more. Knowing how to avoid the most common welding hazards ensures a safe, productive work
environment.
Electric Shock:
Electric shock is one of the most serious and immediate risks facing a welder. Electric shock can
lead to severe injury or death, either from the shock itself or from a fall caused by the reaction to
a shock.
Electric shock in welding can come from two sources. Welding machines connected to primary
voltages of typically 120V, 230V or 460V pose the greatest threat. Connection and maintenance
of the primary system should only be done by qualified personnel. Inside the machine, primary
voltages are transformed to the secondary voltages and currents required for the welding arc. Once
energized, many components of the welding operation are electrically “hot” including the electrode
holder, gun or torch, the wire feeder, and the spool or coil of wire.
An electrical circuit exists between these and the work connection. If welders insert themselves
into this circuit, shock will occur. Care should be taken to wear the proper personal protective
equipment (PPE) and assure that they are in good repair. Even heavy welding gloves, if wet, can
cause shock to the welder. Welding equipment electrical systems should only be installed and
repaired by qualified personnel.
Eye and Face Protection:
The proper eye and face protection for welding safety varies depending on the welding process, its
heat or current, and other factors. Helmets, hand shields, goggles, safety glasses, or a combination
of these may be required based on the application. Arc welding requires the proper filter lens shade
based on process and current settings.
According to OSHA 29 CFR 1910.252, "Helmets and hand shields shall protect the face, forehead,
neck and ears to a vertical line in back of the ears, from the arc direct radiant energy and weld
spatter."
OSHA requires that when arc cutting or arc welding with open arc, helmets or hand shields with
filter lenses and cover plates be used by welders and welding operators. Anyone in the area welding
should be shielded from the arc or be wearing proper eye protection. Safety glasses with a Shade
2 lens are recommended for general-purpose protection for distant workers who may inadvertently
view the arc.
Protective Clothing:
The ANSI standard requires all welders and cutters to wear protective flame-resistant gloves, such
as leather welder's gloves, which provide the heat resistance needed for welding. Gloves should