HEALTH AND

SAFETY IN
WELDING
Published by the Department of Labour
Wellington
New Zealand
October 2006
ISBN 0-478-28075-0
Contents
Introduction 5
Part 1: Welding hazards 6
Part 2: Training, qualifications and competency 9
Part 3: Equipment selection, maintenance and safety 11
Part 4: General health and safety in welding 12
Part 5: Fire and explosion prevention and hot work 13
Part 6: Personal protective equipment (PPE) 16
Part 7: Fume and gas control 18
Part 8: Local exhaust ventilation for welding processes 21
Part 9: Electrical safety 24
Part 10: Safe use of welding gases 26
Part 11: Hazardous substances 28
Part 12: Metal preparation 32
Part 13: Welding in confined spaces 33
Part 14: Hot metals sparks 36
Part 15: Radiation(ultraviolet, infrared and lasers) 37
Part 16: Working technique 38
Part 17: Noise and vibration 39
Part 18: Manual handling 40
Part 19: Hand tool fitness and safety 41
Part 20: Specific requirements of the Health and Safety
in Employment Act 1992 42
Part 21: Welding fume control summary worksheet 45
Introduction

Welding poses a range of both well known and subtle hazards to health and
safety. These can act quickly or may show up only in the long term. They can be
rapidly fatal (electric shock or exposure to cadmium fumes) or have delayed
effects (lung changes over time).
The Department of Labour has adopted the following documents, published
by the Welding Technical Institute of Australia (WTIA), as its main sources of
advice about health and safety in welding:
• Health and Safety in Welding 2004 – Technical Note 7 (TN7)
• Fume Minimisation Guidelines (FMG)
Printed copies of TN7 may be obtained from:
Heavy Engineering Research Association
PO Box 76134
Manukau City
Auckland
Tel (09) 262 2885
www.hera.co.nz
The Fume Minimisation Guidelines can be downloaded free from:
www.wtia.com.au/fmg.html
This booklet summarises some of the main points in the relevant sections of
both the above publications.
The Welding Health and Safety Assessment Tool, along with other related
information, can be downloaded from the Department of Labour website:
www.dol.govt.nz
Providing health and safety information and advice for employees who carry
out welding and cutting processes can be complex. There are many subtleties
and traps for the unwary or inexperienced. If you have any doubt that the
information available on the Department of Labour website or in the WTIA
publications covers your situation, get help from a specialist.

Health and Safety in Welding 

Part 1: Welding hazards

Fires and explosions

These are an ever-present hazard with many welding processes.

Burns
Welding causes items to become hot – creating a risk of burns and fires from
hot metal and welding spatter.

Fumes
Fumes generated by different welding processes may range from being of
nuisance value to highly toxic. Health effects can occur very soon after
exposure (e.g. exposure to cadmium fumes can be fatal within hours) or may not
result until after many years. Fume control requires appropriate ventilation
equipment and may require advice from a specialist.

Electric shock
Welding processes that use electricity pose both obvious and subtle hazards
of electric shock – which can be fatal. Standard precautions, as explained in
this book, need to be taken during the use of welding equipment, and expert
assistance can be needed in some circumstances to identify subtle hazards.
Equipment selection, set-up and maintenance is important and may require
specialist advice to ensure safety.

Compressed gases
Compressed gases in cylinders pose a number of hazards. Methods for their
safe use are outlined in TN7 chapter 5.

Hazardous substances
Hazardous substances used during some welding processes can require highly
specialised methods of control (e.g. the extremely toxic hydrofluoric acid.)

 Health and Safety in Welding

Toxic gases
Toxic gases may be:
• used in, or generated by, the process (e.g. acetylene, ozone, nitrogen oxides,
carbon monoxide)
• generated when coatings on metal surfaces are heated (e.g. epoxy resins,
degreasing agents, paint)
• generated when the arc flash and some degreasing chemicals or paints
react (e.g. phosgene or phosphine).
Precautions for preventing these hazards from causing harm are outlined in
TN7 chapters 5 and 10.

Suffocation
Inert gases used during welding can flood an area and lower its oxygen content,
especially in confined spaces. Suffocation can result.

Radiation
Arc flash is a well known hazard of welding. Standard precautions (see part 15)
should be used to prevent eye and skin exposure – both for the worker and for
people in the vicinity. Reflecting surfaces make exposure to radiation more
likely.

