JSA FOR WELDING OPERATIONS

Welding operations present several hazards to both those undertaking the activity and others in the
vicinity. Therefore, it’s important that you are aware of the risks and hazards welding poses, and
understand what precautions you can take to protect yourself.

Electric Shock
During the arc welding process, live electrical circuits are used to create a pool of molten metal.
Therefore, when welding, you are at risk of experiencing an electric shock. Electric shock is the most
serious hazard posed by welding and can result in serious injuries and fatalities, either through a
direct shock or from a fall from height after a shock. You are also at risk of experiencing a secondary
electric shock should you touch part of the welding or electrode circuit at the same time as touching
the metal you are welding.

Exposure to UV and IR Radiation

Looking at the intense bloom of UV light produced when welding, without appropriate PPE or welding
curtains, can result in a painful and sometimes long-lasting condition called arc-eye. Many factors can
affect the severity of a flash burn injury, such as distance, duration and the angle of penetration. Long-
term exposure to arc flashes could also potentially result in cataracts and lead to a loss of vision.

Exposure to Fumes and Gases

Undertaking welding activities will expose you to invisible gaseous fumes, including ozone, nitrogen
oxides, chromium and nickel oxides, and carbon monoxide which can easily penetrate into your lungs.
Depending on the gas or fume, the concentration and duration of your exposure, the resultant
damage can be severe.

Illnesses caused by welding fumes and gases include:

 Pneumonia. Regular exposure to welding fumes and gases can result in a lung infection
which could then develop into pneumonia. While antibiotics can usually stop the infection,
severe pneumonia can result in hospitalisation, serious illness and fatalities.
 Occupational asthma. Chromium oxides and nickel oxides produced by stainless steel and
high nickel alloy welding can both cause asthma.
 Cancer. All welding fumes are internationally considered ‘carcinogenic’.
 Metal fume fever. Welding or hot work on galvanised metal and high steel weld fume
exposure can often result in ‘flu-like’ symptoms, which are usually worse at the start of the
working week. 
 Throat and lung irritation, including throat dryness, tickling of the throat, coughing and tight
chests.

Burns
The combination of high-temperature welding arcs, UV rays and molten metal means you are
susceptible to severe burns when welding. These burns can affect the skin or eyes and can be very
serious. They can also happen very quickly Burns usually occur when welders think they can skip
taking precautions for a few quick welds. This is bad practice.
Welding Safety Precautions
Ensuring high levels of safety is vital when undertaking any welding activity. Ignoring your PPE and
safe working practices can have serious repercussions and might even lead to fatalities. Therefore,
you should follow the safety precautions below to protect yourself at work.

Always Wear Appropriate PPE

Your employer or manager has a duty to provide you with appropriate Personal Protective
Equipment (PPE). The PPE you receive will include:

 Welding helmets with side-shields. Welding helmets protect you from UV radiation,

particles, debris, hot slag and chemical burns. It’s important that you wear the right lens
shade for the work you are carrying out. Follow the manufacturer’s guidelines and gradually
adjust the lens filter until you have good visibility that does not irritate your eyes.
 Respirators. Respirators protect you from fumes and oxides that the welding process
creates. Your respirator must be suitable for the work you are carrying out.
 Fire resistant clothing. Fire resistant clothing protects you from heat, fire and radiation
created in the welding process and shields you from burns. It should have no cuffs, and
pockets must be covered by flaps or taped closed. You should not use synthetic clothing.
Instead, opt for leather and flame-resistant treated cotton.
 Boots and gloves. Insulated, flame resistant gloves and rubber-soled, steel toe-capped
safety shoes shield you from electric shocks, heat, fire, burns and falling objects.

To receive full protection from your PPE, you must not:

 Roll up sleeves or trousers. Rolling up your clothes will leave you susceptible to molten
metal or sparks getting caught in the folds, which could potentially lead to severe burns. You
should also never tuck your trousers into your work boots.
 Remove your helmet while welding. You must always wear your helmet when welding and
when in the vicinity of another welder. While the intensity of the radiation produced decreases
the further you are from a welding arc, those less than 10 metres away are still susceptible to
arc-eye. Therefore, it’s important that you remain behind welding curtains or wear the correct
PPE, even if you aren’t the worker carrying out the welding operation.

