A Metalworker's Guide to Safe Welding, Cutting and Brazing

A professional welder in heavy protective gloves and helmet works with metal, causing bright sparks during the welding process.

Welding, cutting and brazing are the backbone of metalworking, integral to construction, shipbuilding, manufacturing and maintenance. However, these so-called "hot work" operations also present serious safety risks, including fire hazards, toxic fumes and physical injury. Whether these tasks are performed on a high-rise construction site, in a shipyard or in a small machine shop, safety depends on understanding the risks and following established safety standards.

Definitions

Arc Cutting: A process that uses an electric arc to cut metals by melting and blowing away the material
Brazing: A metal-joining process using a filler metal with a melting point above 840°F but below that of the base metals
Cutting: Separating metal using heat from flames or electric arcs
Fire Watch: A trained worker assigned to watch for fires during and after hot work operations
Gas Welding: Fusing metals using a gas flame, typically fueled by oxygen and acetylene
Hot Work: Any job involving open flames, heat or sparks, including welding and brazing.
Hot Work Permit: An authorization form confirming that fire safety procedures are in place
Oxygen-Fuel Cutting: Metal cutting using preheated metal and concentrated oxygen
Shielded Metal Arc Welding (SMAW): A manual arc welding process using a consumable electrode covered with flux
Welder: A qualified individual who operates welding or cutting equipment
Welding: Joining metal parts by melting the base material

Welding Hazards

Welding and cutting introduce both physical and chemical hazards. Burns, electric shock, UV radiation and mechanical injuries are common physical risks. And chemically, workers are often exposed to fumes and gases containing chromium, nickel, manganese and zinc that can cause acute and chronic respiratory issues. Adequate ventilation and fume extraction systems are critical to reduce exposure and keep workers safe.

Electric Welding and Cutting

Electric arc methods such as SMAW, MIG and TIG offer precision but create intense heat, bright light and hazardous vapors. To keep yourself safe while doing this work:

Shield nearby workers with welding curtains.
Wear proper eye protection.
Maintain ventilation systems to capture and filter airborne contaminants.
Follow all OSHA standards and NFPA 70E training in electrical safety protocols.

Gas Welding and Cutting

Gas welding and oxygen-fuel cutting use flammable gases that can leak or flash back. Whenever you use these processes:

Test your equipment for leaks before use.
Store gas cylinders upright and securely.
Inspect hoses for cracks or contamination.
Purge lines before lighting.
Use flashback arrestors and check valves.
Keep cylinders away from high-traffic spaces and heat sources.

Welding Operator Protection

Welders must always keep their workspace free of combustible materials and follow the NFPA 51B hot work safety standard. Supervisors also need to do their part to keep welders safe, including making sure that:

Ventilation systems are operational.
PPE is available and in good condition.
Fire extinguishers are nearby and accessible.
Workers are trained in emergency procedures.

Personal Protective Equipment

Proper PPE is critical, and it's also an OSHA requirement under 29 CFR 1910 Subpart I. Required items include:

ANSI-approved welding helmets with filter lenses
Flame-resistant gloves and clothing (cotton or treated wool preferred)
Steel-toed safety boots
Respirators when working with hazardous materials like cadmium or hexavalent chromium.

All PPE must be regularly inspected and replaced as needed.

Hot Work Areas

Hot work should only occur in designated safe zones or areas authorized with a hot work permit. These spaces must:

Be free of flammable materials or have them shielded
Have adequate ventilation systems
Display signs warning others of hot work in progress
Have fire suppression equipment

Fire Watch

Fire watch duties are critical for safety. Under OSHA regulations, a fire watch is required if:

Flammable materials are within 35 feet
Combustibles cannot be moved
Wall or floor openings could expose other areas to sparks

Fire watches must remain on-site for at least 30 minutes after work ends and be trained to operate extinguishers and sound alarms.

Equipment Inspection and Handling

To prevent mechanical failures or leaks:

Inspect all gas hoses, electrodes and electrical cords for damage before use.
Verify that regulators, torches and valves are functioning and leak-free.
Store gas cylinders upright and away from heat.
Use only manufacturer-recommended replacement parts.