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Welding and cutting are hazardous activities that pose a combination of safety and health risks. Everyone involved in these operations must take precautions to prevent fires, explosions, injuries, and health problems such as UV radiation exposure. Employers must protect their workers by following safety precautions and proper procedures, providing appropriate safety equipment such as fire extinguishers and PPE, and inspecting and maintaining welding equipment.
Welding, cutting, and brazing are common procedures in many industries. Whenever welding, cutting, or brazing occurs, everyone involved in the operation must take precautions to prevent fires, explosions, or personal injuries.
By the nature of these processes and the materials often involved, welding, cutting, and brazing pose unique threats to the health and safety of workers. These hazards can affect not only the person doing the work, but other people in the area and nearby flammable materials and structures.
The Occupational Safety & Health Administration’s (OSHA) welding requirements apply to any employer with welding and cutting operations as part of its business.
To understand the Welding and Cutting topic, it is important to first understand what certain terms mean. These terms, as defined here, are used throughout this topic.
Any time work is performed using equipment that produces a spark or an open flame, or a process that generates excessive heat, there is a risk of fire. Work involving electric or gas welding, cutting, brazing, or similar flame-producing operations is known as “hot work.”
The Occupational Safety & Health Administration (OSHA) doesn’t specifically require companies to have a written permit to perform hot work. However, OSHA prefers that they be used. Many companies choose to have these permits to demonstrate that their hot work program is in compliance. 29 CFR 1910.252 gives general requirements for performing hot work safely.
Some administrative procedures are required before hot work begins:
In addition to being inspected by the designated individual, the area must be made as hazard-free as possible before hot work begins:
Appropriate safety equipment is required for hot work:
Some hot work conditions are dangerous enough to require a fire watch:
Types of welding
Welding is classified into two groups:
Welding, cutting, and brazing are common in many fields. The Occupational Safety & Health Administration (OSHA) regulates these practices in general industry in 29 CFR 1910, Subpart Q.
Some general requirements include administrative controls to be put in place before any hot work begins. Employers must:
Employers must also train personnel in, facilitate, and enforce safe work practices, including:
All necessary equipment must be provided and maintained in good working condition, including:
Regulations
The OSHA requirements for welding, cutting, and brazing in general industry are found in 29 CFR 1910, Subpart Q. Specific subtopics include:
These regulations might be helpful for further information:
Individual states may adopt OSHA’s standards and enforcement programs or use their own. State Plans are required to be at least as effective as OSHA's and may have different or more stringent regulations. There are 28 OSHA-approved State Plans operating statewide occupational safety and health programs.
Several of the Occupational Safety & Health Administration’s (OSHA) welding and cutting standards require employers to train workers and specify who needs training, the frequency of training, and recordkeeping requirements. Extended classroom and hands-on training for welders and welding helpers (such as fire watchers) may be needed to meet requirements.
The table below gives an overview of the OSHA regulations that apply to training for hot work in general industry:
Subject | Regulation | Who to train | When | Records to keep |
Welding, cutting, and brazing | 1910.252 | Cutters, welders, and their supervisors in safe equipment operation | Initially, and judged competent prior to assignment | No specific training documentation is required |
Oxygen-fuel gas welding and cutting | 1910.253 | Employees in charge of the oxygen or fuel-gas supply equipment | Initially, and judged competent prior to assignment | No specific training documentation is required |
Arc welding and cutting | 1910.254 | Employees who will operate arc welding equipment | Initially, or prior to assignment | No specific training documentation is required |
Resistance welding | 1910.255 | Employees who will operate resistance welding equipment | Initially, or prior to assignment | No specific training documentation is required |
Welding training should be provided in a language that the trainees understand. If a trainee’s vocabulary is limited, employers should account for that limitation. Translators may be needed.
Trainees should be made familiar with the company welding safety program. Anyone working welding or working around welding and other hot work should know:
An effective welding training program may also address:
Training for fire watchers
Fire watchers provide additional safeguards against fire during and after welding, cutting, or heating operations. Their responsibilities are addressed by OSHA in 1910.252 and by the American National Standards Institute (ANSI) in Z49.1-1967.
Training for fire watchers must include:
Training for arc welders and cutters
OSHA requires companies to instruct employees in the safe means of arc welding and cutting. In addition to general content about hot work and the company welding safety program, employees should learn about:
Welding, cutting, and brazing pose a combination of safety and health risks to more than 500,000 workers in a wide variety of industries. The risk from fatal injuries alone is more than four deaths per thousand workers over a working lifetime.
Health hazards from welding, cutting, and brazing operations include exposures to metal fumes and to ultraviolet (UV) radiation. Safety hazards from these operations include burns, eye damage, electrical shock, cuts, and crushed toes and fingers.
These hazards can affect not only the person doing the work, but the people, materials, and structures nearby. Many of these risks can be controlled with proper work practices and personal protective equipment (PPE).
General hot work hazards
Hot work hazards vary, depending upon the facility, equipment, number of workers present, and the job at hand. Examples include:
General protective measures
Many hazards of hot work can be minimized or avoided with proper equipment and practices.
Gas fumes, radiation, and electric shock are some of the hazards involved in arc welding. A welding arc emits blinding light and is hot enough to melt steel. It generates toxic fumes that are composed of microscopic particles of molten metal. Sparks and molten slag thrown by the arc can fly up to 35 feet and can cause fires and explosions.
Despite all these hazards, arc welding can be safe with proper precautions and work practices. Arc welders can protect themselves and others in several ways:
Fumes, gases, and ionizing radiation formed or released when welding, cutting, or brazing are associated with numerous health hazards, including:
The risks vary depending on the welding materials used and surfaces welded. The presence of oil or grease is one potential source of fire danger for gas welders. This danger can be reduced by:
Safe handling of compressed gas cylinders
Handling compressed gas cylinders safely is crucial in preventing fires and explosions. Cylinders must be stored under the proper conditions:
Cylinders must be kept far enough away from a welding or cutting project so that sparks, hot slag, or flames do not reach them. When this is impractical, fire shields must be used.
Valve protection caps must be in place, hand-tight, except when cylinders are in use or connected for use. Before a regulator is connected to the cylinder valve, the valve must be cracked (opened slightly and closed immediately). This clears the valve of dust or dirt that could enter the regulator.
Welding and metal cutting operations produce molten metal, sparks, weld spatter, slag, and hot work surfaces. All of these can create a situation that can cause fires. At 1910.252, the Occupational Safety & Health Administration (OSHA) addresses the fire hazards of hot work.
When the object to be welded, cut, or heated | And | Then |
Can be moved | A safe, fire-resistant workplace is available | The object should be moved to that space for working |
Cannot be readily moved | All fire hazards are moved at least 35 feet away or are protected | The object can be worked in place |
Cannot be moved | All fire hazards cannot be removed | Steps must be taken to confine the heat, sparks, and slag to protect the immobile fire hazards |
Cannot be moved | Normal fire prevention precautions are not sufficient | Additional personnel shall be assigned to guard against fire during the work and for a sufficient amount of time afterward |
To best prevent and address fires, workers must be well-informed about:
They should also know when and how to involve a fire watcher.
When are fire watchers required?
Fire watchers provide additional safeguards against fire during and after welding, cutting, or heating operations. A fire watcher is required in situations where:
The fire watch is to be maintained for at least 30 minutes following completion of the work.
Welders can be exposed to a number of fumes, gases, and dusts. These contaminants can harm the health of workers and/or accumulate to the point of causing a fire. Ventilation helps to reduce the concentration of contaminants and prevent the accumulation of flammable gases, vapors, and dusts.
According to the Occupational Safety & Health Administration (OSHA), whenever and wherever welding occurs, everyone involved in the operation must be aware of welding fumes and gases and take necessary, especially ventilation, precautions. Even in metal cutting jobs that are considered routine, established safety procedures should always be followed.
Welding ventilation techniques vary. Often, however, a relatively simple ventilation method like the appropriate use of fans will be all that is required to provide good ventilation during hot work.
OSHA specifies in 1910.252(c) that if mechanical ventilation is used, it must consist of either:
Related regulations
OSHA and the American National Standards Institute (ANSI) both have standards that can be relevant to ventilation during hot work:
Types of ventilation
Ventilation can be provided by a general mechanical or local exhaust system. Open spaces can also help to reduce accumulations.
General mechanical ventilation lowers contamination levels by using fans of various types to dilute the contaminated air with fresh air. OSHA requires mechanical ventilation to be provided when welding or cutting is done in certain circumstances on most metals, with some exceptions (including zinc, lead, cadmium, beryllium, and mercury) that have more specific requirements. Mechanical ventilation is required when welding is performed:
Outside of these conditions, natural ventilation is considered sufficient.
Local exhaust systems remove fumes and smoke at the source using either of the following:
The need for local exhaust ventilation for welding or cutting outside of confined spaces depends on the individual circumstances. However, it is recommended for fixed-location production welding and for all production welding on stainless steels.
Ventilation in confined spaces
All welding and cutting operations in confined spaces must be adequately ventilated to prevent toxic material accumulation or oxygen deficiency. Only clean, breathable air can be used to replace air withdrawn from the confined space.
If it’s not possible to provide adequate ventilation, workers must use airline respirators or hose masks approved by the National Institute for Occupational Safety and Health (NIOSH).
The many hazards associated with welding operations include exposure to several types of air contaminants:
These contaminants can harm workers’ health. Fortunately, there are ways to reduce or eliminate them.