Receive Appropriate Training

Prior to starting any welding work, it’s important that you receive adequate training in the use and
safety of your work.

Ensure Your Workspace is Free of Flammable Material.

You should avoid keeping flammable materials in the vicinity of welding processes as sparks, heat
and molten metal splatters produced in the welding process could potentially set flammable material
on fire.
 JSA FOR GRINDING OPERATIONS
Pre-start Checks Electric Shock Flying objects:
Check the casing for any damages, missing screws and cracks. Check the plug and lead wire for
damage. Make sure all controls operate properly. Inspect the disc for uneven or excessive wear,
damage or cracks. Check if the disc being used is suitable for the work. The guard must be fitted
tightly and should not be loose. All grips and handles must be fitted securely and should not be loose.

If you locate any damage, out of test or missing parts, arrange for repairs straightaway - DO NOT
USE THE MACHINE. Replace the inappropriate or the faulty disc with the right disc suited to the task
and the machine. NEVER EVER use a machine without suitable guards.

Replacing Discs Moving parts Cuts and/or abrasion injury to hand Tiny
particles in eye:
Before starting on maintenance, unplug the machine. For carrying out any maintenance, the machine
must always be placed on a stable and firm surface such as a bench. Loosen the spindle nut using
the correct tools / spanners supplied. Clean the backing plate, spindle and guard using a brush.
Ensure the replacement disc is compatible, is of the right type for grinding the material, has the proper
matching speed, the right hole diameter for the spindle, and the right outer diameter. After mounting
the disc, washers and nut in the proper order, use the right tools/spanners to tighten firmly.

Whenever handling sharp or rough parts, protect your hands by wearing leather gloves. When
cleaning with compressed air wear eye protection. Never use a disc which is incompatible, or does
not meet the requirements. Ensure all surfaces are clean. The nut must never be over tightened.

Work area preparation Tripping, slipping and Fire (ignition at source) Flying
particles:
The person using the power tool must have a good foothold. There must be no readily ignited material
or flammable liquids in the work area, or ensure they are covered to protect from sparks when
grinding. Sparks must be prevented from affecting or entering adjacent areas of work. Restrict the
area where grinding is being carried out. The work piece must be secure and must have no accidental
movement when being worked upon.

Sweep the floor of the work area to keep it clear of debris and rubbish. Ensure the presence of
suitable fire extinguishers. Cover with fire blankets. Prevent with the use of welding curtains or similar.
Prevent entry to restricted area by using barricades.

Operation with Safety:

Always grind in a manner that directs the sparks away from your body. Never direct the sparks
towards another person. Wear eye protection to avoid getting debris and dust in the eye. Use
additional protection to eyes and face when working in restricted areas where the sparks can get
reflected back towards the user. Loud noise can be a hazard, especially in restricted or closed areas.
Grinding of uneven surfaces may cause the grinder to move or vibrate in hands. For excessive
vibration, switch off the grinder and check the disc for signs of damage.

Always use protective clothing such as trousers, long sleeves, overalls and apron. Advisable to use
safety goggles. Use face shield together with other eye protections. It is essential to wear hearing
protection. It is essential to wear a respirator or a suitable mask to filter particulate dust. Heavy gloves
can be used to reduce the effects of vibration.
 JSA FOR HEIGHT WORK
Working at height remains one of the biggest causes of occupational fatalities and major injuries.
Cases commonly involve over-reaching, over-balancing or the failure of a fragile surface. Falls from
height can also be due to unguarded holes in floors such as hatchways, inspection holes and pits, and
from falls into process tanks and machinery.

Other significant hazards associated with working at height include falling objects and the potential for
a working platform to collapse or overturn as well as contact with overhead electrical services.

The exact height at which employers have to implement controls will vary from country to country, but
generally, work at height can be taken to mean any work where, if there are no precautions in place, a
person could fall a distance liable to cause personal injury (through a fragile roof, for example). It
should be remembered that access and egress to a workplace could also constitute working at height.

