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745 Welding, Cutting, and Brazing Safety
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745 Welding, Cutting, and Brazing Safety

Welding Safety Plan

Scope

This written Welding Safety Plan (the Plan) explains safety rules and procedures for doing welding, cutting, brazing, and similar hot work tasks. These jobs can cause fires, explosions, harmful fumes, burns, and other injuries if not done safely. This Plan helps keep workers safe by setting clear rules.

The Plan includes activities like:

  • Welding (arc welding, oxygen-fuel gas welding, and resistance welding)
  • Cutting (arc cutting, oxygen cutting, and torch cutting)
  • Open-flame soldering
  • Brazing
  • Grinding
  • Heat treating
  • Hot riveting
  • Any other activity that creates sparks, flames, or heat

This Plan does not cover:

  • Hot work in confined spaces (see the Confined Space Entry Plan)
  • Lockout/tagout procedures (see the Lockout/Tagout Plan)
Policy

It is the policy of ____________________ to keep all workers and company property safe from fire, explosion, and other dangers related to welding, cutting, brazing, and similar hot work operations. This Plan must be followed at all times when doing hot work.

Plan Administration

The roles and responsibilities for managing this Plan are shown in the Program Contact Information table. The Plan Administrator or designee is in charge of making sure hot work is done safely, and that this written Plan stays up to date. Below are administrator, supervisor, and operator responsibilities.

Plan Administrator Responsibilities

  • Check each area where hot work is done or hot work equipment is stored to identify any hazards.
  • Review hazard assessments done by contractors or consultants and keep them on file.
  • Set up designated areas for welding and cutting, and decide on safety steps for other areas based on fire risks.
  • Choose who can approve hot work in areas not set up specifically for that purpose.
  • Make sure that welders, cutters, and supervisors are trained to use their equipment safely.
  • Inform contractors of any flammable materials or other hazards they may not be aware of.

Supervisor Responsibilities

  • Ensure the safe use of welding and cutting equipment.
  • Check the work area for flammable or combustible materials.
  • Make sure flammable materials are protected or removed as required.
  • Get approval for hot work from the Administrator or their designee.
  • Approve hot work only when conditions are safe to begin.
  • Ensure fire protection equipment is available before starting work.
  • Make sure a fire watch is assigned when needed.

Operator Responsibilities

  • Only start hot work after receiving written approval from the Administrator or designee.
  • Use equipment safely and follow all safety steps to protect people and property.
  • Stop work if unsafe conditions appear.
  • Tell the Administrator or designee if unsafe conditions are suspected or if anyone is concerned about safety.
Hazard Assessment

The Plan Administrator or designee is responsible for making sure a hazard assessment is completed in every area where welding or hot work is done or might be done. This assessment helps identify things that could harm workers, like:

  • High heat or fire risks
  • Bright light (optical radiation) from welding arcs
  • Harmful fumes or gases
  • Molten (melted) metal or flying objects

Each hazard assessment must list the hazards, suggest ways to control them, and explain what kind of personal protective equipment (PPE) is needed if the hazards can’t be fully removed.

The Plan Administrator can use the Job Hazard Analysis Worksheet and the PPE Hazard Assessment Certificate to help with these evaluations.

Hazard Assessment Procedure

The following steps must be followed to check for hazards when workers are performing or located near hot work:

  1. Survey the area: Look at each work location to decide if there are known or likely hazards that require controls or PPE.
  2. Review records and layout: Look at injury reports, how the area is set up, and where workers are placed.
  3. Organize the data: Collect and arrange any useful data about the area, and estimate the risk of injuries based on possible sources of harm.
  4. Evaluate the risk: For each hazard, identify the type and seriousness of possible injuries, and check if workers could be exposed to more than one hazard at a time.
  5. Record the hazards: Write down the types of hazards found during the assessment.
  6. Choose protections: Decide which engineering controls, administrative controls, or PPE are needed to protect workers.
  7. Update the Plan: Add the results of the hazard assessment and protection recommendations to this Plan and other safety documents.
General Requirements for Hot Work Personnel

Below are the general requirements for hot work operators and fire watch personnel. Requirements for hot work permits are also summarized.

Hot Work Operators: Hot work operators are the people who perform welding, cutting, or other hot work. They must follow safety rules at all times to protect themselves and others. Hot work operators must:

  • Be trained to use their equipment safely and understand the correct way to perform hot work tasks.
  • Know the risks involved with hot work and what to do in case of a fire or emergency.
  • Use tools and equipment safely, following this Plan and the manufacturer’s instructions.
  • Get written approval from the Plan Administrator or designee before starting any hot work.
  • Stop work right away if unsafe conditions appear, and tell the supervisor or Administrator to reassess the situation.

