Plasma Cutting Safety

Plasma cutting uses an electrically ionised gas jet to cut through conductive metals at high temperatures.
The plasma arc reaches temperatures exceeding 20,000°C — far hotter than oxy-acetylene cutting.
Plasma cutting produces intense UV radiation, molten metal spatter, noise, and hazardous fumes.
The process generates fine metal fume particles that are respirable and cause occupational lung disease.
Electrical hazards include the high-frequency start circuit and the DC power supply to the torch.
A hot works permit is required for all plasma cutting operations on construction sites.
Cutting galvanised, painted, or coated steel produces additional toxic fumes including zinc oxide.
The high-speed gas jet creates a significant noise hazard, often exceeding 100 dB at the operator.
Reflected UV radiation can cause arc eye in nearby workers who are not wearing eye protection.
Fire risk from spatter and hot metal can extend several metres from the cutting point.

Burn injuries	Temperatures exceeding 20,000°C and molten spatter cause severe burns to exposed skin instantly.
Fume exposure	Metal fumes from plasma cutting cause metal fume fever, lung disease, and cancer with repeated exposure.
Fire and explosion	Hot spatter travels several metres and ignites combustible materials, creating fire and explosion risk.

Do

Don't

Obtain a hot works permit before starting any plasma cutting operation
Wear a welding helmet with the correct shade lens for plasma cutting
Use flame-resistant clothing, gauntlets, and safety boots with metatarsal guards
Provide local exhaust ventilation or fume extraction at the cutting point
Wear hearing protection rated for the noise level of the plasma cutter
Clear combustible materials from the work area and provide a fire extinguisher
Erect welding screens to protect nearby workers from UV radiation and spatter
Inspect the plasma cutter, leads, and torch before each use
Maintain the fire watch for the required period after cutting is complete
Ensure the workpiece is securely clamped and grounded before starting the cut

DON'T operate a plasma cutter without a hot works permit in place
DON'T cut galvanised or coated steel without additional fume extraction measures
DON'T allow unprotected workers within the UV radiation and spatter zone
DON'T use the plasma cutter near flammable liquids, gases, or combustible dust
DON'T touch the torch tip or nozzle immediately after cutting — they retain heat
DON'T cut in confined spaces without forced ventilation and atmospheric monitoring
DON'T bypass the earth clamp — poor grounding increases electrical shock risk
DON'T use a plasma cutter on containers that may have held flammable substances
DON'T ignore tingling or electric shock sensations from the equipment
DON'T leave the plasma cutter powered on and unattended at any time

See also: Hot Works Permit Requirements | Welding Fume Extraction and LEV

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