Workers in maintenance and construction are particularly at risk, but many other people in a variety of
jobs could also be at risk of falling from height. Such professions include: painters, decorators and
window cleaners and those who carry out ad hoc work without proper training, planning or equipment.

Whatever the task, any working at height needs to be planned in advance, with careful consideration
given to the selection and use of work equipment and means of escape in an emergency.

Hierarchy of control measures

When planning any activities which may involve working at height, the following hierarchy of control
measures should be considered:

 Avoidance where possible, of working at height

 Working from an existing place of work, or using an existing means of access and egress
 Provision of suitable work equipment to prevent a fall occurring, e.g. edge protection
 Provision of work equipment to minimise the distance and consequences of a fall, e.g. fall
arrest systems
 Instruction and training and/or other means.

Where possible, working at height should be avoided, usually by carrying out tasks from the ground.
Some practical examples include using extendable tools to remove the need to climb a ladder. Other
examples include the installation of cables at ground level, lowering a lighting rig to ground level or
assembly of edge protection on the ground.

A safe place of work

Where work at height cannot be avoided, an existing safe place of work should be used. These
workplaces (and means of access or egress) should:

 Be stable and of sufficient strength and rigidity for their purpose

 Rest on stable and suitably strong surfaces
 Be of sufficient size to allow safe use for persons, plant and material
 Have suitable means for preventing a fall
 Have a surface which has no gap through which a person or material could fall and cause
injury
 Be constructed, used and maintained to prevent the risks of slipping, tripping or any person
being trapped between them and any adjacent structure
For example, an existing flat roof with permanent edge protection may be used for work at height
activities.

When carrying out such roof work, fragile surfaces present a significant risk – no person should pass
or work on or near to a fragile surface unless it is not reasonable to carry out the work elsewhere.

 
Where it isn’t reasonable to avoid work on or near a fragile surface:

 Suitable protection, such as platforms, coverings, crawling boards or guardrails, must be

provided
 Where this is not practicable, measures should be taken to minimise the distance and
consequence of any fall, e.g. fall arrest systems, safety nets and air bags.

Prominent warning signs should be posted at any location where persons may pass near to or work
on a fragile surface.

Where there is no suitable existing safe place to work from, work equipment or other measures to
prevent falls should be provided such as access equipment fitted with guard rails. Independent
scaffolds, tower scaffolds and mobile elevating work platforms (MEWPs) are examples.

Prioritising collective measures

When selecting work equipment to prevent falls, employers should give priority to collective measures
over personal protection. Equipment should be strong enough for the work and any loads placed on it,
taking into account:

 The working conditions and risks to safety at the place where the equipment is to be used
 In the case of work equipment for access and egress, the distance that has to be negotiated
 The distance and consequences of any potential fall
 The duration and frequency of use
 The need for easy and timely evacuation and rescue in an emergency
 Any additional risks posed by the use, installation or removal of the work equipment, e.g. the
erection and dismantling of scaffold on a busy street

Other measures to minimise the distance and consequences of a fall

Where the risk of falls cannot be prevented, work equipment or other measures to minimise the
distance and consequences of a fall (should one occur) need to be provided, e.g. fall arrest systems,
safety netting or air mats.

This equipment does not stop people falling, but minimises the potential injuries if they do.

Safety nets
Safety nets should be manufactured to recognised standards and may be designed to catch falling
personnel or falling materials. They should be erected as close as possible to the work – the further a
person may fall, the larger the net needs to be. The use of safety nets is normally limited to high level
work such as roof work and steel erection. If the net is too close to the ground it won’t be able to
safely accommodate the deflection arising from the impact of a falling person.

Safety nets should be erected by competent persons able to ensure that the net tension will allow the
safe catching of a falling person, that the supporting framework can withstand impact or shock
loadings, and that it does not in itself present a hazard to falling persons.
Air bags
Air bags tend to be used where there is insufficient height to accommodate a safety net or to provide
anchorage for a fall arrest system. The strength of the material and the air pressure within the bag are
critical to ensuring the safety of a falling person. Because of this, they should only be installed by
competent specialist suppliers.