Related regulations
The Occupational Safety & Health Administration (OSHA)) and the American National Standards Institute (ANSI) both have standards that can be relevant to fumes and gases encountered during hot work:
Types of fumes and gases
During welding and cutting operations, metal fumes may be released, gas byproducts may be formed, and shielding gases used during the process may escape into the air.
Metal fumes produced during hot work depend on the circumstances of the operation —the metal, metal preservatives, electrode, or filler rod used. Some common welding fumes that can have negative health effects include:
Gases are also released during welding operations. These gases can form in many ways. Carbon monoxide, for example, can form when carbon dioxide shielding gas is used in gas metal arc welding. Gas byproducts formed during welding may include:
Certain other gases are not byproducts but used as shielding gases supplied during the welding process, including:
Health effects
Fume and gas exposure can cause an array of health effects, both short- and long-term. Acute exposure to welding fumes and gases can result in eye, nose, and throat irritation; dizziness; and nausea. Workers should be alert for these symptoms and leave the area if any develop. Prolonged exposure to welding fumes may cause lung damage and various types of cancer, including lung, larynx, and urinary tract.
Depending on the fume or gas, health effects may also include metal fume fever, stomach ulcers, kidney damage, and nervous system damage. For example, prolonged exposure to manganese fumes can cause Parkinson’s-like symptoms.
Some gases, such as helium, argon, and carbon dioxide, displace oxygen in the air. This can lead to suffocation, particularly during welding in enclosed spaces. Carbon monoxide gas can form, posing an asphyxiation hazard.
Factors affecting exposure
Factors that affect exposure to welding fumes or gases depend on a number of circumstances:
Minimizing health hazards from fumes and gases
While there are a lot of health hazards associated with fumes and gases from hot work, there are also many ways to control or eliminate them.
Before welding begins, some hazards can be prevented by:
Workers can reduce their risks with safety equipment, including:
Workers can also reduce their risks with their work practices, including:
Compressed gases in cylinders present special hazards that include the possibility of oxygen displacement and toxic effects from the gas itself, as well as fire and explosion risks due to the high pressure. Thus, gas cylinders may only be handled and used by trained workers.
The Occupational Safety & Health Administration (OSHA) addresses compressed gases in general at 1910.101, which adopts by reference some regulations from the Compressed Gas Association (CGA).
Marking gas cylinders
Cylinders, containers, pipes, etc., must be clearly marked so that the gas can be easily identified. Labels should not be defaced or removed. Containers whose content labels are not legible should be returned unused to the supplier. Containers should not be repainted, and container color should not be used to identify the cylinder content.
All gas lines leading from a compressed gas supply should be clearly labeled or identified. Some states require specific labeling of cylinders, containers, and pipes.
Inspecting gas cylinders
Employers must visually inspect compressed gas cylinders to determine that they are in safe condition under 1910.101.
Visual inspections must be conducted as prescribed in the Hazardous Materials Regulations of the Department of Transportation (49 CFR Parts 171–179 and 14 CFR Part 103) when applicable. Otherwise, they must be conducted in accordance with CGA Pamphlet C-6-1968.
In general, all parts of a cylinder (valves, neck rings, hoses, manifold, regulator, etc.) should be inspected for:
Storing gas cylinders
Proper storage of gas cylinders is crucial for maintaining a safe workplace. According to CGA P-1, storage areas must:
Containers must be:
Moving gas cylinders
Safe handling of gas cylinders includes moving them carefully, both within and between facilities.
Practices to avoid include:
Protective caps and outlet caps or plugs should be replaced before empty cylinders are returned to the supplier.
OSHA states that compressed gas cylinders that are not secured to a “special truck” must have their regulators removed and valve-protection caps installed. A special truck is a vehicle or cart that provides stable support of vertical standing Department of Transportation portable gas cylinders during movement and at various work locations. It must include protection of cylinder valves and regulators. CGA Pamphlet P-1 allows for a “suitable hand truck, forklift truck, or similar material handling device,” as long as cylinders are properly secured to it by a chain or other comparable method.
Using gas cylinders
When using any compressed gas (i.e., cylinders, portable tanks, rail tank cars, or motor vehicle cargo tanks), employers must comply with the provisions outlined in CGA Pamphlet P-1-1965, which is incorporated by reference in the OSHA standard.
When handling compressed gas cylinders, workers should always follow these procedures:
Several substances that welders may encounter are regulated individually because of their specific hazards. These include acetylene, hexavalent chromium, and cadmium.
Acetylene
Acetylene is a colorless gas that has many industrial uses, from being a raw material to use in welding. It poses a flammability hazard and must be used, transported, and stored properly.
The Occupational Safety & Health Administration (OSHA) requirements apply to employers who have employees who use or are exposed to acetylene. The specific requirements vary depending on the application.
Relevant citations:
To comply with requirements and provide a safe workplace, employers must:
Hexavalent chromium
Chromium hexavalent (Cr[VI]) compounds, often called hexavalent chromium, may be created during hot work such as welding on stainless steel or melting chromium metal. The high temperatures involved in the process result in oxidation that converts chromium to a hexavalent state.
Hexavalent chromium can pose a serious hazard to workers. Chromium is converted to its hexavalent state, Cr(VI), during the welding process, and Cr(VI) fume is highly toxic and can damage the eyes, skin, nose, throat, and lungs and cause cancer. OSHA regulates worker exposure to Cr(VI) under 1926.1126, which has a permissible exposure limit (PEL) of 5 ?g/m 3 as an eight-hour average.
Cadmium
The Agency for Toxic Substances and Disease Registry estimates that about 300,000 workers in the U.S. face exposure to cadmium each year. Cadmium exposure can threaten workers who perform activities like the following without wearing some type of personal protection:
OSHA has set the PEL for cadmium in work area air at 5 micrograms per cubic meter of air (5 ?g/m3) for an 8-hour workday.
Cadmium exposure may occur in several ways:
Type | Route | Effects | Prevention |
Inhalation | Dust or fumes in the air (e.g., from welding with cadmium solder) | Short term: Constriction of the throat, chest pain, weakness, fever, lung damage, death Long term: Kidney disease, lung damage, fragile bones | Wearing a respirator |
Ingestion | Handling cadmium-contaminated food, cigarettes, cosmetics, etc. | Short term: Stomach irritation, vomiting, diarrhea Long term: Kidney disease, lung damage, fragile bones | Avoiding eating, smoking, etc. around cadmium, and cleaning up carefully |
Eye exposure | Dust or fumes in eyes; touching eyes with cadmium-contaminated hands | Redness and pain | Wearing eye protection, avoiding touching eyes, washing eyes with water if exposure occurs |
Skin exposure | Dust spilling or blowing onto skin; accidental touches | Irritation | Wearing gloves, washing skin with water if exposure occurs |
Welding involves many types of equipment, some of which the Occupational Safety & Health Administration (OSHA) regulates specifically and some it does not. Some examples are discussed below.
Welding hoses
Employers should check with the manufacturer of hoses and gauges to see what restrictions or cautions are noted, or to see how lines should be purged after turning off the gases.
Fuel gas and oxygen hoses must be easily distinguishable from each other, either with color contrast or surface characteristics that are noticeable to the touch.
All hoses carrying acetylene, oxygen, natural/manufactured gas, or any ignitable or combustible gas or substance must be inspected at the beginning of each work shift. Defective hoses must be removed from service.
No specific regulation addresses storage of welding hoses. If there is a known hazard, OSHA would expect that an employer address it under their General Duty Clause obligations.
Fuel gas and oxygen manifolds
Fuel gas and oxygen manifolds must bear the name of the substance they contain in letters at least 1 inch high. The letters must be either painted on the manifold or a sign permanently attached to it.
Hose connections must be kept free of grease and oil and be capped when not in use.
Torches
Torches must be inspected for leaks at the beginning of each work shift, and defective torches removed from service.
Torches should never be lit using matches or from hot work.
If torch tip holes become clogged, they should be cleaned with suitable cleaning wires, drills, or other devices designed for this purpose.
Regulators and gauges
Oxygen and fuel gas pressure regulators, including related gauges, must be inspected to verify that they are in good working order.
Curtains/booths
OSHA prefers that welding be shielded from other operations when possible, using weld curtains or booths.
At 1910.252(b)(2)(iii), OSHA states, “Where the work permits, the welder should be enclosed in an individual booth painted with a finish of low reflectivity such as zinc oxide (an important factor for absorbing ultraviolet radiations) and lamp black, or shall be enclosed with non-combustible screens similarly painted.” Passersby should be separated from welding using these curtains, booths, or screens, or else should wear suitable eye protection.
Welding, cutting, and brazing are common in many fields. The Occupational Safety & Health Administration (OSHA) regulates these practices in the construction industry in 29 CFR 1926, Subpart J.
Most requirements for hot work in construction are the same as those in general industry. However, there are some differences, such as whether gas cylinders may be permanently stored on a transport dolly. OSHA says that due to the rougher nature of most construction sites, cylinders must be put into more secure storage if gas is not to be drawn for 24 hours.
Regulations
OSHA’s Subpart J welding requirements apply to any employer performing welding operations during construction activities.
General requirements
Construction employers must:
Training
Training requirements for welding and cutting that are specific to construction are found in 29 CFR 1926.350, .351, .352, and .354.
Several OSHA regulations apply to training for hot work in the construction industry.
