Section 9: Hot Work – Grinding,
Welding, Soldering, and Brazing
OVERVIEW
This section contains the documents referenced in the Shop Safety Reference Manual –
Section 9 – Hot Work – Grinding, Welding, Soldering, and Brazing.
When using information in this section for training remember:
• Effective dissemination of safety information is an integral part of the Illness and
Injury Prevention Program.
• Training must be completed before the use of any tool or piece of equipment,
exposure to any hazardous conditions, and/or when new hazards are identified.
• The training must be documented using the training documentation form (see
Section 2).
• Be prepared to demonstrate the techniques, equipment and/or tools discussed in
the handout materials.
• Have copies of the training handouts to give to the trainees.
• Contact the EH&S Department if you need assistance finding supplemental
training materials.
This Section includes:
1. Tail Gate Meeting and Training Handout Materials:
a. Welding, Soldering and Brazing Code of Safe Practice
b. Welding, Soldering and Brazing – Hazards & Controls
c. Welding Eye Protection Code of Safe Practice
2.
3.
4.
5.
Hot Work Permit Form
Safety Sign Samples
Quiz
Quiz Answers
Shop Safety Managers Tool Kit
Section 9 – Hot Work – Grinding, Welding, Soldering, and Brazing
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1. TAIL GATE MEETING AND TRAINING
HANDOUT MATERIALS
Shop Safety Managers Tool Kit
Section 9 – Hot Work – Grinding, Welding, Soldering, and Brazing
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Welding, Soldering, and Brazing – Code of Safe
Practice
Welding is the most common method of joining metals.
Many times shop operations involve metal fabrication,
which requires metal welding and/or cutting. Soft
soldering, using an electric soldering iron, is another
common practice. Brazing is similar to soldering; however,
the temperatures used to melt the filler metal are higher.
Welding, soldering, and brazing present significant
hazards including exposure to hot materials, ultraviolet
light, gases, fumes, noise, and heat stress. Only trained
employees and students are authorized to operate
perform welding, soldering, or brazing work.
General Safety:
1. Protect all persons adjacent to the welding areas from
the infrared rays through the use of noncombustible or flameproof screens or shields.
2. Require appropriate safety goggles for all persons who may view the welding or cutting
operations.
3. Use all required personal protective equipment, such as leathers, gloves, welding helmets or
hoods, leather shoes, fire retardant overalls, and goggles in all welding and soldering
operations.
4. Maintain your personal protective equipment in good condition. Talk to your supervisor or
instructor if you have any questions about the requirements.
5. Inspect welding helmets, soldering goggles and hand shields for leaks, openings, or highly
reflective surfaces. Replace them as needed.
6. Conduct cutting, welding and soldering operations only in:
a. Areas that are, or have been made, fire safe.
b. Well-ventilated areas: use local exhaust ventilation, such as snorkel hoods or backdraft
slot hoods to control fugitive emissions.
7. Maintain suitable fire extinguishing equipment ready for use during welding and cutting
operations.
8. Maintain designated fire watches whenever cutting, welding, or soldering.
9. Never use creams or ointments on burns. Expose the burnt area to cold water for at least 15
minutes. Seek medical treatment for any large burns and/or if the burn is second degree
(blisters) or third degree (the skin is charred).
10. Ensure an emergency response fire blanket is available.
11. Discard welding rods, solder, and dross in accordance with the University’s Hazardous
Waste Disposal procedures. Contact the EH&S Department if you are unsure.
12. Do not store, prepare, or consume food and beverage in and around areas where cutting,
welding or soldering operations occur.
13. Always wash your hands with soap and water upon completion of welding, soldering or
brazing work, and before preparing or consuming food and beverages.
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Gas Welding:
1. Store and transport compressed gas cylinders in the upright position with the valve
protective caps on. Secure the cylinders in an upright position using two restraining devices
made of non-combustible material, such as metal straps or chains; place the restraining
devices within the top and bottom 1/3 of the tank. Never use ropes or canvas straps as
these will be destroyed in a fire.
2. Ensure cylinders in portable service are secured in an upright position.
3. Never store or place cylinders where they are exposed to heat, flame, impact, electric arcs
or circuits, high temperature process equipment, or sparks.
4. Tag empty cylinders with an “EMPTY” tag, and store them separately from full cylinders
with the valve cap in place.
5. Ignite torches using only friction lighters or other approved devices.
Arc Welding and Cutting:
1. Remove electrodes from the holders prior to leaving the area. Situate electrode holders so
as to prevent injury for unintentional contact.
