Guidance Note
Metal welding safety
Practical advice for employers on controlling hazards
when welding.
June 2011
Background
How to use the table
Metal welding involves the application of heat to join two
metals together. The heat is generated through electric
currents (arc welding) or gases (gas welding).
The table over the page lists and shows examples of the
main hazards related to welding. It also includes the
possible consequences of the hazard and provides a list of
recommended controls. The zone numbers in the table refer
to what is shown in the picture below.
Welding is undertaken in many industries for purposes
including the manufacture of machinery, tools and
equipment and repair and maintenance work. Those most
at risk of welding-related injuries are operators producing
industrial or commercial machinery and fabricated metal
products.
Main hazards
The most common causes of injury from welding result
from:
• manual handling
• fire, explosions and radiation exposure
• electric shock.
Employers must provide a safe work environment for
workers by implementing adequate controls for all identified
workplace hazards.
1
4
5
2
3
6
Zone 1: Welding equipment
Zone 2: The welding process
Zone 3: Work pieces being welded
Zone 4: Welding with gases
Zone 5: The operator
Zone 6: Welding workspace
Note: This guidance note does not include information on
welding in confined spaces or under water.
GUI0145/01/04.11
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Guidance Note Metal welding safety
Hazard
Possible consequence
Recommended controls
Welding equipment can fail.
Failure of hoses and fittings
allows gas to escape resulting in
a fire or explosion.
• Regularly inspect and maintain welding equipment
(including the insulation).
Damaged electrical components
can result in electric shocks to
the operator.
• Store welding equipment where it cannot be
damaged (particularly for portable or mobile
oxy-fuel gas welding).
Welding leads and hoses are not
uncoiled before use.
High currents passing through
coiled leads can result in
damage from heat increasing
the risk of electric shock.
• Completely uncoil welding leads before use.
Worn or damaged electrical
leads, power points and
extension cords.
Electrical faults can cause
electric shock or, where they
interact with flammable
substances, burns.
• Use cables that are appropriate for the current
being carried.
Zone 1: Welding equipment
Welding equipment (body, hoses
and hand gun) is worn, damaged
or poorly maintained.
• Repair or discard damaged or worn parts (giving
consideration to decommissioning processes).
• Maintain leads, power points and extension cords in
good working condition.
• Ensure installation and servicing of electrical supply
circuits is done by a qualified electrician.
• Regularly inspect insulation on cords and remove
damaged cords from use.
The open circuit voltage is not
reduced to a safe level.
Operator receives an electric
shock.
• Ensure the open circuit voltage is within safe limits
and, where necessary, use voltage limiting devices
(VLDs).
Welding currents are not
grounded.
Operator receives an electric
shock.
• Ensure proper grounding methods have been
applied within the welding area and they are in
good working order.
Lack of familiarity with the gases
used or fumes produced during
welding processes.
Workers can become ill if
dangerous fumes are not
removed from the workplace.
• Ensure familiarity with materials being used (such
as gases, base metals, coatings and cleaners) and
their possible health impact. Where necessary,
engage a suitably qualified person such as an
industrial hygienist to assist.
Exposure to welding arc.
Operators can experience burns
to skin and eyes from radiation
(ultraviolet and infrared).
• Wear auto darkening helmets.
Zone 2: The welding process
• Carry out welding processes in booths or use
welding screens to protect nearby workers.
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Guidance Note Metal welding safety
Hazard
Possible consequence
Recommended controls
Fumes produced during welding
processes.
Workers can experience eye,
skin and respiratory system
irritation, nausea, headaches and
dizziness.
• Ensure fumes and gases are removed from the
breathing zone. Eg. Ventilation.
Dust and fumes can cause
serious lung diseases and
increase the risk of asthma and
cancer and possibly lead to
asphyxiation.
General ventilation
• When used by itself, ensure general ventilation
removes welding fumes from the breathing zone
(including on days with little wind).
Mechanical ventilation
• Ensure the speed of the systems is great enough
to draw fumes out of the breathing zone.
• Where the fumes are drawn downward, ensure
work pieces do not cover too much of the ducting
or the exhaust effect will be lost.
• Ensure mechanical ventilation removes fumes close
to the source. Flexible ducting allows the capture
device to be moved to the appropriate position
(see picture).
• Ensure that fumes drawn outside are not able
to re-enter the workplace.
• Ensure mechanical ventilation units are maintained
in good working order.
• Undertake health surveillance to monitor workplace
exposure to hazardous substances.
Zone 3: Work pieces being welded
Welding objects or plant that
contain/have contained (with
traces remaining) flammable or
explosive substances or gases.