Fire Watch Personnel: Fire watch personnel are responsible for watching the work area for any signs of fire during and after hot work is completed. Fire watch personnel must:

  • Stay in the hot work area while the work is being done and for at least 30 minutes after the work is finished.
  • Know the fire risks in the work area and understand the hot work being performed.
  • Make sure that conditions stay safe while hot work is being done.
  • Be allowed to stop the hot work if unsafe conditions develop.
  • Have fire extinguishing equipment nearby and know how to use it properly.
  • Know where to find fire alarms and how to activate them if needed.
  • Watch all areas around the hot work for possible fires and try to put them out only if it is safe to do so.
  • Immediately call the Supervisor or Plan Administrator if a fire becomes too large to control.

Hot Work Areas:

There are two types of areas where hot work may be done: designated areas and permit-required areas. Each type has specific safety rules.

A designated area is a specific place that has been approved for hot work. Examples include maintenance shops or outside locations that are built from noncombustible (non-burning) materials. These areas:

  • Are kept clear of flammable or combustible materials
  • Are separated from other work areas
  • Usually do not require a fire watch during hot work because they are already made fire-safe

A permit-required area is not normally used for hot work. Before hot work can be done in this area, it must be made safe by:

  • Removing or covering nearby flammable materials
  • Setting up ventilation and protective barriers
  • Getting a signed hot work permit
Hot Work Permit

Authorization: Only people who are approved by the Plan Administrator can give out hot work permits. Before starting hot work in a permit-required area, a written permit must be completed and signed. The Administrator or designee will decide how long the permit is good for based on the specific job and area.

Posting: A signed and dated copy of the hot work permit must be posted at the entrance to the hot work area. A copy of the standard permit form is included in this Plan. The form can be updated to include more safety steps if needed for special tasks.

General Hot Work Permit Requirements: The Administrator or designee must check all of the following before hot work begins:

  • All tools and equipment (welders, shields, PPE, fire extinguishers) must be working properly and in good condition.
  • The floor within 35 feet must be clean and free of things like paper, wood shavings, or dust.
  • Combustible floors (except wood on concrete) must be wet or covered with damp sand. Workers must be protected from shock if the floor is wet.
  • Flammable materials must be moved at least 35 feet away. If they can't be moved, they must be covered with fire-retardant blankets or shields.
  • Covers used on the floor must be tight so that sparks cannot get under them.
  • Any openings in walls, floors, or ducts within 35 feet must be sealed with fireproof material to block sparks.
  • When working near combustible walls, ceilings, or roofs, use fireproof shields to prevent fires.
  • If welding or cutting must be done on walls or roofs, check the other side for combustibles. If they cannot be moved, a fire watch must be posted on that side.
  • Do not do hot work on walls or ceilings with flammable insulation or sandwich panels.
  • Do not weld on pipes or metal objects that touch combustibles if they can heat up and cause a fire.
  • Have the right kind of fire extinguisher nearby and ready to use. Regular building extinguishers may not be enough.
  • Take extra care around automatic sprinkler systems or fire alarms so they are not triggered by mistake.
  • Protect nearby workers from sparks, slag, and heat.
Fire Prevention and Protection

All welding, cutting, and other hot work must follow the safety rules in the NFPA 51B Standard for Fire Prevention During Welding, Cutting, and Other Hot Work. If the fire risks cannot be removed or safely guarded, hot work must not be done.

General Procedures Before Hot Work Begins

These steps must be completed before any welding or hot work starts:

  • Move all fire hazards, such as paper, wood, chemicals, and flammable liquids, at least 35 feet away if possible.
  • If the object being welded or cut cannot be moved, use guards to keep sparks, heat, and slag from reaching nearby materials.
  • If there are cracks, holes, or open doorways or windows near the hot work, block them to stop sparks from spreading to other areas.
  • Make sure fire extinguishers, buckets of water, sand, or hoses are ready and close by, depending on the types of materials in the area.
Prohibited Conditions for Hot Work

Hot work is not allowed in the following situations unless the hazard has been removed or fixed when:

  • There is a risk of explosion because of flammable gases or liquids
  • There is flammable dust, lint, oil, or other materials nearby
  • There are containers, like drums or tanks, that could release toxic fumes when heated
  • The work will be done in a confined space that has not been checked and approved for hot work
Administrative Precautions

Other operations that could create heat, sparks, or flames should not be scheduled at the same time as welding or hot work if they increase the chance of a fire.