2. Keep the power supply switch in the “off” position when arc operators stop work or leave the
area, as well as, when the welding machines are moved.
3. Never unplug a machine while it is in the “on” position.
4. Require all students, employees, and observers to cover their skin completely while
conducting or observing welding operations to prevent ultraviolet burns or damage.
5. Keep power cables and welding leads clear of walking and working areas to reduce the
potential of a trip and fall injury.
Soldering and Brazing:
1. Always wear appropriate protective eyewear. Soft soldering using an electric soldering iron
does not require tinted safety glasses or goggles; however, protective eyewear must be
worn as solder can spit and create an eye hazard from the molten metal. Brazing and torch
soldering require tinted safety goggles or helmets due to the higher temperatures and
potential exposure to ultraviolet light.
2. Use lead free solder to reduce the potential exposure to lead fumes, dust and debris.
3. Conduct soldering operations on a fire-proof or non-flammable surface to reduce the risk of
fire. Keep the work area clean and free of clutter and combustible materials.
4. Always use a secured soldering stand, and always place the soldering iron in the stand
when you put it down.
5. Never touch the tip or element of the soldering iron to check if it is hot.
6. Let the soldering iron fall if you drop it; NEVER try to catch it as it falls. Immediately, pick it
up by the handle and place it in the stand.
7. Allow the work piece to cool prior to touching it.
8. Always unplug the soldering iron prior to leaving the area and when the job is finished.
9. Never leave a hot soldering iron unattended.
Shop Safety Managers Tool Kit
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Welding, Soldering, Brazing – Hazards & Controls
Welding, soldering, and brazing activities present many hazards for the operator and for those
in the area of the welding, soldering, or brazing activities. These activities can also endanger
property if precautions are not taken. Knowing the hazards, understanding the hazard controls,
and implementing the controls will greatly reduce the risk of injury and property damage.
The Hazards
Air Contaminants:
Welding, soldering, and brazing operations
produce metal fumes, smoke particulates, and
toxic gases.
The adverse health effects of overexposure to
welding fumes and gases can range from
systemic poisoning to respiratory tract
irritations.
The Controls
Ventilation:
• The first line of defense is to remove the
metal fumes, smoke, and toxic gases from
the breathing zone of the operator through
the use of ventilation hoods and smoke
extraction equipment. These systems pull
the fumes, particulates, and toxic gases
away from the operator’s breathing zone
passing them through a filtering medium
before exhausting them.
Personal Protective Equipment:
• The second line of defense is the use of
respiratory protection. Employee use of
respiratory protection is regulated by the
University’s Respiratory Protection
Program.
Light and Radiation:
Fuel gas welding emits both bright visible light
and infrared (IR) radiation (heat), while arc
welding produces light, IR and ultraviolet
radiation.
The intense light and radiation produced by
welding and cutting operations can cause skin
and eye damage, including: burns, cancer,
cataracts, and retinal burns.
Personal Protective Equipment:
The first line of defense for the operator is the
use of personal protective equipment,
including:
• Eye Protection: Wear the appropriate level
of eye protection. The level of eye
protection required will depend on the
operation. Wee the eye protection chart
handout.
• Face and Head Protection: Use welding
helmets with the appropriate eye protection
level for all welding operations.
• Protective Clothing: Wear long sleeves,
gloves, long pants, safety shoes.
• Welding Curtains and Shields: Place
welding curtains and shields around the
work area to reduce the risk of injury to
persons walking into the shop or area
during welding operations.
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The Hazards
The Controls
Exposure to Electric Current:
Equipment:
Metal welding rods, the metals being joined or • Ensure the equipment is properly grounded
cut, and components of the welding equipment
and in good condition.
can easily conduct electric currents.
• Never place electrode holders or welding
guns under your armpits.
• Always remove the electrode from the
holder at the end of task and ensure the
welding equipment is turned off.
• Turn off the equipment when it is not in
active use.
Personal Protective Equipment:
• Wear welding gloves when handling
electrodes and welding equipment – never
use your bare hands.
• Wear dry clothes.
Positioning:
• Place plywood, rubber mats or other dry
non-conductive material between your body
and the ground.
• Never lean on the metal being worked.
• Never place your body between two welding
cables.
• Never coil the electrode lead around your
body.
Fire:
Shields:
The heat and sparks created by the welding • Place welding curtains and shields around
process present fire hazards.
the work area to contain hot and molten
metal debris.
Fire Extinguishers:
• Maintain fire extinguishers within the
welding shop/area.
• Inspect the fire extinguishers monthly to
ensure they are present and in good
operating conduction.
