Issues
The Occupational Safety and Health Administration (OSHA) reports that welding, cutting, and brazing are among the most hazardous activities in the workplace, with potential risks including fires, explosions, burns, eye damage, and exposure to toxic fumes.
Each year, there are an estimated 4,000 non-fatal welding injuries and more than 100 fatal welding accidents. The most common welding injuries are burns, eye injuries, and physical injuries caused by tank ruptures or projectile cylinders. Therefore, implementing comprehensive safety measures is not only a legal requirement but also essential for your safety and the well-being of your fellow employees. Remember, your family counts on you to be healthy and present.
Key Hazards
- Fire and explosions are a major concern. Sparks, heat, and molten metal can easily ignite nearby combustible materials, and gas leaks may lead to dangerous explosions. While oxygen itself is not flammable, it intensifies combustion, causing materials to burn more rapidly and severely.
- Burns are another common hazard. The flame produced by a cutting torch is extremely hot, and contact with the flame or hot metal can result in severe skin burns.
- Toxic fumes and gases are generated during the cutting and welding process. Inhaling these airborne contaminants can lead to respiratory irritation or more serious health effects, especially in enclosed or poorly ventilated spaces.
- Cylinder risks should not be overlooked. Gas cylinders are under high pressure and can rupture or become projectiles if damaged, dropped, or improperly handled.
- Eye injuries are a risk due to the bright flame, flying debris, and sparks. Without proper eye protection, workers are vulnerable to burns, irritation, and long-term vision damage.
- Backfire can be caused by operating the torch at lower pressures than required, touching the tip against the workpiece, overheating the tip, or an obstruction in the tip.
- A flashback may be caused by a clogged tip, valves that are not functioning correctly, or incorrect gas pressure.
- Lack of equipment inspections before each use and throughout the workday.
- Improper storage of equipment not in use or extra cylinders.
- Lack of comprehensive training programs. Training should cover all aspects of cutting and welding safety, including theoretical knowledge, practical skills, hazard identification, and hazard mitigation techniques.
- Cutting or welding in confined spaces poses critical risks, including asphyxiation from oxygen displacement, toxic fume accumulation, fire, and explosions.
Summary
- Before using a welding or cutting torch, inspect all equipment and ensure a safe setup. Do not use damaged, defective, or improperly adjusted equipment.
- Make sure levers and valves operate properly, threads are clean (free of grease or oil) and not damaged, gauges are intact and easy to read, regulators are clean and free of oil or dirt, and fittings are properly sized for the cylinder.
- Make sure hoses are clean (free of grease or oil), ferrules are properly installed so fittings cannot slip inside the hose, and all connections are tight.
Control Measures
1. Personal Protective Equipment (PPE)
Personal protective equipment (PPE) is essential when using a cutting torch to protect against burns, sparks, and flying debris. Clothing and gear should be free of grease, oil, solvents, and other flammable substances. Wear dry, heavy-duty welding gloves, leather leggings, sturdy work boots, and flame-resistant clothing. Avoid cuffs and open pockets that can catch sparks.
Depending on the work environment, additional PPE may include a respirator, fire-resistant hearing protection, and a head covering to protect the head and neck.
2. Ventilation and Air Quality Control
When working indoors, ventilate the area and/or use local exhaust ventilation at the flame. If ventilation is inadequate, workers performing cutting operations should wear an approved supplied-air respirator.
3. Fire Safety
Maintain a 35-foot clear area around hot work, use fire-resistant shields and curtains, assign a trained fire watch, and ensure fire extinguishers are readily available and accessible.
4. Equipment Safety
Inspect welding and cutting equipment regularly for damage, leaks, faulty gauges, and damaged hoses. Use flashback arrestors on gas lines and ensure proper grounding of electric welding machines.
5. Work Area Preparation and Housekeeping
Keep floors and work areas free of combustible materials, cover openings to prevent sparks from passing through, cordon off work areas, and maintain clear walkways to minimize slips and falls.
6. Training and Certification
Ensure all personnel performing welding or cutting are trained, authorized, and familiar with SOPs and safety procedures. Workers should understand the proper use of equipment, PPE, hot work permits, and risk assessment procedures.
Regulations
OSHA 29 CFR 1926 Subpart J – Welding and Cutting
- 1926.351 – Arc welding and cutting
- 1926.352 – Fire prevention
- 1926.353 – Ventilation and protection in welding, cutting, and heating
- 1926.354 – Welding, cutting, and heating in way of preservative coatings
OSHA Standard 1926.350(g)(2)
Torches in use shall be inspected at the beginning of each work shift for leaking shutoff valves, hose couplings, and tip connections. Defective torches shall not be used.
