OCCUPATIONAL SAFETY AND

OSHA HEALTH ADMINISTRATION

U.S. DEPARTMENT OF LABOR

WELDING, CUTTING AND BRAZING

SUBPART Q
29 CFR 1910.251 – 29 CFR 1910.255
INTRODUCTION
Welding is the most common method of joining metals in industry today.
When welded, two pieces of similar metals are fused (melted) together.
Once completed, the welded joint is as strong or stronger than the pieces
from which the joint is formed. General hazards of welding include
impact, penetration, harmful dust, smoke, fumes, heat and light radiation.
The proper personal protective equipment can protect you from these
hazards.

TYPES OF WELDING
 Gas welding
 Arc welding
 Oxygen and Arc cutting

Gas welding – In gas welding two metals are joined by melting or fusing
their adjoining surfaces. This is done by directing a gas flame over the
metals until a molten puddle is formed. The energy for gas welding
comes from the combustion of a fuel with oxygen or air. A few of the
most popular fuels are acetylene, Mapp gas and hydrogen. Since gas
welding is slower and easier to control than electric arc welding, it is
often used in applications such as general maintenance work, brazing and
soldering.

Arc welding – Arc welding involves a different process-two metals are

joined by generating an electric arc between a covered metal electrode
and the base metals. Heat is produced by the arc which in turn melts the
metal and mixes the molten deposits of the coated electrode. The arc
energy is provided by a power supply unit that furnishes direct or
alternating current. The electrodes carry the current to form the arc,
producing a gas that shields the arc from the atmosphere, and add metal
to control the weld shape.
When an arc is struck using a coated electrode, the intense heat melts the
tip of the electrode. The drops of metal from the electrode enter the arc
stream and are deposited on the base metal.

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The equipment needed for electric arc welding is a power supply,
electrode holder, ground clamp, protective shield, and welder’s protective
clothing.

Oxygen and Arc Cutting – Metal cutting in welding is severing or

removal of metal by a flame or arc. The most common cutting processes
are:
 Oxygen Cutting: Metal is heated by gas flame and an oxygen jet
does the cutting.
 Arc Cutting: Intense heat of electric arc melts away the metal.

29 CFR 1910.251
DEFINITIONS
“Hot Work”: Work which may generate heat, flame, or sparks. This may
include, but is not limited to, welding, torch, cuttings, brazing, soldering,
and grinding.
“Welder” and “Welding Operator”: mean any operator of electric or
gas welding and cutting equipment.
“Approved” means listed or approved by a nationally recognized testing
laboratory.