When Fire Watch Personnel Are Required

A fire watch must be assigned when:

  • There are combustible materials closer than 35 feet to the hot work area.
  • Combustible materials farther than 35 feet away could still catch fire from sparks.
  • There are openings in floors or walls within 35 feet that lead to areas with flammable materials.
  • Combustible materials are located on the opposite side of a metal wall, ceiling, or roof and could be ignited by heat transfer.
Housekeeping

Welders must keep their work area clean and organized. Welding cables and other equipment must not block walkways, stairs, or ladders.

Inspections

Before welding or other hot work begins, the Plan Administrator or their designee must inspect the work area. The inspection ensures the area is safe and that workers have the equipment they need to do the job safely.

The person doing the inspection must record the results in writing. Below is a checklist of items to inspect. This can be done using a checklist or a copy of the hot work permit.

What Must Be Checked During an Inspection
  • All hot work equipment is working properly and in good condition
  • Compressed gas cylinders are stored and used safely, as explained in this Plan
  • Electrical systems used for hot work are in good shape and follow safety rules
  • All trash, rags, and open containers of flammable liquids have been removed
  • Flammable or toxic materials have been removed, or are safely covered
  • Fire hazards near the hot work area have been removed or protected
  • Ventilation is good enough to keep the air safe for breathing
  • Nearby spaces that could be affected by hot work have also been inspected
  • All workers are wearing the required personal protective equipment (PPE)
  • Fire watch personnel are present if needed
  • Flammable coatings or insulation have been removed from work surfaces
  • Coatings containing toxic chemicals have at least 4 inches stripped away from the hot work area—or airline respirators are used
Additional Permit-Specific Inspections

If hot work is done in a permit-required area, the inspector must also complete any extra checks listed on the hot work permit.

Recordkeeping

All inspection records must be saved as required by the Recordkeeping section of this Plan. These records must be available for review by safety personnel or regulatory agencies upon request.

Personal Protective Equipment (PPE)

All employees and contractors who perform hot work must wear the proper personal protective equipment (PPE) to stay safe. This includes anyone using welding equipment or working near welding, cutting, or brazing activities.

Eye and face protection is required for all hot work and must meet the standards in ANSI Z87.1, which sets rules for safety glasses, goggles, and face shields.

General PPE Requirements

The type of PPE needed depends on the size of the job, the kind of hot work being done, and where the work is located.

Hot Work Permit Areas

  • Workers must use the PPE listed on the hot work permit before starting the job.

Designated Hot Work Areas

In designated areas where hot work permits are not required, workers must still use the following PPE and safety equipment:

  • Ventilation equipment to keep fumes, dust, and gases below dangerous levels. If not available, workers must use approved respirators.
  • Respiratory protection when needed. No one may use a respirator unless they've completed medical checks, training, and fit testing as required by the Respiratory Protection Plan.
  • Gloves, aprons, and jackets made of heat-resistant and non-electric-conductive material.
  • Welding helmets with the correct filter lenses and cover plates. (See the filter lens shade table below.)
  • Protective screens to shield others from sparks and bright welding light.
  • Harnesses and lifelines if working in a confined space (see Confined Space Entry Plan).

PPE for Arc Welding or Cutting

  • Welders must wear helmets or hand shields for all arc welding, except submerged arc welding.
  • Anyone helping with welding must wear proper eye protection.

PPE for Gas Welding or Oxygen Cutting

  • Goggles or other eye protection must be worn at all times.
  • Safety glasses with side shields and filter lenses are acceptable for light welding, torch brazing, or inspection work.

PPE for Resistance Welding

  • Operators must wear face shields or goggles to protect their eyes and faces during resistance welding or brazing.

Filter Lens Shade Number Table

When welding, it's important to protect your eyes from intense light and harmful radiation. The welding filter lens number helps you choose the right level of shade based on the type of welding you're doing. Higher shade numbers provide more protection and are used for more intense welding jobs. The table below shows the recommended lens shade numbers for different welding tasks and current levels.

Welding Operation Shade Number
Shielded metal-arc welding – 1/16" to 5/32" electrodes 10
Gas-shielded arc welding (nonferrous) 11
Gas-shielded arc welding (ferrous) 12
Shielded metal-arc welding – 3/16" to 1/4" electrodes 12
Shielded metal-arc welding – 5/16" to 3/8" electrodes 14
Atomic hydrogen welding 10–14
Carbon arc welding 14
Soldering 2
Torch brazing 3 or 4
Light cutting – up to 1" 3 or 4
Medium cutting – 1" to 6" 4 or 5
Heavy cutting – over 6" 5 or 6
Gas welding (light) – up to 1/8" 4 or 5
Gas welding (medium) – 1/8" to 1/2" 5 or 6
Gas welding (heavy) – over 1/2" 6 or 8
Hazard Notification

Some materials used in welding, brazing, or cutting can release harmful fumes or gases. Employers must make sure that warning labels are used to let workers know about these dangers. These warnings must be placed on the tags, boxes, or containers of filler metals and other materials used in hot work.

