Stick (MMA) Welding Safety

Stick welding (Manual Metal Arc / MMA) uses a consumable electrode to fuse metals with an electric arc.
MMA welding produces intense UV radiation that causes arc eye (photokeratitis) and skin burns without protection.
Welding fume from MMA electrodes contains metallic particles and gases that are hazardous when inhaled.
Electric shock risk exists from the welding circuit, particularly in wet conditions or confined spaces.
Slag chipping after MMA welding ejects hot fragments that cause eye injuries without safety glasses.
A hot works permit is required before any MMA welding on a construction site.
The welding return clamp must be connected close to the work to prevent stray currents damaging structures.
MMA welding in the open air is affected by wind that blows shielding gas away and reduces weld quality.
The COSHH Regulations 2002 require fume assessment and control for all welding activities.
Electrode stubs are extremely hot after use and must be disposed of in a metal container, not the ground.

Prevent arc eye	UV radiation from the welding arc causes painful arc eye within seconds of unprotected exposure.
Fume inhalation	MMA welding fume is now classified as carcinogenic — extraction or RPE is mandatory for all welding tasks.
Electric shock	The welding circuit carries sufficient current to cause fatal electric shock, especially in wet or confined conditions.

Do

Don't

Wear a welding helmet with the correct shade filter for MMA welding at all times
Use LEV (local exhaust ventilation) or RPE to control welding fume exposure at source
Obtain a hot works permit and position a fire extinguisher before starting any MMA welding
Connect the welding return clamp close to the joint to prevent stray current damage
Wear leather welding gauntlets, apron, and flame-resistant clothing to prevent burns
Wear safety glasses under the welding helmet for slag chipping after each weld run
Inspect welding cables, electrode holder, and return clamp before starting each session
Ensure the welding set is RCD-protected and earthed correctly before energising
Erect welding screens to protect nearby workers from UV radiation and spatter
Dispose of hot electrode stubs in a metal container to prevent fire and burn injuries

DON'T strike an arc without your welding helmet in position with the correct shade filter
DON'T weld without fume extraction or RPE — welding fume is classified as carcinogenic
DON'T weld in wet conditions or standing on wet surfaces without additional insulation protection
DON'T leave the electrode holder energised and unattended with an electrode fitted
DON'T chip slag without safety glasses — hot fragments cause serious eye injuries
DON'T use damaged welding cables with exposed conductors or cracked insulation
DON'T weld near flammable materials without a hot works permit and fire watch in place
DON'T connect the return clamp far from the joint — stray currents damage bearings and steelwork
DON'T weld in confined spaces without forced ventilation and a fume extraction system
DON'T throw hot electrode stubs on the ground — they can ignite debris and cause burns

See also: Welding Safety Awareness (Comprehensive) | Welding Fume Extraction and LEV

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