29 CFR 1910.252
GENERAL REQUIREMENTS:
A. FIRE PREVENTION AND PROTECTION
1. If the object to be welded or cut cannot readily be moved, all
movable fire hazards in the vicinity shall be taken to a safe place.
2. If the object to be welded or cut cannot be moved and if all the fire
hazards cannot be removed, then guards shall be used to confine
the heat, sparks, and slag, and to protect the immovable fire
hazards.
3. If the above requirements cannot be met, then welding and cuttings
shall not be performed.
4. Suitable fire extinguishing equipment shall be maintained in a state
of readiness for instant use. Such equipment may consist of pails of
water, buckets of sand, hose or portable extinguishers depending
upon the nature and quantity of the combustible material exposed.
5. Fire watchers are required whenever welding or cutting is
performed in locations where other than a minor fire might
develop, or any of the following conditions exist:
i) Appreciable combustible materials, in building construction
or contents, closer than 35 feet to the point of operation.
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ii) Appreciable combustibles must than 35 feet away but are
easily ignited by sparks.
6. A fire watch shall be maintained for at least a half hour after
completion of welding or cutting operations to detect and
extinguish possible smoldering fires.
7. Fire watchers shall have fire extinguishing equipment readily
available and be trained in its use. They shall be familiar with
facilities for sounding an alarm in the event of a fire. They shall
watch for fires in all exposed areas, try to extinguish them only
when obviously within the capacity of the equipment available, or
otherwise sound the alarm. A fire watch shall be maintained for at
least a half hour after completion of welding or cutting operations
to detect and extinguish possible smoldering fires.
8. Floors. Where combustible materials such as paper clippings, wood
shavings, or textile fibers are on the floor, the floor shall be swept
clean for a radius of 35 feet (10.7m). combustible floors shall be
kept wet, covered with damp sand, or protected by fire-resistant
shields. Where floors have been wet down, personnel operating arc
welding or cutting equipment shall be protected from possible
shock.
9. Cutting or welding shall not be permitted in the following
situations:
 In areas not authorized by management.
 In sprinklered buildings while such protection is impaired.
 In the presence of explosive atmospheres (mixture of flammable
gases, vapors, liquids, or dusts with air), or explosive atmospheres
that may develop inside uncleaned or improperly prepared tanks or
equipment which have previously contained such materials, or that
may develop in areas with an accumulation of combustible dusts.
10. Welding or Cutting Containers
No welding, cutting, or other hot work shall be performed on used
drums, barrels, tanks or other containers until they have been
cleaned so thoroughly as to make absolutely certain that there are
no flammable materials present or any substances such as greases,
tars, acids, or other materials which when subjected to heat, might
produce flammable or toxic vapors. Any pipe lines or connections
to the drum or vessel shall be disconnected or blanked.
11. Confined Spaces:
When arc welding is to be suspended for any substantial period of
time, such as during lunch or overnight, all electrodes shall be
removed from the holders and the holders carefully located so that
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accidental contact cannot occur and the machine be disconnected
from the power source.
12. In order to eliminate the possibility of gas escaping through leaks
or improperly closed valves, when gas welding or cutting, the torch
valves shall be closed and the gas supply to the torch positively
shut off at some point outside the confined area whenever the torch
is not to be used for a substantial period of time, such as during
lunch hour or overnight. Where practicable, the torch and hose
shall also be removed from the confined space.
13. Combustible walls. Where cutting or welding is done near walls,
partitions, ceiling or roof of combustible construction, fire-resistant
shields or guards shall be provided to prevent ignition.
14. Noncombustible walls. If welding is to be done on a metal wall,
partition, ceiling or roof, precautions shall be taken to prevent
ignition of combustibles on the other side, due to conduction or
radiation, preferably by relocating combustibles. Where
combustibles are not relocated, a fire watch on the opposite side
from the work shall be provided.

B. PROTECTION OF PERSONNEL
1. A welder or helper working on platforms, scaffolds, or
runways shall be protected against falling through the use of
railings, safety belts, life lines, or some equally effective
safeguards.
2. Welding cable. Welders shall place welding cable and other
equipment so that it is clear of passageways, ladders, and
stairways.
3. Helmets or hand shields shall be used during all arc welding
or arc cutting operations, excluding submerged arc welding.
Helpers or attendants shall be provided with proper eye
protection.
4. Helmets and hand shields shall be made of a material which
is an insulator for heat and electricity. Helmets, shields and
goggles shall not be readily flammable and shall be capable
of withstanding sterilization.
5. Helmets and hand shields shall be arranged to protect the
face, neck and ears from direct radiant energy from the arc.
6. Welders should always select clothing materials which will
provide maximum protection from sparks and hot metal.
Protective eyewear, safety shoes, fire-resistant clothing, and
fire-resistant gauntlet gloves are recommended.
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Additionally, the shirt should have full sleeves, no pockets
and should be worn outside the trousers with collar buttoned.
The trousers should have no cuffs and should extend well
down to the safety shoes.
7. Goggles or other suitable eye protection shall be used during
all gas welding or oxygen cutting operations. Spectacles
without side shields, with suitable filter lenses are permitted
for use during gas welding operations on light work, for
torch brazing or for inspection.
8. All operators and attendants of resistance welding or
resistance brazing equipment shall use transparent face
shields or goggles, depending on the particular job, to
protect their faces or eyes, as required.
9. Helmets shall be provided with filter plates and cover plates
designed for easy removal.
10. Protective clothing – General requirements. Employees
exposed to the hazards created by welding, cutting, or
brazing operations shall be protected by personal protective
equipment in accordance with the requirements of 1910.132.
Appropriate protective clothing required for any welding
operation will vary with the size, nature and location of the
work to be performed.

