A comprehensive risk assessment for welding PPE should consider several key factors. Hazards associated with welding include exposure to intense light radiation, sparks, hot materials, fumes, and potential electrical hazards 1, 2, 3. The risk level depends on the specific welding task, environment, and materials used 1, 3.

To mitigate these risks, the following PPE is recommended:

• Eye and Face Protection: Helmets or hand shields with appropriate filter lenses are essential during arc welding or cutting to protect against radiant energy 2, 3, 9. Goggles should also be worn for additional protection from flying objects and rays from adjacent work [1]. For gas welding or oxygen cutting, use goggles or spectacles with suitable filter lenses [1]. All filter lenses and plates must meet the test for transmission of radiant energy prescribed in ANSI Z 87.1-1968 [2] or the updated standards like ANSI Z87.1-2003 [3] or CSA Standard Z94.3-15 5, 20.
• Body Protection: Wear flameproof gauntlet gloves and flameproof aprons made of leather, asbestos, or other suitable material to protect against radiated heat and sparks [2]. Woolen clothing is preferable to cotton, but if cotton is used, it should be chemically treated to reduce combustibility [2]. Sleeves and collars should be buttoned, and pockets eliminated from the front of overalls and aprons to prevent sparks from lodging [2]. For heavy work, use fire-resistant leggings, high boots, or other equivalent means [2]. If a worker may be exposed to a flash fire or electrical equipment flashover, ensure the worker wears personal protective equipment that includes flame resistant outerwear [3].
• Respiratory Protection: Welding in confined spaces requires adequate ventilation to prevent the accumulation of toxic materials or oxygen deficiency 4, 6. Use airline respirators or hose masks approved by NIOSH when ventilation is insufficient [4]. In areas immediately hazardous to life, use a full-facepiece, pressure-demand, self-contained breathing apparatus [4]. When welding or cutting involving fluxes, coverings, or other materials which contain fluorine compounds, perform the work in accordance with ventilation requirements 7, 12.
• Head Protection: Leather skull caps may be worn under helmets to prevent head burns during overhead welding or cutting operations [5]. Where there is exposure to sharp or heavy falling objects, or a hazard of bumping in confined spaces, hard hats or head protectors must be used [5].
• Foot Protection: Ensure that a worker uses footwear that is appropriate to the hazards associated with the work being performed and the work site [3].

In addition to PPE, engineering controls like individual booths painted with low-reflectivity finish or noncombustible screens can protect adjacent workers from arc welding rays 1, 3. Administrative controls include ensuring a fire watch is maintained for at least 1/2 hour after welding to detect and extinguish possible smoldering fires [6]. Regularly inspect and maintain all PPE to ensure it is in good working condition [7]. Provide training on the correct use, care, and limitations of PPE [7].

Regularly monitor the work area for hazards and review the risk assessment to ensure it remains effective. Consider air sampling to ensure that exposures to hazardous fumes are below allowable limits [8].