welding

Generated on: June 5, 2025

Safe Work Procedure: Welding

Document Number: [SWP-NUMBER] Revision Date: [DATE] Next Review Date: [NEXT REVIEW DATE] Department: [DEPARTMENT NAME]

1. Scope

This Safe Work Procedure (SWP) outlines the necessary safety precautions and procedures to be followed when performing welding operations. It applies to all employees, contractors, and visitors who are involved in or present during welding activities. This procedure covers various types of welding, including arc welding, gas welding, and other allied processes [1]. It includes guidelines for fire prevention, personal protective equipment (PPE), equipment inspection, and emergency response.

This SWP applies to all work environments where welding activities are conducted, including but not limited to construction sites [2], maintenance shops [3], and confined spaces [4]. It is applicable to both indoor and outdoor welding operations.

This SWP should be used in conjunction with other relevant safety procedures and guidelines, including the manufacturer's instructions for welding equipment and any site-specific safety requirements.

2. Definitions

Welding or Allied Process: Any specific type of electric or oxy fuel gas welding or cutting process including arc welding, brazing, solid-state welding, soldering, resistance welding, arc cutting, oxygen cutting, thermal spraying, thermal adhesive bonding and other cutting [1].

Competent Person: A person who is qualified because of knowledge, training and experience to organize the work and workplace to perform the work safely [1].

Confined Space: A relatively small or restricted space such as a tank, boiler, pressure vessel, or small compartment of a ship [4].

3. Responsibilities

3.1 Supervisors

Ensure that all workers are properly trained and competent to perform welding tasks [5].
Provide workers with the necessary personal protective equipment (PPE) and ensure that it is used correctly [6].
Conduct regular inspections of welding equipment and work areas to identify and correct hazards [6].
Ensure that fire prevention measures are in place, including the availability of fire extinguishers and fire watches when required [3].
Secure authorization for cutting or welding operations from the designated management representative [3].

3.2 Workers

Participate in required training and demonstrate competency in welding procedures [5].
Inspect welding equipment and PPE before each use and report any defects to the supervisor [6].
Use the correct PPE for the welding task being performed [6].
Follow all safety procedures and instructions provided by the supervisor [5].
Report any hazards or incidents to the supervisor immediately [5].
Ensure that adequate precautions have been taken to remove all hazardous material or processes that produce combustible, flammable or explosive material, dust, gas or vapour; and to prevent fire or explosion [1].

3.3 Health and Safety Representative

Assist in the development and implementation of welding safety procedures [5].
Conduct workplace inspections to identify potential welding hazards [5].
Investigate incidents and recommend corrective actions [5].
Promote a culture of safety and awareness regarding welding hazards [5].

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Electric Shock	Electrocution, burns	Ensure welding equipment is properly grounded [7]. Use equipment with low open circuit voltage [8]. Avoid welding in wet conditions [8].
Fire and Explosion	Burns, property damage	Remove or protect combustible materials from the welding area [5]. Maintain fire extinguishing equipment [9]. Ensure proper ventilation to prevent the accumulation of flammable gases [10].
Exposure to Fumes and Gases	Respiratory irritation, long-term health effects	Use local exhaust ventilation to remove fumes and gases from the breathing zone [10]. Provide respiratory protection when ventilation is inadequate [10].
Eye Injuries	Burns, vision loss	Use appropriate welding helmets or hand shields with filter lenses [11]. Ensure that helpers and other personnel in the area also wear eye protection [11].
Burns	Skin damage	Wear appropriate protective clothing, including flameproof gloves, aprons, and sleeves [12].
Confined Spaces	Asphyxiation, toxic exposure, fire/explosion	Ensure adequate ventilation [4]. Station an attendant outside the confined space [4]. Use appropriate respiratory protection [10].
Hot Surfaces and Materials	Burns	After welding operations are completed, the welder must mark the hot metal or provide some other means of warning other workers [4].
Falling Tools or Parts	Injury to personnel, damage to equipment	Retrieve any tools that fall immediately [13]. Always secure tools or parts that are near the machine and store tools properly after maintenance is complete [13].

5. Personal Protective Equipment (PPE)

It is essential to use the proper PPE to protect against the hazards associated with welding operations [12].

Welding Helmet or Hand Shield - Protects the face and eyes from arc radiation, heat, and sparks. Select the appropriate filter lens shade for the welding process being used [11].
Safety Glasses or Goggles - Provides additional eye protection from flying debris and arc flash, especially when lifting the welding helmet or performing non-welding tasks in the area [11].
Flame-Resistant Clothing - Protects the skin from burns caused by sparks, heat, and UV radiation. This includes a jacket, trousers, and sleeves made of leather or flame-retardant material [12].
Gauntlet Gloves - Protects hands and wrists from heat, sparks, and cuts. Gauntlet gloves should be made of leather or other flame-resistant material [12].
Leather Boots - Protects feet from falling objects, sparks, and burns. High-top leather boots are recommended [12].

Inspect all PPE before each use for damage or wear. Replace damaged PPE immediately. Clean and maintain PPE according to the manufacturer's instructions.

6. Equipment and Tools

It is essential to use the proper equipment and tools for welding operations and to maintain them in good working condition [6].