C. HEALTH PROTECTION AND VENTILATION

1. Mechanical ventilation is required when welding or cutting
is done with materials not specifically mentioned in this
section. These materials – fluorine compounds, zinc, lead,
beryllium, cadmium, mercury, cleaning compounds, and
stainless steel are partially hazardous and have specific
control requirements.
2. Screens. When welding must be performed in a space
entirely screened on all sides, the screens shall be so
arranged that no serious restriction of ventilation exits. It is
desirable to have the screens so mounted that they are about
2 feet (0.61m) above the floor unless the work is performed
at so low a level that the screen must be extended nearer to
the floor to protect nearby workers from the glare of
welding.
3. Maximum allowable concentration. Local exhaust or general
ventilating systems shall be provided and arranged to keep
the amount of toxic fumes, gases, or dusts below the
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maximum allowable concentration as specified in 1910.1000
of this part.
4. Mechanical ventilation shall be provided:
 In a space of less than 10.000 cubic feet (284 m3) per
welder.
 In a room having a ceiling height of less than 16 feet
(5m)
5. Minimum rate. Such ventilation shall be at the minimum rate
of 2.000 cubic feet (57m3) per minute per welder, except
where local exhaust hoods and booths, or airline respirators
approved by the U.S. Bureau of Mines for such purposes are
provided. Natural ventilation is considered sufficient for
welding or cutting operations where restrictions are not
present.
6. Hoods. Freely movable hoods intended to be placed by the
welder as near as practicable to the work being welded and
provided with a rate of air-flow sufficient to maintain a
velocity in the direction of the hood of 100 linear feet (30m)
per minute in the zone of welding when the hood is at its
most remote distance from the point of welding.
7. Oxygen for ventilation. Oxygen shall never be used for
ventilation.

D. HOT WORK PERMIT

A written permit must be obtained prior to starting any welding,
cutting or hot work operations. Ensuring that all safety precautions
have been taken.

29 CFR 1910.253
Gas Welding and Cutting
A. GENERAL REQUIREMENTS:
1. Maximum pressure. Under no condition shall acetylene be
generated, piped (except in approved cylinder manifolds), or
utilized at a pressure in excess of 15 psig (pounds per square inch
gauge) or 30 psia (pounds per square inch absolute) .
2. Apparatus. Only approved apparatus such as torches, regulators or
pressure-reducing valves, acetylene generators, and manifolds shall
be used.

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3. Using acetylene at pressures in excess of 15 psi gauge pressure (or
about 30 psi absolute pressure) is a hazardous practice. Free
gaseous acetylene is potentially unstable at pressures above 15 psig
and could decompose with explosive violence. Experience
indicates that 15 psig is generally acceptable as a safe upper
pressure limit.
4. The decomposition characteristics of acetylene gas are avoided by
keeping the gas in liquid solution and storing it in cylinders of
unique construction. Internally, acetylene cylinders are not
designed like other kinds of compressed gas cylinders. Acetylene
cylinders are never hollow. These cylinders contain a porous,
calcium silicate filler and a suitable solvent, usually acetone,
because, under pressure, acetylene by itself is unstable. Acetone is
used because it has the ability to absorb over 400 times its own
volume of acetylene at 70 F.
5. Millions of microscopic pores make up the calcium silicate filler.
Although it appears to fill the steel shell, approximately 90 percent
of the filler’s volume consists of “pore space” for holding and
evenly distributing the acetylene/acetone solution.
6. When absorbed in this filler, the acetylene is divided into such
small units that, should acetylene decomposition take place in one
pore, the heat released is not enough to raise the temperature of the
acetylene in surrounding pores to the point where it, too, will
decompose.
7. Acetylene is usually supplied in cylinders which have a capacity of
up to 300 cubic feet of dissolved gas under pressure of 250 psig at
70 F.

