.8 kg) pounds, when contained in metal containers.
Oxygen cylinders stored in outside generator houses shall be separated from the
generator or carbide storage rooms by a noncombustible partition having a fireresistance rating of at least 1 hour. This partition shall be without openings and
shall be gastight.
Cylinders shall not be dropped or struck or permitted to strike each other violently.
Cylinder valves shall be closed before moving cylinders.

M. William

OSHA
21.

22.
23.

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

Cylinders shall be kept far enough away from the actual welding or cutting
operation so that sparks, hot slag, or flame will not reach them, or fire-resistant
shields shall be provided.
Fuel- gas cylinders shall be placed with valve end up whenever they are in use.
Liquefied gases shall be stored and shipped with the valve end up.
Fuel-gas cylinders connected to one manifold having an aggregate capacity
exceeding 300 pounds (135.9 kg) of liquefied petroleum gas or 3,000 cubic feet
(48 m (3)) of other fuel-gas shall be located outdoors, or in a separate building or
room constructed.

C.

PROTECTIVE EQUIPMENT, HOSE, AND REGULATORS

1.

The operator must use the proper hose. Fuel gas hose is usually red (sometimes
black) and has a left-hand threaded nut for connecting to the torch. Oxygen hose is
green and has a right-hand threaded nut for connecting to the torch.
Hose and hose connections shall be clamped or otherwise securely fastened in a
manner that will withstand, without leakage, twice the pressure to which they are
normally subjected in service, but in no case less than a pressure of 300 psi. Oilfree air or an oil-free inert gas shall be used for the test.
Hose showing leaks, burns, worn places, or other defects rendering it unfit for
service shall be repaired or replaced. When inspecting hoses, look for charred
sections close to the torch. These may have been caused by flash-back. Also check
that hoses are not taped up to cover leaks.

2.

3.

4.

Pressure-reducing regulators shall be used only for the gas and pressures for which
they are intended.

USING OXYACETYLENE EQUIPMENT:

M. William

OSHA

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

An oxyacetylene welding outfit is basically made up of the following: cylinders of

oxygen and acetylene, regulators, hoses, and a torch.
Oxygen and acetylene are stored in separate cylinders. A great deal of gas is forced into
each cylinder. This result in very high pressures. The high pressures are controlled and
adjusted by the regulators.
Hoses carry the gases from the cylinders to the torch. The green hose carries oxygen. The
red hose carries acetylene.
The gases are mixed inside the torch. When burned, they produce a very hot flame. The
flame is regulated (adjusted and controlled) by interchangeable torch tips and by the
torch valves.

OXYACETYLENE CUTTING

M. William

10

OSHA

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

To cut steel using an oxyacetylene outfit, use a cutting torch instead of a welding torch.
Adjust the regulators for the torch tip and the thickness of the metal to be cut.
1.
Light the torch, and adjust it to a neutral flame.
2.
Locate the inner core of the flame just above the work surface.
3.
Tilt the tip slightly, and preheat the metal in a single spot. Keep heating until it is
cherry red.
4.
Push down on the oxygen cutting lever. A jet stream of oxygen burns through the
metal.
5.
Position the torch at a 90-degree angle to the work surface, and continue cutting
along the desired line. Move the torch smoothly.
LIGHTING THE TORCH
1.

2.
3.
4.
5.

6.

7.

Select the correct size tip for the thickness of material to be welded. Thin metal
will require a small tip with a small opening. Thick metal will require a larger tip
with a larger opening.
Turn the regulator adjusting knobs (screws) counterclockwise until they turn
freely.
Slowly open the oxygen cylinder. Turn the valve as far as it well go.
Slowly open the acetylene valve to turn. Do not remove the cylinder wrench
from the cylinder.
Open the oxygen adjustment valve on the torch one full turn. (Remember, the
oxygen valve is connected to the green hose.) With this valve open, turn the
regulator knob (screw) clockwise until the correct operating pressure is reached.
When the regulator is adjusted, turn off the oxygen valve.
Adjust the acetylene operating pressure. This done in the same manner as for the
oxygen (step 5). The acetylene valve is connected to the red hose. Adjust the
acetylene to the correct operating pressure.
After both regulators are properly adjusted, the torch is ready to light. Point the tip
of the torch away from the cylinders, yourself, and others. Slightly open the
acetylene valve. Light the acetylene with a spark lighter. Continue to turn the
acetylene valve until the flame burns with very little smoke. Then slowly turn on
the oxygen valve until a small blue cone forms in the center of the flame. Adjust
the torch for the type of flame that you need.

M. William

11

OSHA

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

SHUTTING OFF THE WELDING UNIT

1.
2.
3.