Heat stress
Working for long periods in hot environments can lead to distress and in an
extreme, fatal heat stroke. Specialist advice must be sought if welders work in
hot environments. (See TN7 chapter 23.)

Dust
Associated processes (grinding) may generate hazardous levels of dust.

Noise and vibration

Noise and vibration levels during some welding processes can be high and
should be controlled and/or appropriate hearing protection should be worn.

Health and Safety in Welding 

Manual handling
Some welding processes may involve heavy and or repetitive handling.

Specific processes
Several processes, not covered by this booklet, are discussed in TN7:
• thermit welding
• laser welding
• electroslag welding
• plasma cutting
• resistance welding
• electron beam welding
• brazing and soldering
• thermal lancing.

 Health and Safety in Welding

Part 2: Training, qualifications and
competency

General
Welding involves a wide range of processes carried out in a variety of working
conditions.
Certain work, especially where safety critical items are fabricated, requires a
high level of skill and competency (e.g. welding pressure vessels) whereas a high
skill level may not be so critical in some general purpose welding.
Only workers with appropriate levels of competence and skill should do welding.
They must know:
• the right way to do the work
• the hazards of the work
• how to prevent those hazards causing harm.
Competence in welding may be shown by an appropriate qualification issued by
a registered training organisation (such as an industry training organisation
(ITO)) or relevant unit standards for welding from the National Qualifications
Framework. Welders should not use equipment for which they are not certified.
Welders should be trained in the use of fire extinguishers and hot work permits,
if they are used.

The value of experience

Welding is often a complex, safety critical operation and a great deal of
knowledge may be required to provide for all aspects of health and safety.
This knowledge will not come entirely by reading or training. Experience, skill and
practice should also inform safe working practices.
This means that welding safety should be considered a team effort, with team
leaders actively coaching team members and team members referring to
knowledgable team members if they are not sure of correct health and safety
practices. This is especially important when doing new tasks.

Health and Safety in Welding 

Relevant standards
Standards applying to welding processes include:
• NZS 4711: 1984. Qualification tests for metal-arc welders.
• AS/NZS 1338.1:1992 Filters for eye protectors–Filters for protection
against radiation generated in welding and allied operations
• The AS/NZS 1554 series. Covers: Welding of steel structures; Welding of
high strength quenched and tempered steels; Welding of steel structures to
high levels of fatigue loading; Welding stainless steel for structural purposes
• AS 1796–Certification of welders and welding supervisors
• AS 2214–Certification of welding supervisors – structural steel welding.
• AS/NZS 3100:2002 Approval and test specification – General requirements
for electrical equipment
• AS/NZS 3195:2002 Approval and test specification – Portable machines for
electric arc welding and allied processes
• AS/NZS 1995:2003 Welding cables
• AS/NZS 3957:2006 Light-transmitting screens and curtains for welding
operations.
The New Zealand Qualifications Authority (NZQA) publish a list of over 30 unit
standards for welding processes. This includes US 21907 Demonstrate and
apply knowledge of safe welding procedures under supervision, and there are
also health and safety components in each of the unit standards listed. See
the Department of Labour website.

10 Health and Safety in Welding

Part 3: Equipment selection, maintenance
and safety

Consult TN7 for details of

selecting the right equipment for
the particular welding process
being carried out.
Generally, the manufacturer
or supplier of the equipment
will give detailed directions for
setting up the equipment, safe
usage and maintenance. These angle grinder

directions should be followed.

Health and Safety in Welding 11

Part 4: General health and safety
in welding

Good housekeeping
Good housekeeping, especially the removal of combustible materials, is
essential.

Gas
If you can smell gas – don’t light any gas torches or use electric welding
equipment, but don’t rely wholly on your sense of smell to warn you.

Eye protection
Wear eye protection and cover bare skin. Be aware that:
• arc flash can occur through the side of the eye
• arc flash can cause ‘sunburn’ on exposed skin.

Hot surfaces
Mark hot surfaces as such. Better still, assume everything is hot.

First aid
In addition to standard training, first-aiders in welding situations should know
about the symptoms of electric shock, arc flash and the consequences of
exposure to heated coatings on metals (e.g. when galvanised metal is welded).