B. CYLINDERS AND CONTAINERS:

1. All portable cylinders used for the storage and shipment of
compressed gases shall be constructed and maintained in
accordance with the regulations of the U.S. Department of
Transportation.
2. Compressed gas cylinders shall be legibly marked, for the purpose
of identifying the gas content, with either the chemical or trade
name of the gas. Such marking shall be by means of stenciling,
stamping, or labeling, and shall not be readily removable.
Whenever practical, the marking shall be located on the shoulder of
the cylinder.
3. Cylinders shall be kept away from radiations and other sources of
heat.
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4. Inside of buildings, cylinders shall be stored in a well-protected,
well-ventilated, dry location, at least 20 feet (6.1 m) from highly
combustible materials.
5. Cylinders should be stored in definitely assigned places away from
elevators, stairs, or gangways, or other areas where they might be
knocked over or damaged by passing or falling objects, or subject
to tampering.
6. Empty cylinders shall have their valves closed.
7. Valve protection caps, where the cylinder is designed to accept a
cap, shall always be in place, hand-tight, except when cylinders are
in use or connected for use. The valve protection cap is designed to
take the blow in case the cylinder falls.
8. Inside a building, cylinders, except those in actual use or attached
ready for use, shall be limited to a total gas capacity of 2,000 cubic
feet (56 m3) or 300 pounds of liquefied petroleum gas.
9. Acetylene cylinders shall be stored valve end up. If the cylinder is
on its side, acetone may leak out and create a dangerous condition.
10. Oxygen cylinders in storage shall be separated from fuel-gas
cylinders or combustible materials (especially oil or grease), a
minimum distance of 20 feet (6.1 m) or by a non-combustible
barrier at least 5 feet (1.5 m) high having a fire-resistance rating of
at least one-half hour. This requirement is intended to reduce the
possibility of any fire support when a fire occurs among the fuel
gas storage. This is illustrated in the figure below:

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11. Cylinders, cylinder valves, couplings, regulations, hose and
apparatus shall be kept free from oily or greasy substances. Oxygen
cylinders or apparatus shall not be handled with oily hands or
gloves. A jet of oxygen must never be permitted to strike an oily
surface, greasy clothes, or enter a fuel oil or other storage tank.
12. Valve-protection caps shall not be used for lifting cylinders from
one vertical position to another.
13. Before a regulator is removed from a cylinder valve, the valve shall
be closed and the gas released from the regulator.
14. An acetylene cylinder valve shall not be opened more than one and
one-half turns of the spindle. This permits adequate flow of
acetylene and allows ready closing of the valve in an emergency
situation. Do not remove the cylinder wrench from the cylinder.
15. All cylinders with a water weight capacity of over 30 pounds (13.6
kg) shall be equipped with means of connecting a valve protection
cap or with a collar or recess to protect the valve.
16. Fuel-gas cylinder storage. Inside a building, cylinders, except those
in actual use or attached ready for use, shall be limited to a total
gas capacity of 2,000 cubic feet (56 m (3)) or 300 pounds (135.9
kg) of liquefied petroleum gas.
17. For storage in excess of 2,000 cubic feet (56 m(3)) total gas
capacity of cylinders or 300 pounds (135.9 kg) of liquefied
petroleum gas, a separate room or compartment conforming to the
requirements specified shall be provided, or cylinders shall be kept
outside or in a special building. special buildings, rooms or
compartments shall have no open flame for heating or lighting and
shall be well ventilated. They may also be used for storage of
calcium carbide in quantities not to exceed 600 (271.8 kg) pounds,
when contained in metal containers.
18. Oxygen cylinders stored in outside generator houses shall be
separated from the generator or carbide storage rooms by a
noncombustible partition having a fire-resistance rating of at least 1
hour. This partition shall be without openings and shall be gastight.
19. Cylinders shall not be dropped or struck or permitted to strike each
other violently.
20. Cylinder valves shall be closed before moving cylinders.
21. Cylinders shall be kept far enough away from the actual welding or
cutting operation so that sparks, hot slag, or flame will not reach
them, or fire-resistant shields shall be provided.

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22. Fuel- gas cylinders shall be placed with valve end up whenever
they are in use. Liquefied gases shall be stored and shipped with
the valve end up.
23. Fuel-gas cylinders connected to one manifold having an aggregate
capacity exceeding 300 pounds (135.9 kg) of liquefied petroleum
gas or 3,000 cubic feet (48 m (3)) of other fuel-gas shall be located
outdoors, or in a separate building or room constructed.