The Welding and Cutting Standard, 29 CFR 1926 Subpart J, does not call for employees to receive training on the health hazards of welding-related fumes and gases. However, 1926.353 requirements lend themselves to training. Welders should be trained to:
Workers who are potentially exposed to toxic and hazardous substances (like cadmium, hexavalent chromium, and lead) specifically regulated at 29 CFR 1926 Subparts D or Z may have further training requirements.
In addition, workers whose activities are regulated by the Confined Spaces in Construction Standard, 29 CFR 1926 Subpart CC, must be provided with training so that they understand the hazards in the permit space and the methods used to isolate, control, or in other ways stay safe from these hazards.
Welding and metal cutting operations produce molten metal, sparks, weld spatter, slag, and hot work surfaces. All of these can create a situation that can cause fires.
29 CFR 1926.352 is concerned with fire hazards in situations where:
Where to go for more information:
Fire watchers in construction
According to 1926.352, construction employees assigned to guard against fire during welding, cutting, or heating operations (and for a sufficient time after completion of the work) are to be instructed on the specific anticipated fire hazards and how the provided firefighting equipment is to be used.
Fire watchers are additional personnel who:
The fire watch is to be maintained for at least 30 minutes following completion of the work.
Fire watchers must be trained in:
It’s crucial that people doing hot work wear flame-retardant clothing and protective equipment for the eyes, ears, and head. Necessary personal protective equipment (PPE) includes the following:
Clothing
At 1910.252(b)(3), the Occupational Safety & Health Administration (OSHA) states, “Appropriate protective clothing required for any welding operation will vary with the size, nature and location of the work to be performed."
This generally means long sleeves and long pants to protect from welding arc burns and welding spatter, but these are not required. Rather, this must be determined based upon the site’s hazard assessment.
With regard to flame-resistant clothing (FRC), OSHA says in a January 12, 2012, Letter of Interpretation that “if welders are exposed to flash fires or short-duration flame exposures, OSHA expects that employers would provide and ensure the use of FRC to protect workers from these hazards . . . Employees wearing FRC may be exposed to hazards relating to heat stress. Therefore, employers should consider the following when selecting personal protective equipment for employees that are exposed to these adverse conditions: provide light weight breathable fabrics and allow employees to drink cold liquids, such as water and other electrolyte replenishing drinks.”
Gas-shielded arc welders should cover all parts of their bodies to protect against ultraviolet and infrared ray flash burn. Dark clothing works best to reduce reflection under the face shield.
Wool, leather, or cotton treated to reduce flammability are preferred for gas-shielded arc welding. Wool has an advantage over cotton because it resists deterioration better. Regardless of material, clothing should be:
Pants shouldn’t have cuffs or front pockets that could catch sparks.
If worn, thermal insulated underwear should be covered by other clothing and not exposed to sparks or other ignition sources. It should be down-filled or waffle weave cotton or wool. Synthetic fabrics won’t necessarily ignite more easily than cotton, but they melt as they burn, sticking tightly to skin, which can result in a very serious burn that is hard to treat and slow to heal.
Eye injuries are a major concern around welding, cutting, and brazing operations, due to the variety of hazards related to this type of work. The following table lists potential eye hazards and their sources:
Type of hazard | Potential sources |
Impact | Operations that create flying objects or particles, such as caulking, chiseling, grinding, hammering, and metal working |
Dust, powder, fume, and mist | Scaling, light grinding, spot welding, and woodworking |
Gas, vapor, liquid, or metal splash | Babbitting, casting of hot metal, dripping in hot metal baths, and working with acids/caustics and vapors |
Electrical | Arcing and sparks |
Thermal and radiation | Welding, metal cutting, exposure to laser beams, and working with ultraviolet light and infrared radiation |
Eye discomfort and fatigue | Glare from the sun |
Requirements for eye protection devices
Because of workplace hazards, the Occupational Safety & Health Administration (OSHA) requires appropriate eye protection to be used to guard against injury in situations where it is reasonable to assume an injury could occur.
Eye protection devices must:
For workers who wear prescription lenses, the employer may offer eye protection that:
Protection for welders
Welders must wear safety glasses in addition to a face shield or helmet. This is because the shield or helmet protects the wearer from the welding glare, but not from sparks.
All filter lenses and plates must meet the test for transmission of radiant energy prescribed in ANSI Standard Z 87.1, “Practice for Occupational and Educational Eye and Face Protection.”
The desirable darkness of the lenses on welding helmets and safety goggles depends on work conditions. The intensity of light or radiant energy produced by welding, cutting, or brazing operations varies according to a number of factors, including:
Choosing appropriate lenses for employees who are exposed to intense radiant energy has two steps:
Minimum eye protection
Workers who walk through or work in areas where welding is being done aren’t exposed to the same level of hazards as the welders themselves, but their eyes still need protecting. OSHA’s preference is for welding to be secluded from other workers, rather than other workers to protect themselves from welding.
At 1910.252(b)(2)(iii), “Protection from arc welding rays,” OSHA says that “Where the work permits, the welder should be enclosed in an individual booth painted with a finish of low reflectivity such as zinc oxide (an important factor for absorbing ultraviolet radiations) and lamp black, or shall be enclosed with non-combustible screens similarly painted. Booths and screens shall permit circulation of air at floor level.”
However, the regulation continues, “Workers or other persons adjacent to the welding areas shall be protected from the rays by noncombustible or flame-proof screens or shields or shall be required to wear appropriate goggles."
Safe working practices
Wisely chosen work practices can minimize hazards and sometimes prevent them entirely. Practices that allow for eye protection include the following:
Working in confined spaces brings its own set of hazards, and performing hot work in these conditions compounds the danger. The two primary hazards of welding, cutting, or brazing in a confined space are flammable air and toxic air contaminants.
Flammable air
Fire and explosion are serious dangers in a confined space. Fumes and vapors will ignite more quickly in the trapped air. Flammable and combustible gases or vapors may be present from previous contents, tank coatings and preservatives, and welding gases.
In locations where flammable vapors may be present, precautions must be taken to prevent ignition by eliminating or controlling the source of ignition or eliminating the flammable air before working. Sources of ignition may include:
Toxic air contaminants
Toxic air contaminants come from:
Toxic gases and vapors present two types of risk to people in a confined space:
Unfortunately, many toxic gases and vapors on the job cannot be smelled or seen. This means that atmospheric testing and monitoring is very important.
Generally, if a space has a hazardous atmosphere, the hazard must be eliminated or reduced by:
If atmospheric hazards cannot be completely eliminated, workers must use appropriate respiratory protection and other personal protective equipment (PPE) as necessary.
To understand the Welding and Cutting topic, it is important to first understand what certain terms mean. These terms, as defined here, are used throughout this topic.
Any time work is performed using equipment that produces a spark or an open flame, or a process that generates excessive heat, there is a risk of fire. Work involving electric or gas welding, cutting, brazing, or similar flame-producing operations is known as “hot work.”
The Occupational Safety & Health Administration (OSHA) doesn’t specifically require companies to have a written permit to perform hot work. However, OSHA prefers that they be used. Many companies choose to have these permits to demonstrate that their hot work program is in compliance. 29 CFR 1910.252 gives general requirements for performing hot work safely.
Some administrative procedures are required before hot work begins:
In addition to being inspected by the designated individual, the area must be made as hazard-free as possible before hot work begins:
Appropriate safety equipment is required for hot work:
Some hot work conditions are dangerous enough to require a fire watch:
Types of welding
Welding is classified into two groups:
Welding, cutting, and brazing are common in many fields. The Occupational Safety & Health Administration (OSHA) regulates these practices in general industry in 29 CFR 1910, Subpart Q.
Some general requirements include administrative controls to be put in place before any hot work begins. Employers must:
Employers must also train personnel in, facilitate, and enforce safe work practices, including:
All necessary equipment must be provided and maintained in good working condition, including:
Regulations
The OSHA requirements for welding, cutting, and brazing in general industry are found in 29 CFR 1910, Subpart Q. Specific subtopics include:
These regulations might be helpful for further information:
Individual states may adopt OSHA’s standards and enforcement programs or use their own. State Plans are required to be at least as effective as OSHA's and may have different or more stringent regulations. There are 28 OSHA-approved State Plans operating statewide occupational safety and health programs.
Several of the Occupational Safety & Health Administration’s (OSHA) welding and cutting standards require employers to train workers and specify who needs training, the frequency of training, and recordkeeping requirements. Extended classroom and hands-on training for welders and welding helpers (such as fire watchers) may be needed to meet requirements.
The table below gives an overview of the OSHA regulations that apply to training for hot work in general industry:
Subject | Regulation | Who to train | When | Records to keep |
Welding, cutting, and brazing | 1910.252 | Cutters, welders, and their supervisors in safe equipment operation | Initially, and judged competent prior to assignment | No specific training documentation is required |
Oxygen-fuel gas welding and cutting | 1910.253 | Employees in charge of the oxygen or fuel-gas supply equipment | Initially, and judged competent prior to assignment | No specific training documentation is required |
Arc welding and cutting | 1910.254 | Employees who will operate arc welding equipment | Initially, or prior to assignment | No specific training documentation is required |
Resistance welding | 1910.255 | Employees who will operate resistance welding equipment | Initially, or prior to assignment | No specific training documentation is required |
Welding training should be provided in a language that the trainees understand. If a trainee’s vocabulary is limited, employers should account for that limitation. Translators may be needed.