Where harnesses are used they must be securely attached to a sufficiently strong anchorage point,
and checks made to ensure that they’re always worn. This requires user discipline and active
management monitoring on a regular basis.

For inspection and short-term light duration construction work where access from a working platform
is not practicable, rope access techniques (abseiling) may be implemented. In this instance,
equipment should only be erected and used by competent persons and should be given a
comprehensive inspection before use. A single suspension point should not be relied upon to ensure
a safe descent. Wherever possible, separate suspension points should be used for the main rope and
the safety rope. Tools required for the work should be tethered to the operator so that they can’t be
dropped and if necessary, the area beneath the work should be fenced off or covered.

In addition to the controls set out above, measures to reduce the risk of a fall should be used, e.g.
information and training, use of competent persons, regular ladder inspections, demarcated areas to
provide a warning, adequate lighting, good housekeeping measures, use of suitable footwear and
checking weather conditions, etc.

Preventing falling objects

Consideration must also be given to the safety of people who work or pass beneath the work at height
activity. In particular, measures should be in place to protect them from falling objects.

In the first instance, steps should be taken to prevent the fall of objects or materials, e.g. sheeting on
scaffolding. Where this isn’t reasonable, measures should be implemented to ensure that persons are
not struck by falling objects, e.g. barrier off danger areas below and prevent unauthorised access.
Chutes may be used to control the transport of materials and waste from a height to a safe location.

The risk presented by falling materials and objects can also be reduced if they’re stored and stacked
in such a way that they are not likely to fall and cause injury. This is particularly important when goods
are stored and retrieved at height, such as in a warehouse.

Storage racking and shelving should be sufficiently strong and stable for the loads that they will need
to support. Racking systems may be lightweight in nature and therefore may be unable to withstand
significant amounts of wear and tear. It is therefore important that operators of workplace transport
are adequately trained and competent in order to reduce the potential for damage that may be caused
by collisions.

Damaged racking and shelving may be substantially weakened, even if supporting less than their
normal working load.

“Even before work at height begins, there is much to be considered”

To ensure the ongoing safety of racking or shelving installations:

 They should be regularly inspected to identify damage and necessary maintenance/repair

 Employees should be encouraged to report any damage
 Maximum load notices should be displayed and strictly adhered to
When carrying out stacking and storing operations, precautions may include:

 Safe stacking on undamaged, suitable pallets

 Banding (or wrapping) to prevent items from falling
 Establishing clear height limits for stacks
 Regular stack inspections
 Instruction and training for workers who are involved in such operations
 Procedures for dealing with any items which may be difficult to store

Using cradles and Scaffolds

Cradles should be carefully selected to ensure they are suitable for the intended task. They should be
installed by competent workers and be thoroughly examined and tested before use. Workers must
also be competent to use or work from a cradle. Even where precautions have been taken, accidents
can still happen, e.g. if a motor of a powered cradle fails, it can make the cradle tip or people may
overbalance and fall while reaching out of the cradle. Safety harnesses should be worn and attached
to suitable anchor points and thorough visual pre-use checks carried out (in addition to regular
inspections/ examinations by a competent person and a record made).

A work restraint, fall prevention system, adjusted or set to a fixed length that physically prevents the
person from getting to the place where they could fall.

There should be safe access to the scaffold, consisting as a minimum, of a tiered ladder. Handrails
and toe boards should also be present. Scaffolding should be designed, erected, altered and
dismantled by competent persons.

Commonly referred to as “Mobile Access Towers” or “Mobile Scaffold Towers” these assemblies are
usually made from pre-fabricated components of aluminium alloys or fibreglass.

A wide range of such prefabricated tower scaffolds are available. Frequently used for light-weight
work of limited duration, they’re involved in numerous accidents each year, usually because the tower
isn’t properly erected or used.

The potential for overturning, especially with lightweight aluminium scaffolds, is a significant hazard,
as is collapse, which can occur if the tower is not properly erected with all parts in place.