C. PROTECTIVE EQUIPMENT, HOSE, AND REGULATORS

1. The operator must use the proper hose. Fuel gas hose is usually red
(sometimes black) and has a left-hand threaded nut for connecting
to the torch. Oxygen hose is green and has a right-hand threaded
nut for connecting to the torch.
2. Hose and hose connections shall be clamped or otherwise securely
fastened in a manner that will withstand, without leakage, twice the
pressure to which they are normally subjected in service, but in no
case less than a pressure of 300 psi. Oil-free air or an oil-free inert
gas shall be used for the test.
3. Hose showing leaks, burns, worn places, or other defects rendering
it unfit for service shall be repaired or replaced. When inspecting
hoses, look for charred sections close to the torch. These may have
been caused by flash-back. Also check that hoses are not taped up
to cover leaks.

4. Pressure-reducing regulators shall be used only for the gas and

pressures for which they are intended.

USING OXYACETYLENE EQUIPMENT:

An oxyacetylene welding outfit is basically made up of the following:
cylinders of oxygen and acetylene, regulators, hoses, and a torch.
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Oxygen and acetylene are stored in separate cylinders. A great deal of
gas is forced into each cylinder. This result in very high pressures. The
high pressures are controlled and adjusted by the regulators.
Hoses carry the gases from the cylinders to the torch. The green hose
carries oxygen. The red hose carries acetylene.
The gases are mixed inside the torch. When burned, they produce a very
hot flame. The flame is regulated (adjusted and controlled) by
interchangeable torch tips and by the torch valves.

OXYACETYLENE CUTTING
To cut steel using an oxyacetylene outfit, use a cutting torch instead of a
welding torch. Adjust the regulators for the torch tip and the thickness of
the metal to be cut.
1. Light the torch, and adjust it to a neutral flame.
2. Locate the inner core of the flame just above the work surface.
3. Tilt the tip slightly, and preheat the metal in a single spot. Keep
heating until it is cherry red.
4. Push down on the oxygen cutting lever. A jet stream of oxygen
burns through the metal.
5. Position the torch at a 90-degree angle to the work surface, and
continue cutting along the desired line. Move the torch smoothly.

LIGHTING THE TORCH

1. Select the correct size tip for the thickness of material to be
welded. Thin metal will require a small tip with a small opening.
Thick metal will require a larger tip with a larger opening.
2. Turn the regulator adjusting knobs (screws) counterclockwise until
they turn freely.
3. Slowly open the oxygen cylinder. Turn the valve as far as it well
go.
4. Slowly open the acetylene valve ¼ to ½ turn. Do not remove the
cylinder wrench from the cylinder.
5. Open the oxygen adjustment valve on the torch one full turn.
(Remember, the oxygen valve is connected to the green hose.)
With this valve open, turn the regulator knob (screw) clockwise
until the correct operating pressure is reached. When the regulator
is adjusted, turn off the oxygen valve.
6. Adjust the acetylene operating pressure. This done in the same
manner as for the oxygen (step 5). The acetylene valve is
connected to the red hose. Adjust the acetylene to the correct
operating pressure.
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7. After both regulators are properly adjusted, the torch is ready to
light. Point the tip of the torch away from the cylinders, yourself,
and others. Slightly open the acetylene valve. Light the acetylene
with a spark lighter. Continue to turn the acetylene valve until the
flame burns with very little smoke. Then slowly turn on the oxygen
valve until a small blue cone forms in the center of the flame.
Adjust the torch for the type of flame that you need.

SHUTTING OFF THE WELDING UNIT

1. First close the acetylene valve, and then the oxygen valve.
2. Tightly close the valves on both cylinders.
3. Open the valve on either the oxygen or acetylene at the torch.
Allow time for the gas to drain from the hose and regulator. Repeat
the procedure for the other gas line.
4. When the high-pressure and low-pressure gauges on both cylinders
read zero, turn the regulator screws counterclockwise as far as they
will go.
5. Close the valves on the torch.

29 CFR 1910.254
ARC WELDING AND CUTTING
INTRODUCTION:
The electric arc welder remains one of our most useful and timesaving
pieces of shop equipment. Most of these welders are typically AC/DC,
240 volt transformer types using electricity as the energy source. Portable
welders are of the diesel/gasoline engine powered type. Properly installed
and used the arc welder is very safe, but if used improperly the operator
can be exposed to a number of hazards including toxic fumes, dusts,
burns, fires, explosions, electric shock, radiation, noise, and heat stress.
Any of these hazards can cause injury or death.
Arc welding uses the heat from an electric arc to melt and fuse base
metals and welding-rod metal into one piece. The heat from the arc melts
the flux (cleaner) coating on the rod.
There are two basic kinds of arc welding machines. Some provide direct
current (DC). Others provide alternating current (AC).