Trainees should be made familiar with the company welding safety program. Anyone working welding or working around welding and other hot work should know:
An effective welding training program may also address:
Training for fire watchers
Fire watchers provide additional safeguards against fire during and after welding, cutting, or heating operations. Their responsibilities are addressed by OSHA in 1910.252 and by the American National Standards Institute (ANSI) in Z49.1-1967.
Training for fire watchers must include:
Training for arc welders and cutters
OSHA requires companies to instruct employees in the safe means of arc welding and cutting. In addition to general content about hot work and the company welding safety program, employees should learn about:
Welding, cutting, and brazing pose a combination of safety and health risks to more than 500,000 workers in a wide variety of industries. The risk from fatal injuries alone is more than four deaths per thousand workers over a working lifetime.
Health hazards from welding, cutting, and brazing operations include exposures to metal fumes and to ultraviolet (UV) radiation. Safety hazards from these operations include burns, eye damage, electrical shock, cuts, and crushed toes and fingers.
These hazards can affect not only the person doing the work, but the people, materials, and structures nearby. Many of these risks can be controlled with proper work practices and personal protective equipment (PPE).
General hot work hazards
Hot work hazards vary, depending upon the facility, equipment, number of workers present, and the job at hand. Examples include:
General protective measures
Many hazards of hot work can be minimized or avoided with proper equipment and practices.
Gas fumes, radiation, and electric shock are some of the hazards involved in arc welding. A welding arc emits blinding light and is hot enough to melt steel. It generates toxic fumes that are composed of microscopic particles of molten metal. Sparks and molten slag thrown by the arc can fly up to 35 feet and can cause fires and explosions.
Despite all these hazards, arc welding can be safe with proper precautions and work practices. Arc welders can protect themselves and others in several ways:
Fumes, gases, and ionizing radiation formed or released when welding, cutting, or brazing are associated with numerous health hazards, including:
The risks vary depending on the welding materials used and surfaces welded. The presence of oil or grease is one potential source of fire danger for gas welders. This danger can be reduced by:
Safe handling of compressed gas cylinders
Handling compressed gas cylinders safely is crucial in preventing fires and explosions. Cylinders must be stored under the proper conditions:
Cylinders must be kept far enough away from a welding or cutting project so that sparks, hot slag, or flames do not reach them. When this is impractical, fire shields must be used.
Valve protection caps must be in place, hand-tight, except when cylinders are in use or connected for use. Before a regulator is connected to the cylinder valve, the valve must be cracked (opened slightly and closed immediately). This clears the valve of dust or dirt that could enter the regulator.
Welding and metal cutting operations produce molten metal, sparks, weld spatter, slag, and hot work surfaces. All of these can create a situation that can cause fires. At 1910.252, the Occupational Safety & Health Administration (OSHA) addresses the fire hazards of hot work.
When the object to be welded, cut, or heated | And | Then |
Can be moved | A safe, fire-resistant workplace is available | The object should be moved to that space for working |
Cannot be readily moved | All fire hazards are moved at least 35 feet away or are protected | The object can be worked in place |
Cannot be moved | All fire hazards cannot be removed | Steps must be taken to confine the heat, sparks, and slag to protect the immobile fire hazards |
Cannot be moved | Normal fire prevention precautions are not sufficient | Additional personnel shall be assigned to guard against fire during the work and for a sufficient amount of time afterward |
To best prevent and address fires, workers must be well-informed about:
They should also know when and how to involve a fire watcher.
When are fire watchers required?
Fire watchers provide additional safeguards against fire during and after welding, cutting, or heating operations. A fire watcher is required in situations where:
The fire watch is to be maintained for at least 30 minutes following completion of the work.
Welders can be exposed to a number of fumes, gases, and dusts. These contaminants can harm the health of workers and/or accumulate to the point of causing a fire. Ventilation helps to reduce the concentration of contaminants and prevent the accumulation of flammable gases, vapors, and dusts.
According to the Occupational Safety & Health Administration (OSHA), whenever and wherever welding occurs, everyone involved in the operation must be aware of welding fumes and gases and take necessary, especially ventilation, precautions. Even in metal cutting jobs that are considered routine, established safety procedures should always be followed.
Welding ventilation techniques vary. Often, however, a relatively simple ventilation method like the appropriate use of fans will be all that is required to provide good ventilation during hot work.
OSHA specifies in 1910.252(c) that if mechanical ventilation is used, it must consist of either:
Related regulations
OSHA and the American National Standards Institute (ANSI) both have standards that can be relevant to ventilation during hot work:
Types of ventilation
Ventilation can be provided by a general mechanical or local exhaust system. Open spaces can also help to reduce accumulations.
General mechanical ventilation lowers contamination levels by using fans of various types to dilute the contaminated air with fresh air. OSHA requires mechanical ventilation to be provided when welding or cutting is done in certain circumstances on most metals, with some exceptions (including zinc, lead, cadmium, beryllium, and mercury) that have more specific requirements. Mechanical ventilation is required when welding is performed:
Outside of these conditions, natural ventilation is considered sufficient.
Local exhaust systems remove fumes and smoke at the source using either of the following:
The need for local exhaust ventilation for welding or cutting outside of confined spaces depends on the individual circumstances. However, it is recommended for fixed-location production welding and for all production welding on stainless steels.
Ventilation in confined spaces
All welding and cutting operations in confined spaces must be adequately ventilated to prevent toxic material accumulation or oxygen deficiency. Only clean, breathable air can be used to replace air withdrawn from the confined space.
If it’s not possible to provide adequate ventilation, workers must use airline respirators or hose masks approved by the National Institute for Occupational Safety and Health (NIOSH).
The many hazards associated with welding operations include exposure to several types of air contaminants:
These contaminants can harm workers’ health. Fortunately, there are ways to reduce or eliminate them.
Related regulations
The Occupational Safety & Health Administration (OSHA)) and the American National Standards Institute (ANSI) both have standards that can be relevant to fumes and gases encountered during hot work:
Types of fumes and gases
During welding and cutting operations, metal fumes may be released, gas byproducts may be formed, and shielding gases used during the process may escape into the air.
Metal fumes produced during hot work depend on the circumstances of the operation —the metal, metal preservatives, electrode, or filler rod used. Some common welding fumes that can have negative health effects include:
Gases are also released during welding operations. These gases can form in many ways. Carbon monoxide, for example, can form when carbon dioxide shielding gas is used in gas metal arc welding. Gas byproducts formed during welding may include:
Certain other gases are not byproducts but used as shielding gases supplied during the welding process, including:
Health effects
Fume and gas exposure can cause an array of health effects, both short- and long-term. Acute exposure to welding fumes and gases can result in eye, nose, and throat irritation; dizziness; and nausea. Workers should be alert for these symptoms and leave the area if any develop. Prolonged exposure to welding fumes may cause lung damage and various types of cancer, including lung, larynx, and urinary tract.
Depending on the fume or gas, health effects may also include metal fume fever, stomach ulcers, kidney damage, and nervous system damage. For example, prolonged exposure to manganese fumes can cause Parkinson’s-like symptoms.
Some gases, such as helium, argon, and carbon dioxide, displace oxygen in the air. This can lead to suffocation, particularly during welding in enclosed spaces. Carbon monoxide gas can form, posing an asphyxiation hazard.
Factors affecting exposure
Factors that affect exposure to welding fumes or gases depend on a number of circumstances:
Minimizing health hazards from fumes and gases
While there are a lot of health hazards associated with fumes and gases from hot work, there are also many ways to control or eliminate them.
Before welding begins, some hazards can be prevented by:
Workers can reduce their risks with safety equipment, including:
Workers can also reduce their risks with their work practices, including:
Compressed gases in cylinders present special hazards that include the possibility of oxygen displacement and toxic effects from the gas itself, as well as fire and explosion risks due to the high pressure. Thus, gas cylinders may only be handled and used by trained workers.
The Occupational Safety & Health Administration (OSHA) addresses compressed gases in general at 1910.101, which adopts by reference some regulations from the Compressed Gas Association (CGA).
Marking gas cylinders
Cylinders, containers, pipes, etc., must be clearly marked so that the gas can be easily identified. Labels should not be defaced or removed. Containers whose content labels are not legible should be returned unused to the supplier. Containers should not be repainted, and container color should not be used to identify the cylinder content.
All gas lines leading from a compressed gas supply should be clearly labeled or identified. Some states require specific labeling of cylinders, containers, and pipes.
Inspecting gas cylinders
Employers must visually inspect compressed gas cylinders to determine that they are in safe condition under 1910.101.
Visual inspections must be conducted as prescribed in the Hazardous Materials Regulations of the Department of Transportation (49 CFR Parts 171–179 and 14 CFR Part 103) when applicable. Otherwise, they must be conducted in accordance with CGA Pamphlet C-6-1968.
In general, all parts of a cylinder (valves, neck rings, hoses, manifold, regulator, etc.) should be inspected for:
Storing gas cylinders
Proper storage of gas cylinders is crucial for maintaining a safe workplace. According to CGA P-1, storage areas must:
Containers must be:
Moving gas cylinders
Safe handling of gas cylinders includes moving them carefully, both within and between facilities.
Practices to avoid include:
Protective caps and outlet caps or plugs should be replaced before empty cylinders are returned to the supplier.
OSHA states that compressed gas cylinders that are not secured to a “special truck” must have their regulators removed and valve-protection caps installed. A special truck is a vehicle or cart that provides stable support of vertical standing Department of Transportation portable gas cylinders during movement and at various work locations. It must include protection of cylinder valves and regulators. CGA Pamphlet P-1 allows for a “suitable hand truck, forklift truck, or similar material handling device,” as long as cylinders are properly secured to it by a chain or other comparable method.
