WLD/Processes/TBT-WLD-020

MIG and MAG Welding Safety

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MIG (Metal Inert Gas) and MAG (Metal Active Gas) welding are widely used on construction sites for structural steel, pipework, and fabrication. These semi-automatic processes produce intense UV radiation, toxic welding fumes, and spatter that can cause burns and fire. Correct equipment setup, ventilation, and PPE are essential to protect welders and nearby workers.

Key Hazards

Arc eye and skin burns from intense ultraviolet radiation

Toxic welding fume inhalation causing occupational lung disease

Fire from hot spatter igniting nearby combustible materials

Electric shock from the welding circuit or damaged equipment

Control Measures

Use a welding helmet with the correct shade lens (typically shade 10-13 for MIG/MAG).
Wear flame-resistant clothing, leather gauntlets, and safety boots with no exposed skin.
Ensure adequate fume extraction is in place using LEV or on-torch extraction systems.
Erect welding screens to protect nearby workers from UV flash and spatter.
Remove or protect all combustible materials within the hot works exclusion zone.
Inspect the welding set, earth clamp, torch, and cables before each use.
Ensure the shielding gas cylinder is secured upright and the regulator is in good condition.
Obtain a hot works permit where required and maintain a fire watch during and after welding.
Ensure the work area is well ventilated, especially when welding galvanised or coated steel.

Remember

Always wear the correct shade lens and full flame-resistant PPE during welding
Fume extraction must be in place for all MIG and MAG welding operations
Erect welding screens to protect nearby workers from UV radiation and spatter
Inspect the welding set, torch, cables, and earth clamp before every use
Obtain a hot works permit and maintain a fire watch as required by site procedures

Applicable Legislation: COSHH 2002 · PUWER 1998 · Health and Safety at Work etc. Act 1974 · EH40 Workplace Exposure Limits

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