Welding operations involve several hazards, including exposure to welding fumes and gases, UV radiation, burns, eye damage, electrical shock, cuts, and the risk of fires and explosions. A job hazard analysis conducted by qualified personnel is essential to determine the necessary safeguards and PPE for each welding task. [1] [3]

Risk control involves elimination and substitution (e.g., using lower fume-generating welding processes), engineering controls (e.g., local exhaust ventilation), work practices (e.g., removing coatings before welding and worker training), and PPE (e.g., respiratory protection). [1]

Appropriate protective clothing for welding operations varies with the work's size, nature, and location and should comply with relevant safety standards. [2]

General requirements include:

• Wearing flameproof gauntlet gloves, except when engaged in light work.
• Using flameproof aprons made of leather, asbestos, or other suitable material for protection against radiated heat and sparks.
• Preferably wearing woolen clothing over cotton, or chemically treating cotton clothing to reduce combustibility; outer clothing should be free from oil or grease.
• Keeping sleeves and collars buttoned, removing pockets from the front of overalls and aprons, and avoiding turned-up trousers or overalls to prevent sparks from lodging in clothing.
• Using fire-resistant leggings, high boots, or other equivalent means for heavy work.
• Using a sheet metal screen for leg protection in production work.
• Wearing capes or shoulder covers made of leather or other suitable materials.
• Using leather skull caps under helmets to prevent head burns during overhead welding or cutting.
• Using ear protection for overhead welding/cutting or in confined spaces.
• Using hard hats or head protectors where there is a risk of sharp or heavy falling objects or bumping in confined spaces.

Eye protection is critical. Use helmets or hand shields during all arc welding or arc cutting operations (except submerged arc welding). Goggles should also be worn for protection from adjacent work and flying objects. Helpers and attendants require proper eye protection. For gas welding or oxygen cutting, use goggles or other suitable eye protection. Transparent face shields or goggles are necessary for resistance welding or brazing. Select filter lenses meeting ANSI Z 87.1-1968 standards for radiant energy transmission. [2] [5] [5] [5]

For confined spaces, ventilation is essential. Gas cylinders and welding machines should remain outside the space, and heavy portable equipment must be securely blocked to prevent movement. Where entering through small openings, provide a means for quick removal in emergencies, such as safety belts and lifelines, with an attendant stationed outside. Remove electrodes from holders when arc welding is suspended and shut off gas supply when the torch is not in use. [4] [4] [4] [4] [4]