12 Health and Safety in Welding

Part 5: Fire and explosion prevention
and hot work

General
Prevent the ignition of combustible materials that may be near the welding
process. If welding a metal wall or partition (or if welding near one), you should
check what is behind it.
Know how to use gas equipment safely.
• Oxygen under pressure can cause the spontaneous combustion of oil or
grease. Keep all regulators and air hoses free of oil and grease, and avoid
getting grease/oil on hands, gloves and overalls.
• Use the right gases for the situation. Never substitute oxygen for
compressed air.
• In confined spaces, the risk of fuel gases and air combining to ignite or
explode is increased. Don’t allow welding gas supply lines to lie in a confined
space where they may leak.
Keep appropriate fire extinguishers available and visible at all times. Make sure
staff are trained in their use.
Consult the relevant sections of TN7 (chapters 5 and 16), NZS 4781:1973 Code
of practice for safety in welding and cutting and AS 2865 Hot work.

Work on drums and tanks

Severe explosions and fires, many resulting in fatalities, have been caused by
welding, cutting, brazing, soldering on pipes, tanks, drums, and similar vessels
which previously contained flammable materials.
Containers which have held petrol, white spirit or other flammable substances
are highly dangerous to work on and a pin-point of heat can be enough to set
off an explosion or fire. Equally dangerous are pipes or containers which have
held substances like linseed oil, soap, diesel oil, acids that react with metals to
produce hydrogen, or combustible solids which may have left a residue of dust.
It is essential to remove all residues. The preferred method is to steam clean
and then either fill with an inert gas such as carbon dioxide or nitrogen, or fill

Health and Safety in Welding 13

with water, leaving a very small vented space at the point where the repair
is to be made. (Allow for the expansion of liquid in small-bore pipes.) Washing
containers with cold or hot water, or blowing with air are both ineffective.
Cleaning with trichloroethylene must be carried out with care, since it is toxic
and decomposes on heating and may form phosgene gas.
Welders should study the booklet Hot Work on Tanks and Drums (obtainable at
any Department of Labour office) before carrying out such repairs. Also, see
TN7 chapter 21. A sample hot work permit follows:

14 Health and Safety in Welding

 On the left is an example of a hot work
HOT WORK PERMIT permit which can be printed on a card and
TO BE DISPLAYED ON THE WELDING OR
attached to a welding trolley.
CUTTING APPARATUS AND RETURNED
TO THE RESPONSIBLE OFFICER ON Below is an example of the hot work permit
COMPLETION OF THE WORK.
advocated in NZS 4781.
Permission granted to: (Name)

To use (Type of equipment)

HOT WORK PERMIT

In (location) ................................................................................
(Name)

is hereby authorised to carry out

On (date)
cutting*, burning*, welding*
(*cross out where not applicable)
From (time) Other work on

To (time ................................................................................
completed) (Plant or equipment)

as from
1. All combustible materials
removed or made safe ................................................................................
(Date, time)
2. No flammable liquids, vapours,
gases or dusts present Signed

3. Extinguishers/hoses provided
................................................................................
on site Factory manager

4. Operator knows how to use fire I have inspected the work. The permit
equipment has been withdrawn as from as from
5. Operator knows location of
telephone/fire alarm ................................................................................
(Date, time)

6. Site inspected after completion Signed

of work.

Permit issued by (responsible officer) ................................................................................

Factory manager (or nominee)

Health and Safety in Welding 15

Part 6: Personal protective
equipment (PPE)

Standard personal protective welding helmet with

equipment (PPE) for the variety of arc flash filter
hearing cap
welding processes includes:
protection goggles
• welding helmet with a suitable arc
dark, flame-proof
flash filter, not less than shade 10.
clothing with long
(Note: A welding helmet does not sleeves and neck
protect against fumes.) fastenings

• eye protection – and use dark gloves

clothing to avoid ultraviolet (UV) apron
rays
• flameproof overalls with long
sleeves and neck fastenings
• gloves (AS/NZS 2161 –
Occupational protective gloves) steel-capped
Full PPE boots
• apron
• respiratory protection
Welding without this protection may
allow bare skin to be exposed to the
Respirator
welding arc.

• hearing protection
Eye protection

Eye protection may be worn under

a welding helmet for additional
protection. Eye protection must be
worn when using a tool such as a
Hearing protection chipping hammer or powered grinder
to prepare or deslag metal.

