Brazing and Soldering

Brazing and soldering join metals using a filler material that melts at a lower temperature than the base metal.
Brazing uses temperatures above 450°C; soldering uses temperatures below 450°C with tin-lead or lead-free alloys.
Both processes use open flames or heated elements that create fire risk and burn injuries.
Flux fumes from brazing and soldering irritate the respiratory tract and can cause occupational asthma.
Lead-based solder releases toxic lead fume; lead-free alternatives should be used wherever possible.
Cadmium-containing brazing alloys produce extremely toxic fume that can be fatal in enclosed spaces.
A hot works permit is required for brazing and soldering wherever there is a fire risk.
LPG and oxy-propane torches used for brazing require safe cylinder storage and handling procedures.
COSHH 2002 requires assessment and control of fume exposure during all brazing and soldering operations.
Adequate ventilation or local exhaust extraction must be provided to remove fume from the breathing zone.

Toxic fume exposure	Brazing and soldering fumes contain metal oxides, flux residues, and potentially lead or cadmium, causing serious illness.
Fire risk	Open flame brazing near combustible materials starts fires. Hot works permits and fire watches are essential.
Lead poisoning	Lead solder fume and residue cause cumulative lead poisoning affecting the brain, kidneys, and nervous system.

Do

Don't

Use lead-free solder in preference to lead-based solder wherever possible.
Provide local exhaust ventilation to remove fume from the breathing zone.
Obtain a hot works permit before brazing or soldering near combustible materials.
Wear heat-resistant gloves and eye protection during all brazing operations.
Store LPG and oxy-propane cylinders upright, secured, and away from heat sources.
Wash hands thoroughly after soldering before eating, drinking, or smoking.
Check for cadmium content in brazing alloys; use cadmium-free alternatives.
Maintain a fire watch during and for 60 minutes after hot work brazing.
Use RPE if local exhaust ventilation cannot adequately control fume exposure.
Attend blood lead level monitoring if regularly using lead-based solder.

DON'T use lead-based solder where lead-free alternatives are available.
DON'T braze or solder without adequate ventilation or local exhaust extraction.
DON'T use cadmium-containing brazing alloys without full COSHH controls in place.
DON'T braze near combustible materials without a hot works permit.
DON'T eat, drink, or smoke after soldering without washing your hands thoroughly.
DON'T touch freshly brazed joints; they remain hot enough to cause burns.
DON'T leave lit torches unattended or point them at flammable materials.
DON'T store LPG cylinders in confined spaces, basements, or below ground level.
DON'T assume soldering fume is harmless because the temperature is lower than welding.
DON'T skip the fire watch period after completing brazing work near combustibles.

See also: Copper Pipe Brazing and Soldering | Hot Works Fire Prevention

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