General Warning: All filler metals and fusible materials must have this label:

  • "CAUTION: Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. Use adequate ventilation. See ANSI Z49."

Cadmium Warning: If the materials contain cadmium, they must include the following label:

  • "WARNING—CONTAINS CADMIUM: Poisonous fumes may be formed when heated. Do not breathe fumes. Use only with proper ventilation, like fume extractors or air-supplied respirators. See ANSI Z49.1. If chest pain, cough, or fever develops, contact a doctor immediately.
Ventilation

Ventilation is important to keep the air safe when doing welding or hot work. Good airflow helps remove toxic fumes and keeps oxygen levels normal.

Natural Ventilation

Natural ventilation (open windows or doors) may be used if the space is large and open enough to allow fumes to escape safely.

Mechanical Ventilation – General Requirements

Mechanical ventilation (fans, blowers, or exhaust systems) is required when:

  • The space is smaller than 10,000 cubic feet per welder
  • The ceiling is lower than 16 feet
  • The area has barriers (walls, equipment) that block air movement
Mechanical Ventilation – Specifications

When mechanical ventilation is used, a special enclosure (like a welding booth) should surround the welding area. This booth should have a top and at least two sides. The ventilation must move air away from the welder at a speed of at least 100 feet per minute.

Special Material Requirements

Some metals and fluxes give off especially dangerous fumes and require special precautions:

  • Fluorine compounds: Use local exhaust or airline respirators. For brazing or welding fluxes with fluorides, use the label: "CAUTION—CONTAINS FLUORIDES: When heated, this flux gives off fumes that may irritate eyes, nose, and throat. Use only in well-ventilated spaces. Avoid contact with skin and eyes. Do not swallow."
  • Zinc, Lead, Cadmium, Mercury, Beryllium: Follow strict ventilation rules. Use airline respirators, local exhaust, or fume extractors as required.
  • Confined spaces: Always use mechanical ventilation or respirators. Follow the rules in the Confined Space Entry Plan.
Fall Protection

Anyone using hot work equipment or helping with hot work on platforms, scaffolds, or runways must be protected from falling if they are working more than 4 feet above the ground. This protection must follow the rules in the company's Fall Protection Program.

Fall protection may include:

  • Guardrails
  • Safety harnesses
  • Other approved safety systems
Special Operations – Confined Spaces

A confined space is a small or limited space that is hard to enter or exit. Examples include tanks, boilers, pressure vessels, and compartments. Working in these spaces is more dangerous and must follow the Confined Space Entry Plan.

Fire Prevention in Confined Spaces

When welding is stopped for a break or the end of a shift, workers must:

  • Remove the electrode from the holder
  • Place the holder so it cannot accidentally make contact
  • Turn off the welding machine’s power

For torch welding:

  • Close the torch valves when not in use
  • Shut off the oxygen and fuel-gas supply outside the confined space
  • Remove the torch and hose from the space when possible

Working Inside Confined Spaces

  • Use ventilation to remove toxic fumes and keep the air safe to breathe
  • Never use oxygen to ventilate a confined space
  • Keep gas cylinders and welding machines outside the confined space
  • Secure equipment with wheels so it doesn't move accidentally
  • If a welder enters through a small opening, provide a rescue plan and equipment

Rescue and Monitoring

When someone works in a confined space:

  • A trained attendant must stay outside and watch at all times
  • The attendant must be ready to carry out a rescue if needed
  • If direct sight is not possible, workers can use tapping or knocking sounds to communicate

After Work is Completed

  • Hot surfaces must be marked or labeled to warn others

Ventilation in Confined Spaces

  • Air must be clean and safe to breathe
  • If proper ventilation isn't possible, use NIOSH-approved airline respirators or hose masks
  • In extremely dangerous areas, workers must use a full-face, pressure-demand respirator, or self-contained breathing apparatus (SCBA)
Fuel-Gas Welding

Fuel-gas welding uses flammable gases (like acetylene) mixed with oxygen to create a high-temperature flame for cutting or welding. These gases can be very dangerous if not handled correctly. The following safety rules must be followed:

  • Do not allow fuel gases to mix with oxygen or air before use, except at the torch tip or burner.
  • Only use approved fuel-gas and oxygen equipment.