Using gas cylinders
When using any compressed gas (i.e., cylinders, portable tanks, rail tank cars, or motor vehicle cargo tanks), employers must comply with the provisions outlined in CGA Pamphlet P-1-1965, which is incorporated by reference in the OSHA standard.
When handling compressed gas cylinders, workers should always follow these procedures:
Several substances that welders may encounter are regulated individually because of their specific hazards. These include acetylene, hexavalent chromium, and cadmium.
Acetylene
Acetylene is a colorless gas that has many industrial uses, from being a raw material to use in welding. It poses a flammability hazard and must be used, transported, and stored properly.
The Occupational Safety & Health Administration (OSHA) requirements apply to employers who have employees who use or are exposed to acetylene. The specific requirements vary depending on the application.
Relevant citations:
To comply with requirements and provide a safe workplace, employers must:
Hexavalent chromium
Chromium hexavalent (Cr[VI]) compounds, often called hexavalent chromium, may be created during hot work such as welding on stainless steel or melting chromium metal. The high temperatures involved in the process result in oxidation that converts chromium to a hexavalent state.
Hexavalent chromium can pose a serious hazard to workers. Chromium is converted to its hexavalent state, Cr(VI), during the welding process, and Cr(VI) fume is highly toxic and can damage the eyes, skin, nose, throat, and lungs and cause cancer. OSHA regulates worker exposure to Cr(VI) under 1926.1126, which has a permissible exposure limit (PEL) of 5 ?g/m 3 as an eight-hour average.
Cadmium
The Agency for Toxic Substances and Disease Registry estimates that about 300,000 workers in the U.S. face exposure to cadmium each year. Cadmium exposure can threaten workers who perform activities like the following without wearing some type of personal protection:
OSHA has set the PEL for cadmium in work area air at 5 micrograms per cubic meter of air (5 ?g/m3) for an 8-hour workday.
Cadmium exposure may occur in several ways:
Type | Route | Effects | Prevention |
Inhalation | Dust or fumes in the air (e.g., from welding with cadmium solder) | Short term: Constriction of the throat, chest pain, weakness, fever, lung damage, death Long term: Kidney disease, lung damage, fragile bones | Wearing a respirator |
Ingestion | Handling cadmium-contaminated food, cigarettes, cosmetics, etc. | Short term: Stomach irritation, vomiting, diarrhea Long term: Kidney disease, lung damage, fragile bones | Avoiding eating, smoking, etc. around cadmium, and cleaning up carefully |
Eye exposure | Dust or fumes in eyes; touching eyes with cadmium-contaminated hands | Redness and pain | Wearing eye protection, avoiding touching eyes, washing eyes with water if exposure occurs |
Skin exposure | Dust spilling or blowing onto skin; accidental touches | Irritation | Wearing gloves, washing skin with water if exposure occurs |
Welding involves many types of equipment, some of which the Occupational Safety & Health Administration (OSHA) regulates specifically and some it does not. Some examples are discussed below.
Welding hoses
Employers should check with the manufacturer of hoses and gauges to see what restrictions or cautions are noted, or to see how lines should be purged after turning off the gases.
Fuel gas and oxygen hoses must be easily distinguishable from each other, either with color contrast or surface characteristics that are noticeable to the touch.
All hoses carrying acetylene, oxygen, natural/manufactured gas, or any ignitable or combustible gas or substance must be inspected at the beginning of each work shift. Defective hoses must be removed from service.
No specific regulation addresses storage of welding hoses. If there is a known hazard, OSHA would expect that an employer address it under their General Duty Clause obligations.
Fuel gas and oxygen manifolds
Fuel gas and oxygen manifolds must bear the name of the substance they contain in letters at least 1 inch high. The letters must be either painted on the manifold or a sign permanently attached to it.
Hose connections must be kept free of grease and oil and be capped when not in use.
Torches
Torches must be inspected for leaks at the beginning of each work shift, and defective torches removed from service.
Torches should never be lit using matches or from hot work.
If torch tip holes become clogged, they should be cleaned with suitable cleaning wires, drills, or other devices designed for this purpose.
Regulators and gauges
Oxygen and fuel gas pressure regulators, including related gauges, must be inspected to verify that they are in good working order.
Curtains/booths
OSHA prefers that welding be shielded from other operations when possible, using weld curtains or booths.
At 1910.252(b)(2)(iii), OSHA states, “Where the work permits, the welder should be enclosed in an individual booth painted with a finish of low reflectivity such as zinc oxide (an important factor for absorbing ultraviolet radiations) and lamp black, or shall be enclosed with non-combustible screens similarly painted.” Passersby should be separated from welding using these curtains, booths, or screens, or else should wear suitable eye protection.
Several of the Occupational Safety & Health Administration’s (OSHA) welding and cutting standards require employers to train workers and specify who needs training, the frequency of training, and recordkeeping requirements. Extended classroom and hands-on training for welders and welding helpers (such as fire watchers) may be needed to meet requirements.
The table below gives an overview of the OSHA regulations that apply to training for hot work in general industry:
Subject | Regulation | Who to train | When | Records to keep |
Welding, cutting, and brazing | 1910.252 | Cutters, welders, and their supervisors in safe equipment operation | Initially, and judged competent prior to assignment | No specific training documentation is required |
Oxygen-fuel gas welding and cutting | 1910.253 | Employees in charge of the oxygen or fuel-gas supply equipment | Initially, and judged competent prior to assignment | No specific training documentation is required |
Arc welding and cutting | 1910.254 | Employees who will operate arc welding equipment | Initially, or prior to assignment | No specific training documentation is required |
Resistance welding | 1910.255 | Employees who will operate resistance welding equipment | Initially, or prior to assignment | No specific training documentation is required |
Welding training should be provided in a language that the trainees understand. If a trainee’s vocabulary is limited, employers should account for that limitation. Translators may be needed.
Trainees should be made familiar with the company welding safety program. Anyone working welding or working around welding and other hot work should know:
An effective welding training program may also address:
Training for fire watchers
Fire watchers provide additional safeguards against fire during and after welding, cutting, or heating operations. Their responsibilities are addressed by OSHA in 1910.252 and by the American National Standards Institute (ANSI) in Z49.1-1967.
Training for fire watchers must include:
Training for arc welders and cutters
OSHA requires companies to instruct employees in the safe means of arc welding and cutting. In addition to general content about hot work and the company welding safety program, employees should learn about:
Welding, cutting, and brazing pose a combination of safety and health risks to more than 500,000 workers in a wide variety of industries. The risk from fatal injuries alone is more than four deaths per thousand workers over a working lifetime.
Health hazards from welding, cutting, and brazing operations include exposures to metal fumes and to ultraviolet (UV) radiation. Safety hazards from these operations include burns, eye damage, electrical shock, cuts, and crushed toes and fingers.
These hazards can affect not only the person doing the work, but the people, materials, and structures nearby. Many of these risks can be controlled with proper work practices and personal protective equipment (PPE).
General hot work hazards
Hot work hazards vary, depending upon the facility, equipment, number of workers present, and the job at hand. Examples include:
General protective measures
Many hazards of hot work can be minimized or avoided with proper equipment and practices.
Gas fumes, radiation, and electric shock are some of the hazards involved in arc welding. A welding arc emits blinding light and is hot enough to melt steel. It generates toxic fumes that are composed of microscopic particles of molten metal. Sparks and molten slag thrown by the arc can fly up to 35 feet and can cause fires and explosions.
Despite all these hazards, arc welding can be safe with proper precautions and work practices. Arc welders can protect themselves and others in several ways:
Fumes, gases, and ionizing radiation formed or released when welding, cutting, or brazing are associated with numerous health hazards, including:
The risks vary depending on the welding materials used and surfaces welded. The presence of oil or grease is one potential source of fire danger for gas welders. This danger can be reduced by:
Safe handling of compressed gas cylinders
Handling compressed gas cylinders safely is crucial in preventing fires and explosions. Cylinders must be stored under the proper conditions:
Cylinders must be kept far enough away from a welding or cutting project so that sparks, hot slag, or flames do not reach them. When this is impractical, fire shields must be used.
Valve protection caps must be in place, hand-tight, except when cylinders are in use or connected for use. Before a regulator is connected to the cylinder valve, the valve must be cracked (opened slightly and closed immediately). This clears the valve of dust or dirt that could enter the regulator.
Welding and metal cutting operations produce molten metal, sparks, weld spatter, slag, and hot work surfaces. All of these can create a situation that can cause fires. At 1910.252, the Occupational Safety & Health Administration (OSHA) addresses the fire hazards of hot work.
When the object to be welded, cut, or heated | And | Then |
Can be moved | A safe, fire-resistant workplace is available | The object should be moved to that space for working |
Cannot be readily moved | All fire hazards are moved at least 35 feet away or are protected | The object can be worked in place |
Cannot be moved | All fire hazards cannot be removed | Steps must be taken to confine the heat, sparks, and slag to protect the immobile fire hazards |
Cannot be moved | Normal fire prevention precautions are not sufficient | Additional personnel shall be assigned to guard against fire during the work and for a sufficient amount of time afterward |
To best prevent and address fires, workers must be well-informed about:
They should also know when and how to involve a fire watcher.
When are fire watchers required?
Fire watchers provide additional safeguards against fire during and after welding, cutting, or heating operations. A fire watcher is required in situations where:
The fire watch is to be maintained for at least 30 minutes following completion of the work.