SELECTING THE ARC WELDER:

When purchasing an arc welder you can be assured of design safety and
safety standards for arc welders as determined by the Underwriters
Laboratories (UL). Be sure that the welder you purchase carries the seal
of approval of UL.
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APPLICATIONS
Voltage
The following limits shall not be exceeded:
Alternating Current (AC) Direct Current (DC)
Manual 80 Volts 100 Volts
Automatic 100 Volts 100 Volts
For AC welding under wet conditions or warm surroundings where
perspiration is a factor, the use of reliable automatic controls for reducing
no-load voltage is recommended to reduce the shock hazard. Some of the
older AC machines do not have an automatic control and are on load all
the time. It is easy to receive an electric shock when the equipment is not
handled properly.

INSTALLING THE ARC WELDER

Prior to installing the arc welder you should determine if your present
electrical system is adequate to handle the increased load required by the
welder. Your local power supplier or a qualified electrician can assist you
in determining this. It is very important for your safety to install the
welder by a qualified electrician. Failure to do so could cause fire, a
ground fault, or equipment failure. The following rules are not a complete
list but are especially important guidelines which should be adhered to:
1. The frame or case of welder shall be properly grounded.
2. A safety-type disconnecting switch or controller shall be located
near the machine.
3. The welder or welders shall be protected by a properly sized fuse
or circuit breaker on an independent circuit.

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VENTILATION
The welder should be located in an area with adequate ventilation. In
general, when welding is being done on metals not considered hazardous,
a ventilation system that will move a minimum of 2000 cubic feet per
minute (CFM) of air per welder is satisfactory.
However, many materials are considered very hazardous and should be
welded only in adequately ventilated areas to prevent the accumulation of
toxic materials or to eliminate possible oxygen deficiency not only to the
operator but to others in the immediate vicinity. Such ventilation should
be supplied by an exhaust system located as close to the work as possible.

When welding or cutting metals with hazardous coatings such as

galvanized metal the operator should use a supplied-air type respirator or
a respirator specially designed to filter the specific metal fume. Materials
included in the very hazardous category are welding rod fluxes,
coverings, or other materials containing fluorine compounds, zinc, lead,
beryllium, cadmium, and mercury.

FIRE PREVENTION
The arc welder is capable of producing temperatures in excess of 10.000
degrees F., therefore it is important that the workplace be made firesafe.
This can be accomplished by using metal sheets or fire resistant curtains
as fire barriers. The floor should be concrete or another fire resistant
material. Cracks in the floor should be filled to prevent sparks and hot
metal from entering. When work cannot be moved to a firesafe area then
the area should be made safe by removing or protecting combustibles
from ignition undetected until the welder has finished the job.

Suitable fire extinguishing equipment such as buckets of sand or a dry

chemical extinguisher of the ABC type should be readily available.

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PERSONAL PROTECTION
It is essential that the operator and helpers be properly clothed and
protected because of the heat, ultra-violet rays, and sparks, produced by
arc welder. For body protection, a pair of fire retardant long sleeved
coveralls without cuffs is a good choice. Always avoid clothing with
tears, snags, rips, or worn spots as these are easily ignited by sparks. The
sleeves and collars should be kept buttoned. The hands should be
protected with leather gauntlet gloves. A pair of high to leather shoes,
preferably safety shoes, is good protection for the feet. Eyes should be
protected by transparent goggles if the person wears prescription glasses
or safety glasses if not. A welding helmet or hand shield with filter plate
and cover plate is mandatory for eye protection from the harmful rays of
the arc. A flameproof skull cap to protect the hair and head as well as
hearing protection in noisy situations is recommended.

* Plastic disposable cigarette lighters are very dangerous around heat

and flame. It is important that they not be carried in the pockets
while welding.

