Check the Risk Assessment and Safe System of Work

Before welding begins, workers should understand the relevant risk assessment, method statement and safe system of work. These documents should identify:

• The hazards associated with the welding process
• The metals, coatings and consumables being used
• The fumes and gases that may be produced
• The required extraction and ventilation
• The correct RPE and other PPE
• Fire and emergency precautions
• Measures needed to protect other people

Workers should only undertake welding activities for which they have received suitable information, instruction and training.

Position Welding-Fume Extraction Correctly

One of the most important safe working practices is positioning the local exhaust ventilation (LEV) correctly before welding begins.

Whether using on-torch extraction, a moveable extraction arm or a portable extraction hood, the equipment must capture the fume close to its source before it enters the welder’s breathing zone or spreads through the workplace.

Using a Moveable Extraction Hood

The hood should be positioned as close to the weld as practicable without interfering with the work or drawing shielding gas away from the welding process.

An extraction hood that is too far away or pointing in the wrong direction will not capture fumes effectively. The hood must be repositioned whenever the welding location or working angle changes.

Using On-Torch Extraction

Before using on-torch extraction, check that:

• The extraction unit is switched on and operating correctly
• The hose and connections are secure and undamaged
• The extraction openings are not blocked
• The airflow indicator shows that the system is working correctly
• The extraction setting follows the manufacturer’s instructions

Keep Your Head Out of the Welding-Fume Plume

Hot welding fumes will generally rise from the weld, although their direction may be affected by draughts, workplace ventilation and the position of the workpiece.

Avoid leaning directly over the welding area. Adjust your posture and, where it is safe to do so, reposition the workpiece so the fumes are directed away from your breathing zone and towards the extraction system.

Never place your head between the weld and the extraction hood, as this can draw the fume through your breathing zone.

Wear the Correct RPE and PPE

Welding can expose workers to fumes, gases, ultraviolet radiation, sparks, molten metal, heat, electricity and noise. The risk assessment should identify the required respiratory protective equipment (RPE) and personal protective equipment.

Depending on the task, this may include:

• Suitable RPE where required
• A welding helmet or visor with the correct filter shade
• Safety glasses or goggles
• Heat-resistant welding gloves
• Flame-resistant protective clothing
• Suitable safety footwear
• Hearing protection where required

Using Respiratory Protective Equipment

RPE must be adequate for the welding hazard and suitable for the wearer, task and working environment. Tight-fitting masks must be face-fit tested for the individual wearer.

The wearer must be clean-shaven wherever a tight-fitting mask seals against the face. RPE must be worn correctly throughout the exposure period and must be compatible with the welding visor and other PPE.

Checking PPE Before Use

Inspect PPE and RPE before starting work. Do not use equipment that is contaminated, damaged, defective or beyond its replacement date. Report problems and obtain suitable replacement equipment before continuing.

Keep the Welding Area Clean and Organised

Good housekeeping helps prevent slips, trips, fires and interference with welding-fume controls. Before welding begins:

• Remove unnecessary materials and waste
• Remove or protect combustible materials
• Keep cables and hoses organised
• Maintain clear access and escape routes
• Keep extraction inlets and airflow routes unobstructed
• Provide suitable containers for welding waste
• Ensure appropriate fire-fighting equipment is available

Dust and residues should be removed using a safe method identified in the risk assessment. Do not use dry sweeping or compressed air where this could spread hazardous contamination.

Use the Correct Welding Process and Settings

Always follow the approved procedure and use the correct settings for the welding process, consumable and material.

Incorrect settings can:

• Increase the amount of fume produced
• Affect weld quality
• Increase spatter and heat
• Damage equipment or materials
• Create additional safety risks

Follow the equipment manufacturer’s instructions, workplace procedures and applicable welding specifications. Do not alter approved settings unless authorised and competent to do so.

Check Coatings and Contamination

Paint, plating, galvanised coatings, oils, solvents and other surface contaminants can produce additional hazardous fumes or gases when heated.

The material should be assessed before work begins. Where necessary, coatings or contamination should be removed using a safe, approved method and suitable exposure controls.

Inspect Welding Equipment Before Use

Welding equipment should be checked before every use. This includes:

• Gas cylinders and valves
• Regulators and gauges
• Hoses and connections
• Welding torches and electrode holders
• Electrical cables and welding leads
• Earth or return clamps
• LEV equipment and extraction hoses
• RPE and other PPE

Look for leaks, damaged insulation, loose connections, blockages, excessive wear and other visible defects.

Report defects immediately and do not use damaged or unsafe equipment. Equipment should only be repaired by someone with the necessary competence and authorisation.

Handle Welding Gas Cylinders Safely

Gas cylinders must be handled, stored and used in accordance with the supplier’s instructions and workplace procedures. Safe practices include:

• Securing cylinders in an upright position where appropriate
• Protecting cylinders from damage and excessive heat
• Using the correct regulator and connections
• Keeping oxygen equipment free from oil and grease
• Closing cylinder valves when equipment is not in use
• Checking for leaks using an approved method
• Moving cylinders with suitable handling equipment

Protect Other People from Welding Hazards

Welding fumes and other hazards can affect anyone in the area, not only the welder. Before starting, identify who else could be exposed and introduce appropriate controls.

These may include:

• Restricting access to the welding area
• Separating welding from other work activities
• Using welding screens to protect people from harmful optical radiation and sparks
• Using suitable enclosure or ventilation to control the spread of fumes
• Positioning extraction so it captures fumes without drawing them towards other workers
• Warning nearby workers before welding begins

Welding screens protect against radiation and sparks, but they do not replace effective fume extraction. Screens and enclosures must also be positioned so they do not prevent the LEV from operating effectively or allow fumes to accumulate.

Report Problems and Stop Work When Necessary

Stop welding and report the problem if:

• The LEV stops working or is not capturing the fume
• Required RPE or PPE is unavailable or defective
• The materials or coatings differ from those identified in the assessment
• The working conditions change significantly
• A gas leak, electrical defect or fire hazard is discovered
• Fumes are spreading towards other people
• You develop symptoms such as coughing, chest tightness, dizziness or breathing difficulty

Work should not restart until the problem has been assessed and suitable controls have been restored.

Key Safe Welding Practices

• Follow the risk assessment and safe system of work.
• Position extraction correctly before welding begins.
• Reposition moveable extraction as the work progresses.
• Keep your head out of the welding-fume plume.
• Wear suitable RPE and PPE correctly.
• Keep the welding area clean and organised.
• Use approved welding processes and settings.
• Check the material for hazardous coatings and contamination.
• Inspect welding and extraction equipment before use.
• Protect everyone who may be affected by the work.
• Stop work and report defective or ineffective controls.