Gas fumes, radiation, and electric shock are some of the hazards involved in arc welding. A welding arc emits blinding light and is hot enough to melt steel. It generates toxic fumes that are composed of microscopic particles of molten metal. Sparks and molten slag thrown by the arc can fly up to 35 feet and can cause fires and explosions.
Despite all these hazards, arc welding can be safe with proper precautions and work practices. Arc welders can protect themselves and others in several ways:
Fumes, gases, and ionizing radiation formed or released when welding, cutting, or brazing are associated with numerous health hazards, including:
The risks vary depending on the welding materials used and surfaces welded. The presence of oil or grease is one potential source of fire danger for gas welders. This danger can be reduced by:
Safe handling of compressed gas cylinders
Handling compressed gas cylinders safely is crucial in preventing fires and explosions. Cylinders must be stored under the proper conditions:
Cylinders must be kept far enough away from a welding or cutting project so that sparks, hot slag, or flames do not reach them. When this is impractical, fire shields must be used.
Valve protection caps must be in place, hand-tight, except when cylinders are in use or connected for use. Before a regulator is connected to the cylinder valve, the valve must be cracked (opened slightly and closed immediately). This clears the valve of dust or dirt that could enter the regulator.
Welding and metal cutting operations produce molten metal, sparks, weld spatter, slag, and hot work surfaces. All of these can create a situation that can cause fires. At 1910.252, the Occupational Safety & Health Administration (OSHA) addresses the fire hazards of hot work.
When the object to be welded, cut, or heated | And | Then |
Can be moved | A safe, fire-resistant workplace is available | The object should be moved to that space for working |
Cannot be readily moved | All fire hazards are moved at least 35 feet away or are protected | The object can be worked in place |
Cannot be moved | All fire hazards cannot be removed | Steps must be taken to confine the heat, sparks, and slag to protect the immobile fire hazards |
Cannot be moved | Normal fire prevention precautions are not sufficient | Additional personnel shall be assigned to guard against fire during the work and for a sufficient amount of time afterward |
To best prevent and address fires, workers must be well-informed about:
They should also know when and how to involve a fire watcher.
When are fire watchers required?
Fire watchers provide additional safeguards against fire during and after welding, cutting, or heating operations. A fire watcher is required in situations where:
The fire watch is to be maintained for at least 30 minutes following completion of the work.
Welders can be exposed to a number of fumes, gases, and dusts. These contaminants can harm the health of workers and/or accumulate to the point of causing a fire. Ventilation helps to reduce the concentration of contaminants and prevent the accumulation of flammable gases, vapors, and dusts.
According to the Occupational Safety & Health Administration (OSHA), whenever and wherever welding occurs, everyone involved in the operation must be aware of welding fumes and gases and take necessary, especially ventilation, precautions. Even in metal cutting jobs that are considered routine, established safety procedures should always be followed.
Welding ventilation techniques vary. Often, however, a relatively simple ventilation method like the appropriate use of fans will be all that is required to provide good ventilation during hot work.
OSHA specifies in 1910.252(c) that if mechanical ventilation is used, it must consist of either:
Related regulations
OSHA and the American National Standards Institute (ANSI) both have standards that can be relevant to ventilation during hot work:
Types of ventilation
Ventilation can be provided by a general mechanical or local exhaust system. Open spaces can also help to reduce accumulations.
General mechanical ventilation lowers contamination levels by using fans of various types to dilute the contaminated air with fresh air. OSHA requires mechanical ventilation to be provided when welding or cutting is done in certain circumstances on most metals, with some exceptions (including zinc, lead, cadmium, beryllium, and mercury) that have more specific requirements. Mechanical ventilation is required when welding is performed:
Outside of these conditions, natural ventilation is considered sufficient.
Local exhaust systems remove fumes and smoke at the source using either of the following:
The need for local exhaust ventilation for welding or cutting outside of confined spaces depends on the individual circumstances. However, it is recommended for fixed-location production welding and for all production welding on stainless steels.
Ventilation in confined spaces
All welding and cutting operations in confined spaces must be adequately ventilated to prevent toxic material accumulation or oxygen deficiency. Only clean, breathable air can be used to replace air withdrawn from the confined space.
If it’s not possible to provide adequate ventilation, workers must use airline respirators or hose masks approved by the National Institute for Occupational Safety and Health (NIOSH).
The many hazards associated with welding operations include exposure to several types of air contaminants:
These contaminants can harm workers’ health. Fortunately, there are ways to reduce or eliminate them.
Related regulations
The Occupational Safety & Health Administration (OSHA)) and the American National Standards Institute (ANSI) both have standards that can be relevant to fumes and gases encountered during hot work:
Types of fumes and gases
During welding and cutting operations, metal fumes may be released, gas byproducts may be formed, and shielding gases used during the process may escape into the air.
Metal fumes produced during hot work depend on the circumstances of the operation —the metal, metal preservatives, electrode, or filler rod used. Some common welding fumes that can have negative health effects include:
Gases are also released during welding operations. These gases can form in many ways. Carbon monoxide, for example, can form when carbon dioxide shielding gas is used in gas metal arc welding. Gas byproducts formed during welding may include:
Certain other gases are not byproducts but used as shielding gases supplied during the welding process, including:
Health effects
Fume and gas exposure can cause an array of health effects, both short- and long-term. Acute exposure to welding fumes and gases can result in eye, nose, and throat irritation; dizziness; and nausea. Workers should be alert for these symptoms and leave the area if any develop. Prolonged exposure to welding fumes may cause lung damage and various types of cancer, including lung, larynx, and urinary tract.
Depending on the fume or gas, health effects may also include metal fume fever, stomach ulcers, kidney damage, and nervous system damage. For example, prolonged exposure to manganese fumes can cause Parkinson’s-like symptoms.
Some gases, such as helium, argon, and carbon dioxide, displace oxygen in the air. This can lead to suffocation, particularly during welding in enclosed spaces. Carbon monoxide gas can form, posing an asphyxiation hazard.
Factors affecting exposure
Factors that affect exposure to welding fumes or gases depend on a number of circumstances:
Minimizing health hazards from fumes and gases
While there are a lot of health hazards associated with fumes and gases from hot work, there are also many ways to control or eliminate them.
Before welding begins, some hazards can be prevented by:
Workers can reduce their risks with safety equipment, including:
Workers can also reduce their risks with their work practices, including:
Compressed gases in cylinders present special hazards that include the possibility of oxygen displacement and toxic effects from the gas itself, as well as fire and explosion risks due to the high pressure. Thus, gas cylinders may only be handled and used by trained workers.
The Occupational Safety & Health Administration (OSHA) addresses compressed gases in general at 1910.101, which adopts by reference some regulations from the Compressed Gas Association (CGA).
Marking gas cylinders
Cylinders, containers, pipes, etc., must be clearly marked so that the gas can be easily identified. Labels should not be defaced or removed. Containers whose content labels are not legible should be returned unused to the supplier. Containers should not be repainted, and container color should not be used to identify the cylinder content.
All gas lines leading from a compressed gas supply should be clearly labeled or identified. Some states require specific labeling of cylinders, containers, and pipes.
Inspecting gas cylinders
Employers must visually inspect compressed gas cylinders to determine that they are in safe condition under 1910.101.
Visual inspections must be conducted as prescribed in the Hazardous Materials Regulations of the Department of Transportation (49 CFR Parts 171–179 and 14 CFR Part 103) when applicable. Otherwise, they must be conducted in accordance with CGA Pamphlet C-6-1968.
In general, all parts of a cylinder (valves, neck rings, hoses, manifold, regulator, etc.) should be inspected for:
Storing gas cylinders
Proper storage of gas cylinders is crucial for maintaining a safe workplace. According to CGA P-1, storage areas must:
Containers must be:
Moving gas cylinders
Safe handling of gas cylinders includes moving them carefully, both within and between facilities.
Practices to avoid include:
Protective caps and outlet caps or plugs should be replaced before empty cylinders are returned to the supplier.
OSHA states that compressed gas cylinders that are not secured to a “special truck” must have their regulators removed and valve-protection caps installed. A special truck is a vehicle or cart that provides stable support of vertical standing Department of Transportation portable gas cylinders during movement and at various work locations. It must include protection of cylinder valves and regulators. CGA Pamphlet P-1 allows for a “suitable hand truck, forklift truck, or similar material handling device,” as long as cylinders are properly secured to it by a chain or other comparable method.
Using gas cylinders
When using any compressed gas (i.e., cylinders, portable tanks, rail tank cars, or motor vehicle cargo tanks), employers must comply with the provisions outlined in CGA Pamphlet P-1-1965, which is incorporated by reference in the OSHA standard.
When handling compressed gas cylinders, workers should always follow these procedures:
Several substances that welders may encounter are regulated individually because of their specific hazards. These include acetylene, hexavalent chromium, and cadmium.
Acetylene
Acetylene is a colorless gas that has many industrial uses, from being a raw material to use in welding. It poses a flammability hazard and must be used, transported, and stored properly.
The Occupational Safety & Health Administration (OSHA) requirements apply to employers who have employees who use or are exposed to acetylene. The specific requirements vary depending on the application.
Relevant citations:
To comply with requirements and provide a safe workplace, employers must:
Hexavalent chromium
Chromium hexavalent (Cr[VI]) compounds, often called hexavalent chromium, may be created during hot work such as welding on stainless steel or melting chromium metal. The high temperatures involved in the process result in oxidation that converts chromium to a hexavalent state.