Fire Watch:
• Post a fire watch during and for 24-hours
after welding and cutting operations that
occur outside of a shop environment.
Housekeeping:
• Remove flammable and combustible
materials from the welding area prior to
beginning welding or cutting operations.
Shop Safety Managers Tool Kit
Section 9 – Hot Work – Grinding, Welding, Soldering, and Brazing
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Welding Eye Protection – Code of Safe Practice
The light and radiation given off during welding, cutting, soldering, and brazing operations can
result in eye injuries and cause permanent eye damage. The level of protection is dependent on
the operations and the intensity of the light and radiation emitted. Cal-OSHA (CCR. Title 8,
Section 3382) provides eye protection tables to help guide the selection of the appropriate level
of eye protection; that information is contained in the tables below reproduced from the
standard/
Filter Lens Shade Numbers for Protection Against Radiant Energy
Operation
Electrode Size
Diameter in Inches
Cal-OSHA Minimum
Protective Shade Number
Soldering
2
Torch Brazing
3 or 4
5/16, 3/8
10
12
14
1/16, 3/32,1/8, 5/32
11
1/16, 3/32,1/8, 5/32
12
1/16, 3/32, 1/8, 5/32
Shielded Metal–Arc Welding
Gas-Shield Arc Welding
(nonferrous)
Gas-Shield Arc Welding (ferrous)
3/16, 7/32, 1/4
Atomic Hydrogen Welding
10-14
Carbon-Arc Welding
Operation
Light Cutting
Medium Cutting
Heavy Cutting
Operation
Gas Welding – Light
Gas Welding – Medium
Gas Welding – Heavy
14
Description
Cal-OSHA Minimum
Protective Shade Number
Up to 1 inch
1 inch to 6 inches
Over 6 inches
3 or 4
4 or 5
5 or 6
Description
Cal-OSHA Minimum
Protective Shade Number
Up to 1/8 inch
1/8 inch to 1/2 inch
Over 1/2 inch
4 or 5
5 or 6
6 or 8
Shop Safety Managers Tool Kit
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2. HOT WORK PERMIT FORM
Shop Safety Managers Tool Kit
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HOT WORK PERMIT
FOR CUTTING AND WELDING WITH PORTABLE GAS OR ARC EQUIPMENT
SECTION 1
Date Issued: _____/______/______
Issued by: ________________________ Permit Expires: _____/______/______
Location of Work:
_____________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
Work to be Done:
_____________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
Type of Work:
[ ] Cutting
[ ] Welding
[ ] Grinding
[ ] Retrofit
[ ] New
Work Performed By:
[ ] In House People
[ ] Business Partner(s)
Cutter/Welder Name: _________________________________________ Certification?
[ ] Yes
[ ] No
[ ] N/A
Is fire watch required?
[ ] Yes
[ ] No
If yes, Name: ____________________________________
Is the fire watcher trained?
[ ] Yes
[ ] No
Is there overhead work?
[ ] Yes
[ ] No
Relocation of combustible materials?
[ ] Yes
[ ] No
Protective covering used?
[ ] Yes
[ ] No
Is there equipment to convey sparks? [ ] Yes
[ ] No
Type of fire extinguisher required.
[ ] Type A
[ ] Type B
[ ] Type C
[ ] Type ABC
Was training required?
[ ] Yes
[ ] No
If so, what type of training? ___________________________________________________________________________________________
Describe precautions required with any combustible materials:
[ ] Floors
[ ] Walls
[ ] Ceilings
[ ] Roof
[ ] Atmosphere
Explain:___________________________________________________________________________________________________________
_________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________
SECTION 2
ATTENTION
Before approving any cutting and welding permit, the fire safety supervisor or his/her appointee shall inspect the work area and confirm that
precautions have been taken to prevent fire in accordance with Hot Work Procedures, OSHA’s 1910.252 (a) and the National Fire Protection
Association’s standard 51B, Cutting & Welding Processes.
PRECAUTIONS
[ ] Sprinkler in service.
[ ] Cutting and welding equipment in good repair.
[ ] Dry floor during arc welding operations to prevent electrical shock.
[
[
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[
[
[
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WITHIN 35 FT. OF WORK AREA
Floors swept clean of combustibles.
Combustible floor wet down, covered with damp sand, metal or other shields (except during arc welding).
No combustible material or flammable liquids.
Combustible and flammable liquids protected with covers, guards or metal shields (assign fire watch).
All wall and floors opening covered.
Welding shields/covers suspended beneath elevated work to collect sparks.
WORK ON WALLS OR CEILINGS
[ ] Constructed non-combustible and without combustible covering (check for combustible sandwich-type construction).