16 Health and Safety in Welding

Additional items of protective
clothing may include:
cap
• a cap
• neck covering (for protection
from arc flash in confined
spaces)
• spats or leggings
• steel-capped boots (AS/NZS
2210 Guide to occupational
protective footwear).
Additional respiratory protection spats or
may be required (e.g. when welding leggings
galvanised metal or when cadmium
is present in welding rods). This
may range from simple filter
masks that fit under the welding steel-
helmet to powered air purifying Welder capped
with PPE boots
respirators. Specialist help may be
needed to select, fit and maintain
these items. Please refer to the
Department of Labour publication A Guide to Respiratory Protection; AS/NZS
1715:1994 Selection, use and maintenance of respiratory protective devices; and
TN7, chapter 19.
Personal protective equipment must be paid for by the employer – see section
10(2) of the Health and Safety in Employment Act 1992. Some protective
equipment is designed to protect people in the vicinity from arc flash – such as
portable welding screens. These should be dark in colour as shiny surfaces can
reflect a significant amount of the arc flash.

Health and Safety in Welding 17

Part 7: Fume and gas control

Exposure to welding gases and fumes can be fatal. Unsafe atmospheres and
toxic welding gases and fumes may create a risk of discomfort, suffocation, fire
and poisoning.
Nuisance dusts include iron and
aluminium oxides generated in large
quantities, which should be controlled
at source.
Examples of toxins are ozone, carbon
monoxide, nitrogen oxides and fumes
from highly toxic metals including
cadmium, zinc, beryllium, lead,
chromium, nickel, manganese and
copper. Fumes from some of these
metals can cause cancer.
Inert shielding gases may pose risks
Fumes of oxygen depletion and therefore
suffocation, especially in confined
spaces.
Some welding gases present risks of fire and explosion.
Welding in confined spaces may increase the risks of each of these types of
hazard (see Part 13: Welding in confined spaces).
Preparation of metal surfaces may cause toxic fumes or vapours to be
released. Examples include:
• when paints or plastic coatings are heated
• if degreasing agents, oil or grease are not removed from metal surfaces
• welding car parts painted with isocyanate paints.
The interaction of the welding arc and certain degreasing agents can generate
the highly toxic gas phosgene.
Fumes generated by fluxing agents in welding rods, welding pastes and silver
brazing fluxes can cause allergic reactions.

18 Health and Safety in Welding

You cannot rely on the sense of smell to detect any of these hazards. Some
cannot be smelt at all and the sense of smell can become insensitive to those
odours it can detect.
Special efforts to ensure adequate ventilation (especially in confined spaces)
and to control fumes are necessary.

Basic methods of gas and fume control

Create less fumes

• Use a welding technology that creates less fumes (and is also more cost
effective). For example, substitute manual welding with gas metal arc (MIG)
welding, or substitute MIG with submerged arc welding.
• Use electrodes that create less fumes.
• Reduce the current to the minimum possible.
• An approximate decreasing order of fume generation is:

Manual metal arc welding

Most fume
(MMAW)

Gas metal arc welding

Less fume
(MIG)

Gas tungsten arc welding

Least fume
(TIG)

Substitute dangerous work methods

• Substitute a dangerous substance with a less dangerous one.
• Arrange the work so that hot gases and fumes do not rise into the worker’s
face.
• Automate where appropriate.

Use dilution ventilation

This method disperses fumes and gases from near the worker to the wider
workplace. Placing extraction fans in walls and ceilings, keeping doors open or
having a large volume of room space for each worker are common approaches.

Health and Safety in Welding 19

This method is suitable only for low toxicity fumes and is not suitable where
toxic substances or metals are generated or welded.
See TN7 Section 17.4 and Table 17.1.

Use local exhaust ventilation

This is the preferred option.
Local exhaust ventilation systems capture fumes and gases near the point
where they are generated. This method is essential for many welding processes.
See TN7 Chapter 17 and the WTIA Fume Minimisation Guidelines and part 8 of
this guide for more detail.

Limit the exposure period

This administrative control may not prevent toxic effects from short-term
exposure and is unsuitable for toxic contaminants.
It may be essential when working in confined spaces. See part 13: Welding in
confined spaces.

Use personal protective equipment (PPE)

Certain PPE is standard in welding processes, but should be regarded
as a method of last resort for fume control, where other methods prove
unsatisfactory. See details above and in part 8: Local exhaust ventilation for
welding processes.