Hexavalent chromium can pose a serious hazard to workers. Chromium is converted to its hexavalent state, Cr(VI), during the welding process, and Cr(VI) fume is highly toxic and can damage the eyes, skin, nose, throat, and lungs and cause cancer. OSHA regulates worker exposure to Cr(VI) under 1926.1126, which has a permissible exposure limit (PEL) of 5 ?g/m 3 as an eight-hour average.
Cadmium
The Agency for Toxic Substances and Disease Registry estimates that about 300,000 workers in the U.S. face exposure to cadmium each year. Cadmium exposure can threaten workers who perform activities like the following without wearing some type of personal protection:
OSHA has set the PEL for cadmium in work area air at 5 micrograms per cubic meter of air (5 ?g/m3) for an 8-hour workday.
Cadmium exposure may occur in several ways:
Type | Route | Effects | Prevention |
Inhalation | Dust or fumes in the air (e.g., from welding with cadmium solder) | Short term: Constriction of the throat, chest pain, weakness, fever, lung damage, death Long term: Kidney disease, lung damage, fragile bones | Wearing a respirator |
Ingestion | Handling cadmium-contaminated food, cigarettes, cosmetics, etc. | Short term: Stomach irritation, vomiting, diarrhea Long term: Kidney disease, lung damage, fragile bones | Avoiding eating, smoking, etc. around cadmium, and cleaning up carefully |
Eye exposure | Dust or fumes in eyes; touching eyes with cadmium-contaminated hands | Redness and pain | Wearing eye protection, avoiding touching eyes, washing eyes with water if exposure occurs |
Skin exposure | Dust spilling or blowing onto skin; accidental touches | Irritation | Wearing gloves, washing skin with water if exposure occurs |
Compressed gases in cylinders present special hazards that include the possibility of oxygen displacement and toxic effects from the gas itself, as well as fire and explosion risks due to the high pressure. Thus, gas cylinders may only be handled and used by trained workers.
The Occupational Safety & Health Administration (OSHA) addresses compressed gases in general at 1910.101, which adopts by reference some regulations from the Compressed Gas Association (CGA).
Marking gas cylinders
Cylinders, containers, pipes, etc., must be clearly marked so that the gas can be easily identified. Labels should not be defaced or removed. Containers whose content labels are not legible should be returned unused to the supplier. Containers should not be repainted, and container color should not be used to identify the cylinder content.
All gas lines leading from a compressed gas supply should be clearly labeled or identified. Some states require specific labeling of cylinders, containers, and pipes.
Inspecting gas cylinders
Employers must visually inspect compressed gas cylinders to determine that they are in safe condition under 1910.101.
Visual inspections must be conducted as prescribed in the Hazardous Materials Regulations of the Department of Transportation (49 CFR Parts 171–179 and 14 CFR Part 103) when applicable. Otherwise, they must be conducted in accordance with CGA Pamphlet C-6-1968.
In general, all parts of a cylinder (valves, neck rings, hoses, manifold, regulator, etc.) should be inspected for:
Storing gas cylinders
Proper storage of gas cylinders is crucial for maintaining a safe workplace. According to CGA P-1, storage areas must:
Containers must be:
Moving gas cylinders
Safe handling of gas cylinders includes moving them carefully, both within and between facilities.
Practices to avoid include:
Protective caps and outlet caps or plugs should be replaced before empty cylinders are returned to the supplier.
OSHA states that compressed gas cylinders that are not secured to a “special truck” must have their regulators removed and valve-protection caps installed. A special truck is a vehicle or cart that provides stable support of vertical standing Department of Transportation portable gas cylinders during movement and at various work locations. It must include protection of cylinder valves and regulators. CGA Pamphlet P-1 allows for a “suitable hand truck, forklift truck, or similar material handling device,” as long as cylinders are properly secured to it by a chain or other comparable method.
Using gas cylinders
When using any compressed gas (i.e., cylinders, portable tanks, rail tank cars, or motor vehicle cargo tanks), employers must comply with the provisions outlined in CGA Pamphlet P-1-1965, which is incorporated by reference in the OSHA standard.
When handling compressed gas cylinders, workers should always follow these procedures:
Several substances that welders may encounter are regulated individually because of their specific hazards. These include acetylene, hexavalent chromium, and cadmium.
Acetylene
Acetylene is a colorless gas that has many industrial uses, from being a raw material to use in welding. It poses a flammability hazard and must be used, transported, and stored properly.
The Occupational Safety & Health Administration (OSHA) requirements apply to employers who have employees who use or are exposed to acetylene. The specific requirements vary depending on the application.
Relevant citations:
To comply with requirements and provide a safe workplace, employers must:
Hexavalent chromium
Chromium hexavalent (Cr[VI]) compounds, often called hexavalent chromium, may be created during hot work such as welding on stainless steel or melting chromium metal. The high temperatures involved in the process result in oxidation that converts chromium to a hexavalent state.
Hexavalent chromium can pose a serious hazard to workers. Chromium is converted to its hexavalent state, Cr(VI), during the welding process, and Cr(VI) fume is highly toxic and can damage the eyes, skin, nose, throat, and lungs and cause cancer. OSHA regulates worker exposure to Cr(VI) under 1926.1126, which has a permissible exposure limit (PEL) of 5 ?g/m 3 as an eight-hour average.
Cadmium
The Agency for Toxic Substances and Disease Registry estimates that about 300,000 workers in the U.S. face exposure to cadmium each year. Cadmium exposure can threaten workers who perform activities like the following without wearing some type of personal protection:
OSHA has set the PEL for cadmium in work area air at 5 micrograms per cubic meter of air (5 ?g/m3) for an 8-hour workday.
Cadmium exposure may occur in several ways:
Type | Route | Effects | Prevention |
Inhalation | Dust or fumes in the air (e.g., from welding with cadmium solder) | Short term: Constriction of the throat, chest pain, weakness, fever, lung damage, death Long term: Kidney disease, lung damage, fragile bones | Wearing a respirator |
Ingestion | Handling cadmium-contaminated food, cigarettes, cosmetics, etc. | Short term: Stomach irritation, vomiting, diarrhea Long term: Kidney disease, lung damage, fragile bones | Avoiding eating, smoking, etc. around cadmium, and cleaning up carefully |
Eye exposure | Dust or fumes in eyes; touching eyes with cadmium-contaminated hands | Redness and pain | Wearing eye protection, avoiding touching eyes, washing eyes with water if exposure occurs |
Skin exposure | Dust spilling or blowing onto skin; accidental touches | Irritation | Wearing gloves, washing skin with water if exposure occurs |
Welding involves many types of equipment, some of which the Occupational Safety & Health Administration (OSHA) regulates specifically and some it does not. Some examples are discussed below.
Welding hoses
Employers should check with the manufacturer of hoses and gauges to see what restrictions or cautions are noted, or to see how lines should be purged after turning off the gases.
Fuel gas and oxygen hoses must be easily distinguishable from each other, either with color contrast or surface characteristics that are noticeable to the touch.
All hoses carrying acetylene, oxygen, natural/manufactured gas, or any ignitable or combustible gas or substance must be inspected at the beginning of each work shift. Defective hoses must be removed from service.
No specific regulation addresses storage of welding hoses. If there is a known hazard, OSHA would expect that an employer address it under their General Duty Clause obligations.
Fuel gas and oxygen manifolds
Fuel gas and oxygen manifolds must bear the name of the substance they contain in letters at least 1 inch high. The letters must be either painted on the manifold or a sign permanently attached to it.
Hose connections must be kept free of grease and oil and be capped when not in use.
Torches
Torches must be inspected for leaks at the beginning of each work shift, and defective torches removed from service.
Torches should never be lit using matches or from hot work.
If torch tip holes become clogged, they should be cleaned with suitable cleaning wires, drills, or other devices designed for this purpose.
Regulators and gauges
Oxygen and fuel gas pressure regulators, including related gauges, must be inspected to verify that they are in good working order.
Curtains/booths
OSHA prefers that welding be shielded from other operations when possible, using weld curtains or booths.
At 1910.252(b)(2)(iii), OSHA states, “Where the work permits, the welder should be enclosed in an individual booth painted with a finish of low reflectivity such as zinc oxide (an important factor for absorbing ultraviolet radiations) and lamp black, or shall be enclosed with non-combustible screens similarly painted.” Passersby should be separated from welding using these curtains, booths, or screens, or else should wear suitable eye protection.
Welding, cutting, and brazing are common in many fields. The Occupational Safety & Health Administration (OSHA) regulates these practices in the construction industry in 29 CFR 1926, Subpart J.
Most requirements for hot work in construction are the same as those in general industry. However, there are some differences, such as whether gas cylinders may be permanently stored on a transport dolly. OSHA says that due to the rougher nature of most construction sites, cylinders must be put into more secure storage if gas is not to be drawn for 24 hours.
Regulations
OSHA’s Subpart J welding requirements apply to any employer performing welding operations during construction activities.
General requirements
Construction employers must:
Training
Training requirements for welding and cutting that are specific to construction are found in 29 CFR 1926.350, .351, .352, and .354.
Several OSHA regulations apply to training for hot work in the construction industry.
The Welding and Cutting Standard, 29 CFR 1926 Subpart J, does not call for employees to receive training on the health hazards of welding-related fumes and gases. However, 1926.353 requirements lend themselves to training. Welders should be trained to:
Workers who are potentially exposed to toxic and hazardous substances (like cadmium, hexavalent chromium, and lead) specifically regulated at 29 CFR 1926 Subparts D or Z may have further training requirements.