[ ] Combustibles moved away from opposite wall.
WORK ON ENCLOSED EQUIPMENT
(Tanks, containers, piping, ducts, dust collectors, etc.)
[ ] Equipment cleaned of all combustible and flammable materials and residue.
[ ] Containers properly purged of flammable liquid and vapors.
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FIRE WATCH
To be provided during (including lunch and rest breaks) and 30 minutes after operation.
Fire watch patrol for 24-hours after welding/cutting operations.
Supplied with fire extinguishers and small water hose.
Trained in use of equipment and in sounding fire alarm.
The location where the work is to be done has been examined, all necessary precautions taken and permission is granted for this work.
Site Inspection Date/Time:___________________________
Issued By:____________________________________
Cutter/Welder/Grinder:______________________________
Fire Watcher:__________________________________
SECTION 3
FINAL CHECK-UP
Work area and all adjacent areas to which sparks and heat might have spread (including floors above and below and on opposite sides of walls)
were inspected 30 minutes after the work was completed and were found fire safe. All welding equipment must be shutdown, disconnected, and
properly secured (i.e. valves closed, bottles disconnected, electrodes removed, power disconnected).
Shop Safety Managers Tool Kit
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Final Check-up by:______________________________
THIS FORM WILL BE KEPT ON FILE FOR 365 DAYS AFTER ALL WORK IS COMPLETED
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3.SAFETY SIGNS
Print and post the safety signs located on the following pages to provide information, guidance
and warnings to personnel in shop areas. These signs can also be used during training
meetings.
Shop Safety Managers Tool Kit
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DANGER
WELDING
AREA
Shop Safety Managers Tool Kit
Section 9 – Hot Work – Grinding, Welding, Soldering, and Brazing
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DANGER
HOT WORK
PROHIBITED IN
THIS AREA
Shop Safety Managers Tool Kit
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DANGER
WEAR PROPER
EYE PROTECTION
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DANGER
DON’T WATCH
ARC WELDER
AT WORK
THE LIGHT MIGHT BLIND YOU
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CAUTION
PROPER HOT WORK
PROCEDURES
MUST BE FOLLOWED
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CAUTION
HOT WORK PERMIT
REQUIRED
IN THIS AREA
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DANGER
WELDING
GOGGLES
MUST BE WORN
WHEN WELDING
LOOKING AT THE ARC
WITHOUT EYE
PROTECTION
MAY CAUSE
BLINDNESS
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WELDING IN
PROGRESS
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4. QUIZ
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Quiz – Hot Work –
Grinding, Welding, Brazing, and Soldering
Print Trainee Name___________________________ Date _____________________
Trainee Signature _______________________ Supervisor Signature ______________
1. Which of the following are dangerous light rays produced when welding?
a. Infrared
b. Gas
c. Ultraviolet
d. a and c
2. All fumes should be drawn away by a smoke extraction system before they can be
breathed in by the welder.
True or False
3. Which of the following are unsafe practice(s) while arc welding?
a. Welding on a damp floor
b. Welding around paper, rags, paint, and gasses
c. Welding around unprotected bystanders
d. Welding on a container that has not been properly cleaned
e. All of the above
4. It is possible to receive a burn similar to sunburn while arc welding, and PPE must be
worn by the person doing the hot work to protect themselves.
True or False
5. Hot metal sparks can fly around while grinding or welding and could cause fire or injure
someone, and protective screens must be set up to prevent this.
True or False
6. I don’t need to have a signed “Hot Work Permit” if I’m doing hot work outdoors.
True or False
7. A Hot Work Permit must be signed by “Qualified Persons” such as?
a. Building Manager
b. Shop Manager
c. Your Supervisor
d. A fellow student
e. a, b and c above
(See last question on next page.)
Shop Safety Managers Tool Kit
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8. I don’t need to have a signed “Hot Work Permit” if I’m doing hot work in a location that is
designed to have hot work routinely conducted in it with proper ventilation and all
combustibles / flammables removed within 35 feet.
True or False
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5. QUIZ ANSWERS
Shop Safety Managers Tool Kit
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Quiz – Hot Work –
Grinding, Welding, Brazing, and Soldering - ANSWERS
1.
2.
3.
4.
5.
6.
d
True
e
True
True
False – Outdoor work where hot work will be conducted must be cleared of
combustible materials and the same rigor of the “Hot Work Permit” process applied to
the outdoor location as you would apply it to an indoor location.
7. e
8. True – But you must be qualified and authorized by the Supervisor / Shop Manager of
the hot work location before you can use the location to conduct your hot work
activities.
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