4.
5.

First close the acetylene valve, and then the oxygen valve.
Tightly close the valves on both cylinders.
Open the valve on either the oxygen or acetylene at the torch. Allow time for the
gas to drain from the hose and regulator. Repeat the procedure for the other gas
line.
When the high-pressure and low-pressure gauges on both cylinders read zero, turn
the regulator screws counterclockwise as far as they will go.
Close the valves on the torch.

29 CFR 1910.254
ARC WELDING AND CUTTING
INTRODUCTION:
The electric arc welder remains one of our most useful and timesaving pieces of shop
equipment. Most of these welders are typically AC/DC, 240 volt transformer types using
electricity as the energy source. Portable welders are of the diesel/gasoline engine
powered type. Properly installed and used the arc welder is very safe, but if used
improperly the operator can be exposed to a number of hazards including toxic fumes,
dusts, burns, fires, explosions, electric shock, radiation, noise, and heat stress. Any of
these hazards can cause injury or death.
Arc welding uses the heat from an electric arc to melt and fuse base metals and weldingrod metal into one piece. The heat from the arc melts the flux (cleaner) coating on the
rod.
There are two basic kinds of arc welding machines. Some provide direct current (DC).
Others provide alternating current (AC).

SELECTING THE ARC WELDER:

M. William

12

OSHA

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

When purchasing an arc welder you can be assured of design safety and safety standards
for arc welders as determined by the Underwriters Laboratories (UL). Be sure that the
welder you purchase carries the seal of approval of UL.
APPLICATIONS
Voltage
The following limits shall not be exceeded:
Alternating Current (AC)
Direct Current (DC)
Manual
80 Volts
100 Volts
Automatic
100 Volts
100 Volts
For AC welding under wet conditions or warm surroundings where perspiration is a
factor, the use of reliable automatic controls for reducing no-load voltage is
recommended to reduce the shock hazard. Some of the older AC machines do not have an
automatic control and are on load all the time. It is easy to receive an electric shock when
the equipment is not handled properly.
INSTALLING THE ARC WELDER
Prior to installing the arc welder you should determine if your present electrical system is
adequate to handle the increased load required by the welder. Your local power supplier
or a qualified electrician can assist you in determining this. It is very important for your
safety to install the welder by a qualified electrician. Failure to do so could cause fire, a
ground fault, or equipment failure. The following rules are not a complete list but are
especially important guidelines which should be adhered to:
1.
The frame or case of welder shall be properly grounded.
2.
A safety-type disconnecting switch or controller shall be located near the machine.
3.
The welder or welders shall be protected by a properly sized fuse or circuit breaker
on an independent circuit

M. William

13

OSHA

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

VENTILATION
The welder should be located in an area with adequate ventilation. In general, when
welding is being done on metals not considered hazardous, a ventilation system that will
move a minimum of 2000 cubic feet per minute (CFM) of air per welder is satisfactory.
However, many materials are considered very hazardous and should be welded only in
adequately ventilated areas to prevent the accumulation of toxic materials or to eliminate
possible oxygen deficiency not only to the operator but to others in the immediate
vicinity. Such ventilation should be supplied by an exhaust system located as close to the
work as possible.
When welding or cutting metals with hazardous coatings such as galvanized metal the
operator should use a supplied-air type respirator or a respirator specially designed to
filter the specific metal fume. Materials included in the very hazardous category are
welding rod fluxes, coverings, or other materials containing fluorine compounds, zinc,
lead, beryllium, cadmium, and mercury.

M. William

14

OSHA

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

FIRE PREVENTION
The arc welder is capable of producing temperatures in excess of 10.000 degrees F.,
therefore it is important that the workplace be made firesafe. This can be accomplished
by using metal sheets or fire resistant curtains as fire barriers. The floor should be
concrete or another fire resistant material. Cracks in the floor should be filled to prevent
sparks and hot metal from entering. When work cannot be moved to a firesafe area then
the area should be made safe by removing or protecting combustibles from ignition
undetected until the welder has finished the job.
Suitable fire extinguishing equipment such as buckets of sand or a dry chemical
extinguisher of the ABC type should be readily available.
PERSONAL PROTECTION
It is essential that the operator and helpers be properly clothed and protected because of
the heat, ultra-violet rays, and sparks, produced by arc welder. For body protection, a pair
of fire retardant long sleeved coveralls without cuffs is a good choice. Always avoid
clothing with tears, snags, rips, or worn spots as these are easily ignited by sparks. The
sleeves and collars should be kept buttoned. The hands should be protected with leather
gauntlet gloves. A pair of high to leather shoes, preferably safety shoes, is good
protection for the feet. Eyes should be protected by transparent goggles if the person
wears prescription glasses or safety glasses if not. A welding helmet or hand shield with
filter plate and cover plate is mandatory for eye protection from the harmful rays of the
arc. A flameproof skull cap to protect the hair and head as well as hearing protection in
noisy situations is recommended.