In addition, workers whose activities are regulated by the Confined Spaces in Construction Standard, 29 CFR 1926 Subpart CC, must be provided with training so that they understand the hazards in the permit space and the methods used to isolate, control, or in other ways stay safe from these hazards.
Welding and metal cutting operations produce molten metal, sparks, weld spatter, slag, and hot work surfaces. All of these can create a situation that can cause fires.
29 CFR 1926.352 is concerned with fire hazards in situations where:
Where to go for more information:
Fire watchers in construction
According to 1926.352, construction employees assigned to guard against fire during welding, cutting, or heating operations (and for a sufficient time after completion of the work) are to be instructed on the specific anticipated fire hazards and how the provided firefighting equipment is to be used.
Fire watchers are additional personnel who:
The fire watch is to be maintained for at least 30 minutes following completion of the work.
Fire watchers must be trained in:
Welding and metal cutting operations produce molten metal, sparks, weld spatter, slag, and hot work surfaces. All of these can create a situation that can cause fires.
29 CFR 1926.352 is concerned with fire hazards in situations where:
Where to go for more information:
Fire watchers in construction
According to 1926.352, construction employees assigned to guard against fire during welding, cutting, or heating operations (and for a sufficient time after completion of the work) are to be instructed on the specific anticipated fire hazards and how the provided firefighting equipment is to be used.
Fire watchers are additional personnel who:
The fire watch is to be maintained for at least 30 minutes following completion of the work.
Fire watchers must be trained in:
It’s crucial that people doing hot work wear flame-retardant clothing and protective equipment for the eyes, ears, and head. Necessary personal protective equipment (PPE) includes the following:
Clothing
At 1910.252(b)(3), the Occupational Safety & Health Administration (OSHA) states, “Appropriate protective clothing required for any welding operation will vary with the size, nature and location of the work to be performed."
This generally means long sleeves and long pants to protect from welding arc burns and welding spatter, but these are not required. Rather, this must be determined based upon the site’s hazard assessment.
With regard to flame-resistant clothing (FRC), OSHA says in a January 12, 2012, Letter of Interpretation that “if welders are exposed to flash fires or short-duration flame exposures, OSHA expects that employers would provide and ensure the use of FRC to protect workers from these hazards . . . Employees wearing FRC may be exposed to hazards relating to heat stress. Therefore, employers should consider the following when selecting personal protective equipment for employees that are exposed to these adverse conditions: provide light weight breathable fabrics and allow employees to drink cold liquids, such as water and other electrolyte replenishing drinks.”
Gas-shielded arc welders should cover all parts of their bodies to protect against ultraviolet and infrared ray flash burn. Dark clothing works best to reduce reflection under the face shield.
Wool, leather, or cotton treated to reduce flammability are preferred for gas-shielded arc welding. Wool has an advantage over cotton because it resists deterioration better. Regardless of material, clothing should be:
Pants shouldn’t have cuffs or front pockets that could catch sparks.
If worn, thermal insulated underwear should be covered by other clothing and not exposed to sparks or other ignition sources. It should be down-filled or waffle weave cotton or wool. Synthetic fabrics won’t necessarily ignite more easily than cotton, but they melt as they burn, sticking tightly to skin, which can result in a very serious burn that is hard to treat and slow to heal.
Eye injuries are a major concern around welding, cutting, and brazing operations, due to the variety of hazards related to this type of work. The following table lists potential eye hazards and their sources:
Type of hazard | Potential sources |
Impact | Operations that create flying objects or particles, such as caulking, chiseling, grinding, hammering, and metal working |
Dust, powder, fume, and mist | Scaling, light grinding, spot welding, and woodworking |
Gas, vapor, liquid, or metal splash | Babbitting, casting of hot metal, dripping in hot metal baths, and working with acids/caustics and vapors |
Electrical | Arcing and sparks |
Thermal and radiation | Welding, metal cutting, exposure to laser beams, and working with ultraviolet light and infrared radiation |
Eye discomfort and fatigue | Glare from the sun |
Requirements for eye protection devices
Because of workplace hazards, the Occupational Safety & Health Administration (OSHA) requires appropriate eye protection to be used to guard against injury in situations where it is reasonable to assume an injury could occur.
Eye protection devices must:
For workers who wear prescription lenses, the employer may offer eye protection that:
Protection for welders
Welders must wear safety glasses in addition to a face shield or helmet. This is because the shield or helmet protects the wearer from the welding glare, but not from sparks.
All filter lenses and plates must meet the test for transmission of radiant energy prescribed in ANSI Standard Z 87.1, “Practice for Occupational and Educational Eye and Face Protection.”
The desirable darkness of the lenses on welding helmets and safety goggles depends on work conditions. The intensity of light or radiant energy produced by welding, cutting, or brazing operations varies according to a number of factors, including:
Choosing appropriate lenses for employees who are exposed to intense radiant energy has two steps:
Minimum eye protection
Workers who walk through or work in areas where welding is being done aren’t exposed to the same level of hazards as the welders themselves, but their eyes still need protecting. OSHA’s preference is for welding to be secluded from other workers, rather than other workers to protect themselves from welding.
At 1910.252(b)(2)(iii), “Protection from arc welding rays,” OSHA says that “Where the work permits, the welder should be enclosed in an individual booth painted with a finish of low reflectivity such as zinc oxide (an important factor for absorbing ultraviolet radiations) and lamp black, or shall be enclosed with non-combustible screens similarly painted. Booths and screens shall permit circulation of air at floor level.”
However, the regulation continues, “Workers or other persons adjacent to the welding areas shall be protected from the rays by noncombustible or flame-proof screens or shields or shall be required to wear appropriate goggles."
Safe working practices
Wisely chosen work practices can minimize hazards and sometimes prevent them entirely. Practices that allow for eye protection include the following:
Eye injuries are a major concern around welding, cutting, and brazing operations, due to the variety of hazards related to this type of work. The following table lists potential eye hazards and their sources:
Type of hazard | Potential sources |
Impact | Operations that create flying objects or particles, such as caulking, chiseling, grinding, hammering, and metal working |
Dust, powder, fume, and mist | Scaling, light grinding, spot welding, and woodworking |
Gas, vapor, liquid, or metal splash | Babbitting, casting of hot metal, dripping in hot metal baths, and working with acids/caustics and vapors |
Electrical | Arcing and sparks |
Thermal and radiation | Welding, metal cutting, exposure to laser beams, and working with ultraviolet light and infrared radiation |
Eye discomfort and fatigue | Glare from the sun |
Requirements for eye protection devices
Because of workplace hazards, the Occupational Safety & Health Administration (OSHA) requires appropriate eye protection to be used to guard against injury in situations where it is reasonable to assume an injury could occur.
Eye protection devices must:
For workers who wear prescription lenses, the employer may offer eye protection that:
Protection for welders
Welders must wear safety glasses in addition to a face shield or helmet. This is because the shield or helmet protects the wearer from the welding glare, but not from sparks.
All filter lenses and plates must meet the test for transmission of radiant energy prescribed in ANSI Standard Z 87.1, “Practice for Occupational and Educational Eye and Face Protection.”
The desirable darkness of the lenses on welding helmets and safety goggles depends on work conditions. The intensity of light or radiant energy produced by welding, cutting, or brazing operations varies according to a number of factors, including:
Choosing appropriate lenses for employees who are exposed to intense radiant energy has two steps:
Minimum eye protection
Workers who walk through or work in areas where welding is being done aren’t exposed to the same level of hazards as the welders themselves, but their eyes still need protecting. OSHA’s preference is for welding to be secluded from other workers, rather than other workers to protect themselves from welding.
At 1910.252(b)(2)(iii), “Protection from arc welding rays,” OSHA says that “Where the work permits, the welder should be enclosed in an individual booth painted with a finish of low reflectivity such as zinc oxide (an important factor for absorbing ultraviolet radiations) and lamp black, or shall be enclosed with non-combustible screens similarly painted. Booths and screens shall permit circulation of air at floor level.”
However, the regulation continues, “Workers or other persons adjacent to the welding areas shall be protected from the rays by noncombustible or flame-proof screens or shields or shall be required to wear appropriate goggles."
Safe working practices
Wisely chosen work practices can minimize hazards and sometimes prevent them entirely. Practices that allow for eye protection include the following:
Working in confined spaces brings its own set of hazards, and performing hot work in these conditions compounds the danger. The two primary hazards of welding, cutting, or brazing in a confined space are flammable air and toxic air contaminants.
Flammable air
Fire and explosion are serious dangers in a confined space. Fumes and vapors will ignite more quickly in the trapped air. Flammable and combustible gases or vapors may be present from previous contents, tank coatings and preservatives, and welding gases.
In locations where flammable vapors may be present, precautions must be taken to prevent ignition by eliminating or controlling the source of ignition or eliminating the flammable air before working. Sources of ignition may include:
Toxic air contaminants
Toxic air contaminants come from:
Toxic gases and vapors present two types of risk to people in a confined space:
Unfortunately, many toxic gases and vapors on the job cannot be smelled or seen. This means that atmospheric testing and monitoring is very important.
Generally, if a space has a hazardous atmosphere, the hazard must be eliminated or reduced by:
If atmospheric hazards cannot be completely eliminated, workers must use appropriate respiratory protection and other personal protective equipment (PPE) as necessary.