Towers should be erected by a competent person, in accordance with the manufacturer’s instructions.
Instructions should give sufficient advice on the erection sequence and bracing requirements to
ensure the stability of the tower.

To ensure stability, the tower should rest on firm level ground with the wheels or base plates properly
supported. The tower should be checked to ensure that it’s fully vertical before use.

 
A tower on base plates is more stable than one on wheels and should be used in preference to a
wheeled tower when there is no need to move the tower.

If a wheeled tower is used the wheel brakes should be locked on before use.

“Safety harnesses should be worn and attached to suitable anchor points and thorough visual
pre-use checks carried out by a competent person”

The taller the tower, the more likely it is to become unstable. Tower stability will be adversely affected
if it is:

 Sheeted and/or exposed to high winds

  Loaded with heavy items
 Used to hoist heavy materials or support rubbish chutes
 Used for tasks which involve bulky or awkward equipment such as grit blasting, water-jetting,
etc
 Accessed by climbing from the outside
 Used to support ladders

Over-reaching or overbalancing

Every year many people are killed using ladders. Many of the accidents occur because the ladder is
not properly secured, usually because the work was of very short duration. Other typical
accidents include falls as a consequence of over-reaching or overbalancing, or due to losing hold of
the ladder when carrying loads up it.

Safety during the use of ladders, as with all work equipment, can be achieved by ensuring:

 The suitability of the ladder for the operations and operating conditions under which it will be
used
 That systems are in place to inspect and maintain the ladder in a safe condition
 That safe systems of work are devised for the ladder’s use
 That staff are informed, instructed, trained and supervised as necessary to be able to use the
ladder safely

Ladders should be primarily regarded as a means of access to a work platform, rather than as a
workplace. Ladders may, however, be used for work that is short term, light duty and low risk, or
where the site features will not accommodate a working platform (provided that a safe system of work
can be devised).

Work that requires the use of both hands or is in itself inherently dangerous e.g. hot work, should not
be conducted from a ladder.

The length of the ladder also has a significant bearing on its suitability, it must be long enough to allow
an inspection or task to take place without over-reaching, and also to provide a safe means of egress
if necessary at the top landing. The longer the ladder, the more difficult it is to carry around site and
manoeuvre into position.

The material of construction may also be significant. As timber is nonconductive it will prove to be a
more suitable material than aluminium where electrical equipment is being used. Aluminium ladders
may be damaged in corrosive atmospheres, whereas timber ladders are prone to warp if left exposed
to the elements.

Although stepladders provide a freestanding means of access, they require careful use. Usually,
stepladders aren’t designed for any side loading and therefore, can be easily overturned.

The top step of a stepladder

Fatal accidents have occurred when workers have stepped on to the top step of a stepladder, which
has subsequently toppled over. Therefore, the top step of a stepladder should never be used at a
workplace unless guidance from the manufacturer states that the equipment has been designed for
this purpose.
Stepladders should be industrial grade, be used on a level surface and with the hinge fully extended
and locked (or retaining cord fully extended). The workers’ knees should be below the top of the
ladder when in the working position.

Ladders and stepladders should be inspected before each use to ensure that they are suitable for the
job, and in good condition. Damaged stiles, damaged or missing rungs or missing feet should exclude
the ladder from use. Painted ladders should not be used as the paint coating may conceal faults.

Ladders should also be periodically examined by a competent person – management systems are
necessary to ensure all ladders can be individually identified, are properly stored, and are issued for
use to identified personnel.

It is vital that whatever equipment is selected for working at height, it is assembled and installed in line
with manufacturers’ instructions. Equipment should also be inspected regularly for signs of
deterioration.