SAFE OPERATION OF THE WELDER

1. It is important that anyone operating an arc welder be instructed on
its safe use by a qualified person or welder.
2. Because of their potentially explosive nature, we strongly
recommend that no welding, cutting, or hot work be attempted on
used drums, barrels, tanks, or other containers under any
circumstances.
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3. The welder cables should be positioned so that sparks and molten
metal will not fall on them. They should also kept free of grease
and oil and located where they will not be driven over.
4. Electric welders can kill by electric shock. If the welding operation
must be done on steel or other conductive material an insulating
mat must be used under the operator. If the welding area is wet or
damp or the operator is actively perspiring then he/she should wear
rubber gloves under the welding gloves.
5. It is easier and safer to establish an arc on a clean surface than a
dirty or rusty one. Therefore, metal should always be thoroughly
cleaned by wire brushing or other method prior to welding. When
chipping slag or wire brushing the finished bead the operator
should always be sure to protect his eyes and body from flying slag
and chips. Unused electrodes and electrode stubs should not be left
on the floor as they create a slipping hazard.
6. Hot metal should be handled with metal tongs or pliers. When
quenching hot metal in water it should be done carefully to prevent
painful burns from the escaping steam.
7. Any metal left to cool should be carefully marked “HOT”.
8. When welding is finished for the day or suspended for any length
of time electrodes should be removed from the holder.
9. The holder should be placed where no accidental contact could
occur, and the welder should be disconnected from the power
source.

SAFETY PRECAUTIONS FOR ENGINE POWERED WELDERS

1. Always operate in an open well-ventilated area or vent the engine
exhaust directly outdoors.
2. Never fuel the engine while running or in the presence of an open
flame.
3. Wipe up spilled fuel immediately and wait for fumes to disperse
before starting the engine. “Never” remove the radiator pressure
cap from liquid cooled engines while they are hot to prevent
scalding yourself.
4. Stop the engine before performing any maintenance or trouble
shooting. The ignition system should be disabled to prevent
accidental start of the engine.
5. Keep all guards and shields in place.
6. Keep hands, hair, and clothing away form moving parts.

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 OCCUPATIONAL SAFETY AND
OSHA HEALTH ADMINISTRATION
U.S. DEPARTMENT OF LABOR
FIRST AID
The welding area should always be equipped with a fire blanket and a
well stocked first aid kit. It is desirable that one person be trained in first
aid to treat the minor injuries that may occur. All injuries, no matter how
minor they may seem can become more serious if not properly treated by
trained medical personnel.

KEY POINTS TO REMEMBER

1. Be sure the welder is properly installed and grounded.
2. Never weld without adequate ventilation.
3. Take proper precautions to prevent fires.
4. Protect your entire body with fire retardant clothing, shoes, and
gloves.
5. Wear eye protection at all times.
6. Weld only in a firesafe area.
7. Never do any welding, cutting, or hot work on used drums, barrels,
tanks, or other containers.
8. Mark metal “HOT” with a soapstone.
9. Keep a well-stocked first aid kit.

29 CFR 1910.255
RESISTANCE WELDING
GENERAL
Installation
All equipment shall be installed by a qualified electrician in conformance
with Subpart S, Electrical.

SPOT AND STEAM WELDING MACHINES

Interlocks
All doors and access panels of all resistance welding machines and
control panels shall be kept locked and interlocked to prevent access, by
unauthorized persons, to live portions of the equipment.

Guarding
All press welding operations, where there is a possibility of the operator’s
fingers being under the point of operation, shall be effectively guarded by
the use of a device such as an electronic eye safety circuit, two hand
controls, or protection similar to that prescribed for punch press
operations.

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 OCCUPATIONAL SAFETY AND
OSHA HEALTH ADMINISTRATION
U.S. DEPARTMENT OF LABOR
Shields
The hazard of flying sparks shall be, wherever practical, eliminated by
installing a shield guard of safety glass or suitable fire-resistant plastic at
the point of operation. Additional shields or curtains shall be installed as
necessary to protect passing persons from flying sparks.

Foot Switches
All foot switches shall be guarded to prevent accidental operation of the
machine.

Stop Buttons
Two or more safety emergency stop buttons shall be provided on all
special multispot welding machines, including 1-spot and 4-spot weld
presses.

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