OSHA Standard 1926.352(e)
When normal fire prevention precautions are not sufficient, additional personnel shall be assigned as fire watches during welding, cutting, or heating operations and remain after completion of the work until there is no possibility of fire. Fire watch personnel shall be instructed on anticipated fire hazards and the proper use of firefighting equipment.
OSHA Standard 1926.352(f)
When welding, cutting, or heating is performed on walls, floors, or ceilings, precautions shall also be taken on the opposite side to protect against fire hazards caused by heat transfer or sparks.
OSHA Standard 1926.351(e) – Shielding
Whenever practicable, all arc welding and cutting operations shall be shielded by noncombustible or flame-resistant screens to protect employees and others from direct exposure to arc rays.
Example Incidents
- KGNS-TV 8 — December 25, 2024: Construction workers trapped inside a burning building broadcast a desperate plea for help.
- WTVM — May 19, 2023: The Charlotte Fire Chief confirmed that two people died in a massive construction site fire in SouthPark.
What You Need to Know
- Wear appropriate PPE, including welding helmets, safety glasses, flame-resistant clothing, gloves, and steel-toe boots. Ensure PPE fits properly and is in good condition.
- Inspect welding equipment before every job. Report damage, leaks, or malfunctions and do not use defective equipment.
- Prepare the work area by removing flammable materials and clutter. Ensure fire extinguishers and other emergency equipment are readily available.
- Follow established safe work practices, including proper material handling, gas cylinder storage, and lifting techniques.
- Never weld or cut on containers that previously held flammable substances. Residual materials can react and cause explosions or toxic fumes.
- Work in a well-ventilated area. If working in confined spaces, provide adequate ventilation or use appropriate respiratory protection.
- Handle and store gas cylinders carefully. Secure cylinders and protect them from heat, flames, and physical damage. Follow storage requirements for each gas type.
- Know emergency procedures, including evacuation plans, first aid measures, and emergency response procedures.
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Confined space work requires continuous or pre-entry atmospheric testing, forced mechanical ventilation (2,000 CFM per welder), and independent respiratory protection.
a. Emergency Plan: Maintain a documented rescue plan and a trained standby person.
b. Equipment Check: Inspect welding leads and gas hoses for leaks before use.
c. Safe Access: Use specialized equipment, such as fume extractors and compact welding equipment, to improve access and safety.
Important Do’s to Keep in Mind About Welding and Cutting
- Do wear dry, hole-free gloves and inspect them frequently for signs of wear or pinholes.
- Do always refer to the manufacturer’s user manual for assembly, leak testing, operation, shutdown, and maintenance procedures.
- Do regularly inspect welding equipment for wear, damage, or defects in cylinders, gauges, and hoses that could lead to explosions or fires.
- Do ensure the work area is well ventilated.
- Do use fume extraction systems and respiratory protection when required.
- Do remove flammable materials from the work area and utilize fire extinguishers, protective clothing, and fire watches.
- Do use eye and skin protection specifically rated for welding and cutting.
- Do maintain a clean work area and use the correct tool for the task.
- Do wear appropriate PPE, including safety gloves, steel-toe boots, hard hats, and safety glasses.
- Do use only accessories specifically recommended by the manufacturer for your model of welding or cutting torch.
- Do inspect the work area after cutting or welding is complete to ensure it is free of sparks, glowing embers, and flames.
Important Don’ts to Keep in Mind About Welding and Cutting
- Don’t use welding or cutting equipment with damaged hoses.
- Don’t use a cutting torch near degreasing, cleaning, or spraying operations. Heat from the torch can react with vapors to produce highly toxic and irritating gases.
- Don’t cut on sealed air conditioning or refrigeration systems unless all refrigerants have been removed.
- Don’t use cutting equipment with gases or pressures other than those for which it was designed.
- Don’t use a cutting torch if grease or oil is present on the equipment or if the equipment is damaged.
- Don’t forget that flammable gases used in welding, such as acetylene or propane, must be stored safely in accordance with applicable regulations.
- Don’t use matches, lighters, or other hot work to ignite a cutting torch.
- Don’t use a cutting torch where flying sparks can reach flammable materials.
- Don’t use a cutting torch where the atmosphere may contain flammable dust, gases, or vapors.
- Don’t cut on containers that have held combustible materials or on closed containers such as tanks or drums