M. William

15

OSHA

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

Plastic disposable cigarette lighters are very dangerous around heat and flame. It is
important that they not be carried in the pockets while welding.

SAFE OPERATION OF THE WELDER

1.
2.

3.

4.

5.

It is important that anyone operating an arc welder be instructed on its safe use by
a qualified person or welder.
Because of their potentially explosive nature, we strongly recommend that no
welding, cutting, or hot work be attempted on used drums, barrels, tanks, or other
containers under any circumstances.
The welder cables should be positioned so that sparks and molten metal will not
fall on them. They should also kept free of grease and oil and located where they
will not be driven over.
Electric welders can kill by electric shock. If the welding operation must be done
on steel or other conductive material an insulating mat must be used under the
operator. If the welding area is wet or damp or the operator is actively perspiring
then he/she should wear rubber gloves under the welding gloves.
It is easier and safer to establish an arc on a clean surface than a dirty or rusty one.
Therefore, metal should always be thoroughly cleaned by wire brushing or other
method prior to welding. When chipping slag or wire brushing the finished bead
the operator should always be sure to protect his eyes and body from flying slag
and chips. Unused electrodes and electrode stubs should not be left on the floor as
they create a slipping hazard.

M. William

16

OSHA
6.

7.
8.
9.

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

Hot metal should be handled with metal tongs or pliers. When quenching hot metal
in water it should be done carefully to prevent painful burns from the escaping
steam.
Any metal left to cool should be carefully marked HOT.
When welding is finished for the day or suspended for any length of time
electrodes should be removed from the holder.
The holder should be placed where no accidental contact could occur, and the
welder should be disconnected from the power source.

SAFETY PRECAUTIONS FOR ENGINE POWERED WELDERS

1.
2.
3.

4.
5.
6.

Always operate in an open well-ventilated area or vent the engine exhaust directly
outdoors.
Never fuel the engine while running or in the presence of an open flame.
Wipe up spilled fuel immediately and wait for fumes to disperse before starting the
engine. Never remove the radiator pressure cap from liquid cooled engines while
they are hot to prevent scalding yourself.
Stop the engine before performing any maintenance or trouble shooting. The
ignition system should be disabled to prevent accidental start of the engine.
Keep all guards and shields in place.
Keep hands, hair, and clothing away form moving parts.

FIRST AID
The welding area should always be equipped with a fire blanket and a well stocked first
aid kit. It is desirable that one person be trained in first aid to treat the minor injuries that
may occur. All injuries, no matter how minor they may seem can become more serious if
not properly treated by trained medical personnel.
KEY POINTS TO REMEMBER
1.
2.
3.
4.
5.
6.
7.
8.
9.

Be sure the welder is properly installed and grounded.

Never weld without adequate ventilation.
Take proper precautions to prevent fires.
Protect your entire body with fire retardant clothing, shoes, and gloves.
Wear eye protection at all times.
Weld only in a firesafe area.
Never do any welding, cutting, or hot work on used drums, barrels, tanks, or other
containers.
Mark metal HOT with a soapstone.
Keep a well-stocked first aid kit.

M. William

17

OSHA

OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION
U.S. DEPARTMENT OF LABOR

29 CFR 1910.255
RESISTANCE WELDING
GENERAL
Installation
All equipment shall be installed by a qualified electrician in conformance with Subpart S,
Electrical.
SPOT AND STEAM WELDING MACHINES
Interlocks
All doors and access panels of all resistance welding machines and control panels shall be
kept locked and interlocked to prevent access, by unauthorized persons, to live portions
of the equipment.
Guarding
All press welding operations, where there is a possibility of the operators fingers being
under the point of operation, shall be effectively guarded by the use of a device such as
an electronic eye safety circuit, two hand controls, or protection similar to that prescribed
for punch press operations.
Shields
The hazard of flying sparks shall be, wherever practical, eliminated by installing a shield
guard of safety glass or suitable fire-resistant plastic at the point of operation. Additional
shields or curtains shall be installed as necessary to protect passing persons from flying
sparks.
Foot Switches
All foot switches shall be guarded to prevent accidental operation of the machine.
Stop Buttons
Two or more safety emergency stop buttons shall be provided on all special multispot
welding machines, including 1-spot and 4-spot weld presses.
************************************************************************
**********************************************

M. William

18