20 Health and Safety in Welding

Part 8: Local exhaust ventilation
for welding processes

Chapter 17 of TN7 and the Fume

Minimisation Guidelines cover this topic
fully. These notes aim to give a brief
overview of welding ventilation best
practice.
The amount of fume generated depends
on:
• the process being used
• the type of welding consumables
(rods) used
• what is being welded
• any coatings on it
• the temperature
• the amperage and voltage of the welding current
• gas and arc temperatures
• heat input and
• the duration and frequency of the work.
After these aspects of the task have been chosen to minimise fume
generation, some fumes may remain. The best way to prevent exposure is to
provide appropriate ventilation.

Mechanical dilution ventilation

This will be adequate only in the circumstances described in TN7 Section 17.4
and Table 17.1.
Portable fans blowing fume away from the welder’s breathing zone are one way
of providing exhaust fume control. A capture velocity of 0.5 m/s is required.
Velocities up to 2.0 m/s should not interfere with shielding gases. This may not
be suitable in some circumstances.

Health and Safety in Welding 21

Local exhaust ventilation
Local exhaust ventilation has the following
components:
• A hood, a duct system, an air-cleaning
device, an exhaust fan and a stack.
Using portable
• A ventilation slot at the rear of the fume exhaust
welding bench. Precise specifications for
the air-flow rates for different types and
sizes of capture hoods can be found in
TN7.
• Specific purpose ventilation. Fixed hoods
can be located at points where welding
occurs for example, where components
to be welded are held in jigs.
• Ventilation equipment mounted on the welding gun. Care needs to be taken
over the design (for worker acceptance) and the disturbance of shielding
gases, if they are used. Regular maintenance is essential if this equipment is
to work properly.
• Relocatable exhaust hoods connected to fans and air-cleaners by flexible
tubing. These may connect to a fixed fan or vacuum cleaner-type unit. They
allow the welder to reposition the suction inlet as welding proceeds.
Capturing fumes when the point of welding moves may be more difficult, but is
important when exposure is significant.
Local exhaust ventilation may be required whenever:
• welding takes place in confined spaces
• the metals listed in TN7 Table 17.2 are being welded.
Whenever workers may be exposed to beryllium or cadmium, local exhaust
ventilation and personal respiratory equipment must be provided, such is their
toxicity, no matter where welding is carried out.
Coatings on metals often give rise to hazardous exposures. The correct
identification of metal coatings and their removal is the preferred control
measure. Local exhaust ventilation (and possibly personal protective

22 Health and Safety in Welding

equipment) will be essential to control toxic dusts/fumes if these coatings
cannot be removed.
Special measures to control toxic products (phosgene and phosphine) that
can be generated when metals contaminated with degreasing agents and
phosphate paints (respectively) are welded, are described in TN7 part 17.11.
Equipment may be needed to measure the levels of gases such as carbon
monoxide, ozone and nitrogen oxides.
The fume control worksheet shown in part 21 can indicate the level of
protection required in other circumstances.

Health and Safety in Welding 23

Part 9: Electrical safety

See TN7 chapters 4 and 14 for details about general electrical safety and the
specific electrical safety measures required for each different welding process.
Ensure equipment is constructed to the relevant standards (AS 1966 and
AS/NZS 3195).
Ask the advice of the welding equipment supplier or an appropriately qualified
specialist when purchasing and/or installing welding equipment. Some basic
precautions follow.

Equipment electrical safety

• ensure the equipment has the correct
current capacity
• provide an isolating switch
• where a flammable gas or solvent is
present, an electrical spark might
Angle grinder
cause an explosion, so welding should
not occur
• take care to preserve electrical
polarity when using two welding machines on electrically connected metals
• use a welding machine with an automatic cut-out to ensure the duty cycle
cannot be exceeded
• inspect equipment regularly (AS/NZS 3100:2002 Approval and test
specification – General requirements for electrical equipment and
AS/NZS 3195:2002 Approval and test specification – Portable machines for
electric arc welding and allied processes). Do not use equipment with frayed
or cracked leads, connectors or fittings or broken switches and cover
plates. Do not allow them to be used while waiting for repairs
(see AS/NZS 1995:2003 Welding cables). Leads need to be tested and
tagged
• select an appropriate rod holder (AS 2826-1985: Manual metal-arc welding
electrode holders)
• check the electrical safety of the rod holder or welding hand-piece
regularly – maintain or replace as required
24 Health and Safety in Welding
• use the shortest possible leads and ensure they are capable of carrying the
required current safely
• use a residual current device (RCD) when using hand-held power tools
• use appropriately-rated powerboards rather than double adaptors or
piggyback plugs.

