HOT/Specific/TBT-HOT-030
Plasma Cutting Safety and PPE
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Toolbox Talk
Plasma Cutting Safety and PPE
Plasma cutting uses a high-temperature ionised gas jet to cut through steel and other metals. The process generates intense UV radiation, metal fumes, noise, and showers of molten metal spatter. Plasma arc temperatures exceed 20,000°C, making the cut zone extremely dangerous. This talk covers the hazards of plasma cutting and the PPE and controls required for safe operation on construction sites.
Key Hazards
Severe burns from molten metal spatter and the ultra-high temperature plasma arc
UV radiation burns to eyes and skin from the intense plasma cutting arc
Metal fume inhalation causing respiratory illness and metal fume fever
Fire ignition from molten metal landing on combustible materials below the cut
Control Measures
- Wear a full-face auto-darkening welding helmet with the correct shade for plasma cutting intensity.
- Wear flame-resistant clothing, leather gauntlets, and a leather apron to protect against molten spatter.
- Provide local exhaust ventilation or RPE with metal fume filters to control cutting fume exposure.
- Obtain a hot works permit before plasma cutting near any combustible materials on site.
- Clear all combustible materials from below and around the cutting area before starting work.
- Use fire-resistant sheeting to contain molten spatter where clearance of combustibles is not possible.
- Ensure the workpiece is properly earthed and the plasma unit is connected to a suitable power supply.
- Wear hearing protection rated for the noise level generated by the specific plasma system in use.
- Carry out a fire watch for at least 60 minutes after plasma cutting is completed.
Remember
- Wear a full-face welding helmet with the correct shade lens for plasma cutting intensity
- Flame-resistant clothing, leather gauntlets, and a leather apron are mandatory for all operators
- Control metal fumes using local exhaust ventilation or RPE with appropriate filters
- Clear all combustible materials from below and around the cutting area before starting
- A hot works permit is required before plasma cutting near any combustible materials
- Carry out a fire watch for at least 60 minutes after plasma cutting work is completed
Applicable Legislation: COSHH Regulations 2002 · Regulatory Reform (Fire Safety) Order 2005 · Personal Protective Equipment at Work Regulations 1992 · Health and Safety at Work etc. Act 1974
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