WLD/General/TBT-WLD-001

Welding Safety Awareness (Comprehensive)

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Welding joins metals by melting them together using intense heat, producing fumes, UV radiation, sparks, and electrical hazards.
Welding processes on construction sites include MMA (stick), MIG/MAG, TIG, flux-cored arc, and oxy-fuel welding and cutting.
Each welding process has specific hazards, PPE requirements, and safe operating procedures that must be followed.
Welding Procedure Specifications define the exact parameters for each welded joint to ensure structural integrity.
Welder qualifications must match the WPS requirements — welders are tested and certified for specific processes and positions.
Welding fume is now classified as a carcinogen by the HSE — on-tool extraction or LEV is required for all welding in 2026.
Pre-heat and post-weld heat treatment may be required for certain steels to prevent cracking and ensure joint quality.
Welding consumables including electrodes, wire, and filler rods must be stored dry and at the correct temperature.
Non-destructive testing including ultrasonic, radiographic, and magnetic particle inspection verifies weld quality after completion.
A welding coordinator should oversee all welding on structural or coded work to ensure compliance with specifications.

Carcinogenic fume	All welding fume is now classified as a human carcinogen — LEV or extraction is legally required for every welding task.
Structural integrity	Welded joints hold structures together — incorrect procedures, unqualified welders, or poor consumables cause catastrophic failures.
Multiple hazards	Welding combines electrical, thermal, chemical, and radiation hazards — comprehensive controls are needed for every process.

Don't

Ensure you hold a valid welder qualification for the process and position being welded.
Use LEV or on-tool extraction for all welding to capture fume at the source.
Follow the Welding Procedure Specification for every joint without deviation.
Wear the correct PPE: auto-darkening helmet, leather gauntlets, and flame-resistant clothing.
Store welding consumables dry and at the correct temperature as specified.
Apply pre-heat and post-weld heat treatment when required by the WPS.
Erect welding screens to protect nearby workers from UV radiation and sparks.
Submit completed welds for non-destructive testing as required by the inspection plan.
Check welding equipment, cables, and earth returns before starting each shift.
Obtain a hot works permit before all welding on construction sites.

DON'T weld without a valid qualification for the specific process and position.
DON'T weld without fume extraction — welding fume is a confirmed human carcinogen.
DON'T deviate from the Welding Procedure Specification for any joint.
DON'T weld without full PPE including helmet, gauntlets, and flame-resistant clothing.
DON'T use damp, contaminated, or incorrectly stored welding consumables.
DON'T skip pre-heat or PWHT when specified — it prevents cracking in the weld.
DON'T allow unprotected people to observe or work near the welding arc.
DON'T cover welds or move on before required NDT inspections are completed.
DON'T use welding equipment with damaged cables or poor earth connections.
DON'T begin welding on site without a valid hot works permit in place.

See also: Welding Safety | MIG & TIG Welding Safety

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