Welding Machine - Provides the electrical current necessary for welding. Ensure the machine is properly grounded and in good working order [7].
Welding Electrodes or Wire - Consumable materials used to create the weld. Select the appropriate type and size of electrode or wire for the welding process and material being used [7].
Electrode Holder or Welding Gun - Holds the electrode or wire and allows the welder to control the arc. Ensure the holder or gun is properly insulated and in good working order [7].
Ground Clamp - Connects the welding machine to the workpiece, completing the electrical circuit. Ensure the clamp is securely attached to a clean, bare metal surface [7].
Welding Cables - Carries the electrical current from the welding machine to the electrode holder and ground clamp. Inspect cables for damage or wear before each use [7].

Inspect all equipment and tools before each use for damage or wear. Replace damaged equipment immediately. Maintain equipment according to the manufacturer's instructions.

7. Pre-Job Requirements

7.1 Training and Competency

All welders must be trained and certified in the specific welding processes they will be using [5].
Training must include hazard awareness, safe work practices, and emergency procedures [5].
Welders must demonstrate competency in welding techniques and the use of PPE [5].

7.2 Pre-Job Briefing

Conduct a pre-job briefing with all workers involved in the welding operation [5].
Review the scope of work, potential hazards, and control measures [5].
Discuss the safe work procedure and ensure that all workers understand their roles and responsibilities [5].
Identify emergency contact information and evacuation routes [5].

7.3 Work Area Preparation

Inspect the work area for potential fire hazards, such as combustible materials, flammable liquids, and explosive atmospheres [3].
Remove or protect combustible materials from the welding area [5].
Ensure that adequate ventilation is provided to remove fumes and gases [10].
Erect noncombustible screens or shields to protect other workers from arc rays and sparks [6].
Place welding cable and other equipment so that is clear of passageways, ladders, and stairways [11].

8. Safe Work Procedure Steps

Step 1: Equipment Inspection and Setup

Detailed description of step 1: Before starting any welding work, inspect all equipment to ensure it is in safe working condition.

Sub-step 1.1: Check welding machine for any damage to cables, connections, and insulation [7].
Sub-step 1.2: Verify that the welding machine is properly grounded [7].
Sub-step 1.3: Ensure that the correct welding rod or wire is selected for the job [7].

Safety considerations for this step: Damaged or improperly grounded equipment can cause electric shock or fire [7].

Step 2: Work Area Preparation

Detailed description of step 2: Prepare the work area to minimize fire hazards and protect other workers.

Sub-step 2.1: Clear the area of any combustible materials within 35 feet of the welding site [5].
Sub-step 2.2: Use fire-resistant shields or guards to protect combustible walls, partitions, ceilings, or roofs [5].
Sub-step 2.3: Ensure adequate ventilation to remove fumes and gases [10].

Safety considerations for this step: Combustible materials can easily ignite from welding sparks, and inadequate ventilation can lead to exposure to harmful fumes [5].

Step 3: Welding Operation

Detailed description of step 3: Perform the welding operation following safe work practices.

Sub-step 3.1: Wear appropriate PPE, including a welding helmet, gloves, and flame-resistant clothing [12].
Sub-step 3.2: Maintain a safe distance from the welding arc to avoid exposure to harmful radiation [11].
Sub-step 3.3: Use proper welding techniques to ensure a strong and safe weld [14].

Safety considerations for this step: Failure to use proper PPE can result in burns, eye injuries, and exposure to harmful radiation [12].

9. Precautions and Safety Measures

Fire Prevention: Ensure that cutting and welding are so scheduled that plant operations that might expose combustibles to ignition are not started during cutting or welding [3].
Ventilation: Use adequate ventilation to prevent the accumulation of toxic materials or possible oxygen deficiency [10].
Eye Protection: Use helmets or hand shields during all arc welding or arc cutting operations [11].
Protective Clothing: Wear appropriate protective clothing required for any welding operation which will vary with the size, nature and location of the work to be performed [12].
Confined Spaces: When welding or cutting is being performed in any confined spaces you must leave the gas cylinders and welding machines on the outside [4].

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency, immediately stop work and assess the situation. Evacuate the area if necessary and follow the established emergency response plan.

10.2 Specific Emergency Scenarios

Fire: Activate the fire alarm and evacuate the area. Use a fire extinguisher to put out the fire if it is small and contained. If the fire is large or spreading rapidly, call the fire department [9].
Electric Shock: Turn off the power to the welding machine. If the person is still in contact with the electrical source, use a non-conductive object to separate them from the source. Call for medical assistance [7].
Exposure to Fumes or Gases: Move the affected person to fresh air. If breathing is difficult, administer oxygen. Call for medical assistance [10].

10.3 Emergency Contact Information

Emergency Services: 911
[Company Safety Officer]: [PHONE NUMBER]
[Project Manager]: [PHONE NUMBER]

11. Incident Reporting and Investigation

All incidents, near-misses, and hazards must be reported to the supervisor immediately. An investigation will be conducted to determine the root cause of the incident and to implement corrective actions to prevent recurrence.

12. References and Related Documents

Safety Standards for General Safety and Health Standards (Chapter 296-24 WAC)
Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)
Rules for the Administration of the Oregon Safe Employment Act (Construction, Division 3, OSHA Oregon)
CSA standard CSA W117.2, 'Safety in Welding, Cutting, and Allied Processes'

Approved by: [NAME AND POSITION] Date: [APPROVAL DATE]

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