Object being welded can
explode or create a fire resulting
in fatalities, burns or fractures to
operator or nearby workers.
• Ensure welding activity is not performed on objects
or plant in which a flammable substance has been
manufactured, used, handled or stored unless it is
completely free of the substance or gas.
If the contents of the object or plant are unknown, it
should be assumed that it contains flammable or
explosive substances.
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Guidance Note Metal welding safety
Hazard
Possible consequence
Recommended controls
Welding objects are coated in
unidentified paints or metal
coatings.
Dangerous fumes can be
generated when welding some
coatings. This can cause
respiratory distress, eye or skin
irritations, headaches or nausea.
• Identify coatings on work pieces before
commencing work and take actions to prevent
exposure to dangerous fumes (this will vary
depending on the coating).
Pieces of slag or molten metal
come away from work pieces
and make contact with leads
and hoses.
Operators can receive an electric
shock or an explosion can occur.
• Where possible, elevate cables, hoses and wires.
For example, suspend them on hangers or swing
arms.
Flames travel back down the
gas hoses (known as flashback).
Flashback can cause explosions
and fires, burning the operator.
• Ensure hoses are fitted with flashback arrestors
at both ends.
Movement of heavy gas
cylinders.
Regular movement or
replacement of gas cylinders
requires awkward postures and
high forces and may cause
muscle sprains and strains.
• Consider piping gases into the building near
workstations to eliminate the need for operators
to manually handle cylinders (see picture).
Zone 4: Welding with gases
• Use mechanical aids to move cylinders.
• Consider using gases that require less frequent
replacement. For example, LPG lasts longer
than acetylene.
Gases are stored with
incompatible chemicals or in
inappropriate locations.
Gases may explode injuring
operators and nearby workers.
• Store gases in accordance with their
classification and quantities (refer to the
Australian Dangerous Goods Code).
• Store gas cylinders in well ventilated areas and
protected from weather but not at the expense
of ventilation.
4
Guidance Note Metal welding safety
Hazard
Possible consequence
Recommended controls
Gas cylinders are not secured
in location.
If a cylinder falls over the valve
at the top can be knocked off
causing the cylinder to become
a dangerous projectile that can
strike and injure operators.
• Store gas cylinders in a safe location that is
protected from the immediate welding area.
• Secure cylinders using gas cylinder holders
or anchored chains to prevent tipping over
(see picture).
Workers can also inhale the
escaping gases which can
damage the respiratory system
or cause asphyxiation.
Zone 5: The operator
Operators are inexperienced
(eg apprentices, trainees and
young workers) or not trained
to perform welding safely.
Inexperienced or poorly trained
operators are more likely to
make mistakes increasing risk
of injury.
• Ensure operators demonstrate competency
and hold an appropriate certificate or have had
required training or experience.
Lack of or inappropriate
supervision.
Unsupervised operators are at
greater risk due to unsafe work
practices.
• Ensure operators are adequately supervised
by a certified welding supervisor.
Welding is performed on the
ground or requires awkward
positions.
Awkward postures can result in
muscular sprains and strains or
fatigue.
• Position work piece in the best working zone,
between the shoulders and knees (eg using
height adjustable benches or supports).
Low risk
Medium risk
High risk
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Guidance Note Metal welding safety
Hazard
Possible consequence
Recommended controls
Manual movement of heavy
materials and work pieces.
Operator can experience
muscular sprains and strains or
fatigue.
• Design the work environment so that excessive
physical effort is not required to move materials.
Eg use mechanical aids or adjustable rotator or
fixture (jigs) to align parts.
Electrodes or welding wire are
touched with bare hands when in
the holder or welding gun.
Operator will receive an electric
shock if these are touched with
bare skin.
• Ensure electrodes and welding wire in their
holder or the welding guns are never touched
with bare hands.
Holding welding gun under the
armpit.
Electric shock (sweating
increases conductivity).
• Never hold welding guns under the armpit.
Repetitive squeezing of welding
handles or triggers.
Operators can experience strains
from frequently performing the
same task.
• Automate the welding process or reorganise
work practices to eliminate exposure.
Lack of, inappropriate or
damaged personal protective
equipment (PPE) or respiratory
protective equipment (RPE)
worn by operator and nearby
workers.
Cracked or damaged helmets or
inappropriate filters can expose
operators to radiation causing
eye damage.
• Ensure operators are provided with and use task
appropriate PPE and RPE that is in good condition.
