HOT/Specific/TBT-HOT-002

Welding Safety

Hot Works › Specific › Welding Safety

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Welding joins metals using intense heat from an electric arc or gas flame, creating multiple serious health and safety hazards.
Welding fumes contain metal oxides, gases, and particles that cause occupational asthma, metal fume fever, and lung cancer.
The HSE reclassified mild steel welding fume as a human carcinogen in 2019, requiring engineering controls for all welding.
UV radiation from the welding arc causes arc eye (photokeratitis) and severe skin burns to unprotected workers nearby.
A hot works permit is required for all welding on construction sites to control fire risk from sparks and hot metal.
Local exhaust ventilation or on-tool extraction must be used for all welding to capture fume at source.
Electric shock from welding equipment is a risk, particularly in damp conditions or confined spaces.
Welding PPE includes auto-darkening helmet, leather gauntlets, flame-resistant clothing, and safety boots.
Welding near painted, coated, or galvanised steel produces additional toxic fumes requiring enhanced ventilation.
Only qualified welders with approved welding procedure specifications should carry out structural or coded welding work.

Lung cancer risk	Welding fume is now classified as a human carcinogen — engineering controls and RPE are legally required for all welding tasks.
Arc eye and burns	UV radiation from the arc causes instant, painful eye injury and skin burns to welders and anyone watching nearby without protection.
Fire hazard	Welding sparks and molten metal can travel significant distances and ignite combustible materials, causing serious site fires.

Don't

Use local exhaust ventilation or on-tool extraction for all welding operations.
Obtain a hot works permit before starting any welding on a construction site.
Wear an auto-darkening welding helmet with the correct shade for the process.
Wear flame-resistant clothing, leather gauntlets, and safety boots during welding.
Erect welding screens to protect nearby workers from UV radiation and sparks.
Ensure adequate general ventilation in addition to LEV when welding indoors.
Check welding equipment, cables, and earth connections before starting each shift.
Remove combustible materials from the welding area or protect them with fire blankets.
Maintain a fire watch during welding and for at least 60 minutes afterwards.
Hold a valid welder qualification for the process and material being welded.

DON'T weld without local exhaust ventilation or fume extraction in place.
DON'T carry out welding on site without a valid hot works permit.
DON'T look at the welding arc without the correct shade of welding lens.
DON'T weld in ordinary clothing — sparks and UV radiation burn exposed skin.
DON'T allow unprotected persons to watch or work near the welding arc.
DON'T weld in poorly ventilated or enclosed spaces without enhanced extraction.
DON'T use welding equipment with damaged cables, loose connections, or faulty earth returns.
DON'T weld near flammable materials without clearing the area and using fire blankets.
DON'T leave the area unwatched after welding — fires can start up to an hour later.
DON'T weld on coated or galvanised steel without additional fume extraction in place.

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

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