Portable Cylinders

  • Cylinders must meet U.S. Department of Transportation (DOT) regulations (49 CFR Parts 171–179).
  • Each cylinder must be clearly marked with the chemical or trade name of the gas it contains.
  • Markings must be stamped, stenciled, or labeled and must not be easy to remove.
  • Whenever possible, markings should be placed on the cylinder’s shoulder.
Oxy-Acetylene Welding

Oxy-acetylene welding combines oxygen and acetylene gas to produce a flame hot enough to melt metals. This process requires careful setup and handling. Welders must:

  • Check that the cylinder’s safety plug or disk is working properly.
  • Always use a regulator to control gas flow from the cylinder.
  • Stand to the side of the regulator when opening the cylinder valve slowly—do not open it more than 1½ turns.
  • Use pressure settings of 3–7 psi for oxygen and 1–12 psi for acetylene. Never exceed 15 psi for acetylene.
  • Purge gas lines before lighting. Use a striker to light the torch—never use a lighter.
  • Store oxygen and acetylene cylinders upright, with valves closed, and keep them at least 20 feet away from flammable materials.
Arc Welding

Arc welding uses electrical current to create an arc between an electrode and metal to produce high heat. This method can cause electric shock, burns, and exposure to intense light. Welders must:

  • Make sure welding machines are properly grounded.
  • Avoid working in wet or damp areas to reduce the risk of electric shock.
  • Check that all connections are secure and in good condition.
  • Use cables that are insulated and maintained in good repair.
  • Make sure cable splices are not within 10 feet of the electrode holder.
  • Use flash screens to protect others from welding light (arc flash).
  • Follow the manufacturer’s instructions and all fire safety procedures outlined in this Plan.
Resistance Welding

Resistance welding uses pressure and electric current to join metal pieces. The equipment must be inspected and maintained regularly to stay safe. Workers must:

  • Have proper training and be judged competent before operating resistance welding equipment.
  • Report any equipment problems to their supervisor right away.
  • Stop using any equipment with safety defects until it has been repaired.
Inspections
  • Qualified maintenance personnel must inspect the equipment regularly.
  • Inspection records must include the date, inspector’s name, and equipment ID number or serial number.
Emergency Response

Responding to an Injury

If someone is seriously hurt during welding or hot work, follow these steps right away:

  1. Help the injured person. Provide first aid and make the area safe.
  2. Call 911 from a company phone or use the nearest phone to call for emergency help.
  3. Tell the Health and Safety Director or your immediate supervisor.
  4. If someone is available, send them to meet and guide emergency medical services (EMS) when they arrive.
  5. Wait with the injured person until EMS arrives and takes over.
Reporting Accidents and Injuries

Anyone who sees or causes an injury or damage to equipment or property must report it to a supervisor immediately.

Accident Investigation

If a worker gets hurt or sick from a work-related cause, these steps must be followed:

  • The employee or a co-worker must notify the supervisor right away.
  • The supervisor will make sure the injured employee gets medical care quickly.
  • The injured employee must fill out the Employee Accident Report Form.
  • If the injury happened over time (like from repeated stress), write down the last day the employee worked before noticing symptoms.

Note: Use the Accident Investigation Report form attached to this Plan when completing investigations.

Training Requirements

Fire Watchers

Fire watchers must be trained to:

  • Use fire extinguishers and other fire-fighting equipment.
  • Sound the alarm if there is a fire.
  • Watch the hot work area for fires during and for 30 minutes after work ends.
  • Only try to put out fires that they are trained to handle.

Oxygen-Fuel Gas Welders and Cutters

Workers in charge of oxygen or fuel-gas systems must:

  • Be trained and approved by the employer before doing this work
  • Only allow skilled mechanics to repair gas regulators or gauges

Arc Welders and Cutters

  • Must be trained and qualified before using arc welding equipment

Resistance Welders

  • Must be trained and judged competent before operating resistance welding equipment
Recordkeeping

The Plan Administrator or designee is responsible for keeping all records related to this Plan. These records are stored at __________ and must be available for review by safety officials upon request.

Records to Maintain

  • Job hazard assessments
  • List of designated hot work areas
  • Hot work permits
  • Inspection reports and checklists
  • Accident or incident reports and investigations
  • Training records

How Long Records Must Be Kept

  • All records, including training records, must be kept for at least 3 years.
  • Training records include sign-in sheets, training materials, and individual training history.
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