Where the safety of work equipment depends on how it is installed or assembled, e.g. scaffolding, it
should be inspected in place before it is used. Where work equipment is exposed to conditions
causing deterioration that could lead to a dangerous situation, such as high winds for example, it
should be inspected at suitable intervals and each time exceptional circumstances occur that could
jeopardise its safety.
 JSA FOR GAS CUTTING
Oxy/fuel gas equipment has many uses - welding, cutting, heating, straightening. The equipment is
versatile, easy to move and cheap. It is so widely used that sometimes people forget about the
dangers. Many people are injured each year by the incorrect or careless use of oxy/fuel gas
equipment. Some people die. This leaflet describes the hazards associated with portable oxy/fuel gas
equipment and the precautions for avoiding injury and damage to property.

The main hazards are:

■ Fire caused by heat, sparks, molten metal or direct contact with the flame.

■ Explosion when cutting up or repairing tanks or drums which contain or may have contained
flammable materials.

■ Fire/explosion caused by gas leaks, backfires and flashbacks.

■ Fumes created during flame cutting.

■ Fire/burns resulting from misuse of oxygen.

■ Burns from contact with the flame or hot metal.

■ Crushing or impact injuries when handling and transporting cylinders.

Preventing fire from heat, sparks, molten metal or direct contact with
flame:
The flame from an oxy/fuel gas torch (often called a ‘blowpipe’) is a very powerful source of ignition.
Careless use of oxy/fuel torches has caused many fires. The flame will quickly set light to combustible
material such as wood, paper, cardboard, textiles, rubber, and plastics. Many processes also
generate sparks and hot spatter which can also ignite these materials.

The following precautions will help prevent fire.

■ Move the work-piece to a safe location for carrying out hot work.

■ Remove nearby combustible materials (such as flammable liquids, wood, paper, textiles, packaging
or plastics).

■ Protect nearby combustible materials that cannot be moved. Use suitable guards or covers such as
metal sheeting, mineral fibre boards or fire-retardant blankets.

■ Check that there are no combustible materials hidden behind walls or in partitions, particularly if the
welding or cutting will go on for some time. Some wall panels contain flammable insulation materials,
eg polystyrene.

■ Use flame-resistant sheets or covers to prevent hot particles passing through openings in floors and
walls (doorways, windows, cable runs, etc).

■ If the consequences of a fire are severe, eg work inside ships, you may need to appoint a fire watch
during and after the work finishes. It is normal to maintain fire watch for 30 minutes after hot work
finishes
■ Prevent flame, heat, sparks or hot spatter from landing on the hoses.

■ Keep fire extinguishers nearby.

■ Never use an oxy/fuel gas blowpipe on a drum or tank that has contained, or may have contained,
flammable material, unless you know it is safe. It may be safer for a specialist company to carry out
the work. If in doubt, ask.

Fire/explosion caused by gas leaks

Acetylene, LPG and other fuel gases are highly flammable, and form explosive mixtures with air and
oxygen. Even small leaks can cause a flash fire or explosion, particularly if they are leaking into a
poorly ventilated room or confined space where the gases can accumulate. Gas leaks are often the
result of damaged or poorly maintained equipment, poor connections or not closing valves properly
after use.

The following precautions will help to prevent leaks:

■ Turn the gas supply off at the cylinder when the job is finished or before the cylinders are moved or
transported.

■ Isolate and purge or remove hoses and equipment from enclosed or poorly ventilated spaces when
there is a break in work

■ Keep hoses away from sharp edges and abrasive surfaces or where vehicles can run over them.

■ Do not allow hot metal or spatter to fall on hoses.

■ Maintain all equipment and regularly check its condition.

Checking for leaks:

Regularly check all connections and equipment for faults and leaks. Equipment used in aggressive
conditions such as demolition work or heavy engineering will normally need more frequent checks, eg
weekly.

■ Use a proprietary leak detecting spray or solution suitable for use with oxy/fuel systems. Do not use
soapy water or solutions containing grease or oils on oxygen systems.

■ Never look for gas leaks with a naked flame.

■ Immediately repair or replace leaking components. Leaking hoses should not be repaired, but they
can be shortened to remove a damaged section. Refit hose tails using crimp clips designed for that
task. Screw tightened crimps (jubilee clips) are not recommended. There is a risk of leaks due to over-
tightening or under-tightening them.