Synthetic clothing can easily
catch fire. Molten metal and
sparks can enter pockets and
cuffs or make contact with bare
hands resulting in burns.
• Store PPE close to workstations where it can’t be
damaged or contaminated.
Dust and fumes can cause
serious lung diseases increasing
the risk of asthma and lung
cancers.
• Ensure workers are trained on how to correctly use
their PPE and RPE.
• Ensure operators wear:
– task appropriate auto darkening helmets
– fire resistant protective clothing, such as raw
hide operators jacket, cotton heat vests and
long cuff welding gloves/gauntlets
– insulating gloves
– rubber soled boots designed for welding tasks
– securely fitting RPE where RPE is assessed as
necessary.
Zone 6: Welding workspace
Welding in a non-designated
area.
Open flames and sparks from
welding can ignite flammable
substances produced from work
nearby causing burns or
fractures to workers.
• Where possible, set up designated welding
areas.
• Ensure a competent and experienced person has
undertaken a hot work permit prior to
commencing welding processes.
Welding in an uncontrolled open
air environment.
Changes in weather can cause
an explosion if gases travel into
areas with an ignition source.
• Assess the environment where the welding is to
be done before work starts and if necessary
change the location.
• Make sure welding area and equipment is dry
before work starts.
• Never weld near incompatible substances
(including where they are stored).
Operators can receive an electric
shock if welding equipment
gets wet.
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Guidance Note Metal welding safety
Hazard
Possible consequence
Recommended controls
Welding near flammable
substances or materials. This
includes objects, machinery
or equipment that contain,
or has contained flammable
substances, or in areas
containing dusts, grains,
or paperwork.
Substances near the object
being welded can explode
or catch fire, or welding sparks
can ignite materials or dust in
the work area resulting in burns
or fractures.
• Never weld near flammable substances such
as those in objects, machinery or equipment
unless they are rendered free of the substance.
• Remove flammable or toxic materials from
the welding area before work is carried out.
• Inspect and clean work areas regularly.
Workspace is untidy. For
example, cables running across
the floor and waste not regularly
removed.
Workers can trip over objects
(cables, work materials) or slip
on spills.
• Organise the work areas to minimise the number
of cables and position them where they cannot
be stepped or tripped on. Eg suspend hoses off
the ground (see picture) or coil hoses when not
in use.
• Consider installing hoses and cables underground.
• Use boom-mounted wire feeders to eliminate
the lifting of feeders and cable cutter off ground
(see picture).
• Regularly clean work areas to reduce clutter
and prevent the build up of flammable materials
including dust.
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Guidance Note Metal welding safety
Hazard
Possible consequence
Recommended controls
Welding on wet or poorly
insulated floor.
Operator can receive an electric
shock.
• Where possible, work should be performed on
dry insulated surfaces such as wooden platforms
or insulating mats.
Excessive noise from welding
processes
Operator and nearby workers
can suffer hearing loss.
• Where possible, control noise at the source.
• Provide operators with appropriate hearing
protection for the level of noise exposure.
• Where necessary, undertake audiometric testing
of both the work area and operators and put
controls in place.
Lack of, or poorly maintained,
emergency management plan
and emergency equipment
(including lack of training on
how to use it).
Operators cannot effectively
respond in emergency situation
such as explosions or fire, and
will receive burns or fatal injuries.
• Ensure the workplace has fire safety equipment
such as alarm systems, fire extinguishers,
hydrants, hoses and fire blankets.
• Regularly inspect and test fire safety equipment
as per equipment requirements.
• Have an emergency plan in place.
• Ensure workers have been trained in emergency
procedures.
Further information and guidance
Contact the WorkSafe Victoria Advisory Service
on 1800 136 089 or go to worksafe.vic.gov.au
Related WorkSafe publications
• A guide to safety in the metal fabrication industry
• Metal Fabrication – Improving health and safety
through layout and design
• AS 1674.1 Safety in welding and allied processes.
Part 1: Fire precautions
• AS 1674.2 Safety in welding and allied processes.
Part 2: Electrical
• Australian Dangerous Goods Code
Note: This guidance material has been prepared using the best information
available to the Victorian WorkCover Authority, and should be used for
general use only. Any information about legislative obligations or
responsibilities included in this material is only applicable to the
circumstances described in the material. You should always check the
legislation referred to in this material and make your own judgement about
what action you may need to take to ensure you have complied with the law.
Accordingly, the Victorian WorkCover Authority cannot be held responsible
and extends no warranties as to the suitability of the information for your
specific circumstances; or actions taken by third parties as a result of
information contained in the guidance material.
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