Backfires and flashbacks

Backfires:

A backfire is when the flame burns back into the torch, often with a sharp bang. This may happen
when the torch is held too close to the work piece, or if the nozzle is partly blocked. The flame may go
out or it may reignite at the nozzle. Sometimes the flame burns back into the torch, and burning
continues inside it. Backfires do not usually cause injury or damage, but they can indicate a fault in
the equipment.

If a backfire does occur:

■Shut off the torch valves, oxygen first (usually coloured blue) and then the fuel gas (usually coloured
red).

■Shut off the oxygen and fuel gas cylinder valves.

■Cool the blowpipe with water if necessary.

■Check the equipment for damage or faults, particularly the nozzle.

Flashbacks:

Flashbacks are commonly caused by a reverse flow of oxygen into the fuel gas hose (or fuel into the
oxygen hose), producing an explosive mixture within the hose. The flame can then burn back through
the torch, into the hose and may even reach the regulator and the cylinder. Flashbacks can result in
damage or destruction of equipment, and could even cause the cylinder to explode.

The following precautions will help to prevent flashbacks:

■ Use the correct lighting-up procedure. Purge the hoses before lighting the torch to remove any
potentially explosive gas mixtures. Use a spark igniters and light the gas quickly after turning it on.

■ Make sure the blowpipe is fitted with spring-loaded non-return valves.

■ Use the correct gas pressures and nozzle size for the job.

■ Maintain the equipment in good condition.

Protecting cylinders from flashbacks:

Fit flashback arresters to both the oxygen and fuel gas hoses near to the regulators. For long lengths
of hose, fit arresters on both the torch and the regulator. The fitting of a flashback arrester is not a
substitute for safe working practice.

If a flashback does occur:

■If it is safe to do so, close the cylinder valves on both fuel gas and oxygen.

■If the fire cannot be put out at once, evacuate the area and call the emergency fire services.

After a flashback, carefully check for damage to the torch, hoses, regulators, flashback arresters and
other components. Replace parts if you need to. If in doubt, consult your supplier.

Fire/burns from misuse of oxygen

Oxygen leaks also increase the fire risk. Clothing contaminated with oxygen, even fire-retardant
clothing, will catch fire easily and burn very fiercely. Oxygen can cause explosions if used with
incompatible materials. In particular, oxygen reacts explosively with oil and grease.

You must take the following precautions:

■ Never use oxygen to blow dust off clothing.

■ Never attempt to improve air quality inside confined spaces by releasing oxygen in the space.

■ Never allow oil or grease to come into contact with oxygen valves or cylinder fittings.

■ Only use equipment designed for use with oxygen. In particular, check that the regulator is safe for
oxygen and for the cylinder pressure.

Contact burns
The following precautions will help to prevent burns from contact with the flame, hot metal, sparks and
molten slag:

■ Work in a safe location away from other people.

■ Wear protective clothing, boots, gauntlets and eye protection.

■ Shut off the torch when not in use. Do not leave a lighted torch on a bench or the floor as the force
of the flame may cause it to move.

■ Clamp the work-piece, avoid holding it by hand.

Crushing or impact injury

The following precautions will help prevent injury when handling and transporting cylinders.

■ Prevent cylinders from falling or being knocked over by securing them with a stout chain or strap. It
is normal to chain them to a wheeled trolley or against a wall.

■ Avoid moving a cylinder by tilting it on its base and rolling it. It is better to use a trolley.

■ If transported in a road vehicle, the cylinders should be secured so they don’t come loose in an
accident.

Permit-to-work
The potential for injury and property damage are such that many companies want to control hot work
very closely. One way to achieve this is to operate a written permit system for welding and flame
cutting work. Sometimes called hot work permits, they aim to ensure that welding and flame cutting
does not start until after the risks for that particular task are identified and measures to eliminate or
control risk are in place. A permit should specify.

■ What work will be done.

■ How and when it is to be done.

■ What safety and health precautions are needed.

■ Who is responsible for checking it is safe to start.

■ Who will check the work is done safely.

■ Who is responsible for confirming that work is complete and there is no longer a risk from, or to, the
people doing the work.