Safe use of equipment

• be aware of welding where water may be present (showers, kitchens, boats,
spas, swimming pools etc.)
• never twist or knot a lead, bend it sharply, tack it to a wall or drape it over
your body
• dry your hands before welding. If you get sweaty, dry off, take a break and
use a wooden duckboard to insulate yourself
• disconnect electrical equipment immediately after use
• pull on the plug, not the lead, to unplug equipment
• use welding gloves – keep them and any protective clothing dry. Don’t work
in the rain. Don’t hold electrodes under the armpits.
If you use a petrol motor generator to power a welding set, be aware that
carbon monoxide can kill quickly. Don’t use in confined spaces, including ones
that appear to be ventilated, such as a parking garage.
TN 22, Welding Electrical Safety, is also available from the Welding Technical
Institute of Australia.

Health and Safety in Welding 25

Part 10: Safe use of welding gases

Maintenance of gas bottle

integrity
• cylinders should be correctly labelled
chained
• cylinders should be stored in a ventilated halfway
trolley
area
• cylinders should be properly secured
against falls
• fuel gas cylinders and oxygen cylinders
should be stored separately
• gas cylinders should be kept away from
electrical apparatus and sources of heat
• acetylene cylinders should be stored upright
• gas cylinders should be regularly examined for signs of defects, rusting or
leakage
• empty cylinders should be appropriately marked and stored with their
valves closed.

Integrity of equipment connected to gas cylinders

• flashback arrestors must be fitted to fuel and oxygen bottles
• the integrity of the equipment fitted to gas cylinders should be inspected
routinely
• cylinders, cylinder valves, couplings, regulators, hoses and apparatus should
be kept free of oily or greasy substances
• red should be used to identify acetylene (and other fuel gas) hoses, blue for
oxygen hoses, and black for inert gas and air hoses
• copper piping should not be used with acetylene.

26 Health and Safety in Welding

Correct usage of gas equipment
Operators should know:
• the correct assembly procedures for attaching equipment to gas cylinders
• the correct procedures and materials (detergent, not soap) for leak testing
• the correct procedures for lighting gas torches and shutting them off
• the signs of a flashback, what to do in response, how to check if damage
has occurred to equipment and the actions necessary if it has occurred
• never to crack a fuel gas cylinder valve near a source of ignition
• before a regulator is removed, to close the valve and release gas from it
• NOT to use the oxygen cylinder to dust off clothing
• NOT to use the oxygen to ‘sweeten’ the atmosphere.
The use of LPG should be avoided in holes and trenches, where it can pool at a
low level.

Health and Safety in Welding 27

Part 11: Hazardous substances

Hazards from metals used in welding

Metal fumes generated during welding range in toxicity. Because fumes from
different metals are combined in the welding plume, it is clear that avoidance of
the plume is the best protection against inhalation.
Aluminium: Fume group A (least toxic). Exposure to aluminium fumes may
produce some lung effects. There is no clear picture of the dose required
(concentration x time) for these to occur.
Barium: Fume group C (highly toxic). Water or acid soluble barium compounds
are extremely poisonous. Fumes containing barium may result in a lung
condition called baritosis which is one of the benign pneumoconioses in
which inhaled particulate matter lies in the lungs for years without producing
symptoms. Baritosis produces abnormal physical signs including incapacity
for work, interference with lung function, or liability to develop pulmonary or
bronchial infections or other thoracic disease.
Beryllium: Fume group D (extremely toxic). Used mainly as an alloy with other
metals, beryllium is deadly and extreme precautions must be taken. This metal
must be welded in inert atmospheres, inside airtight enclosures, with the
welder outside.
Cadmium: Fume group D (extremely toxic). Used in electroplating and as an alloy
with metals, cadmium is also an ingredient in some paints. A single exposure to
cadmium oxide fumes can cause fatal lung irritation.
Chromium: Fume group C (highly toxic). The oxidation of chromium alloys can
produce chromium trioxide fumes, often referred to as chromic acid. These
fumes may produce skin irritation as well as bronchitis and other problems.
Cobalt: Fume group C (highly toxic). Milling tungsten carbide tips (during saw
sharpening) can cause airborne dust concentrations great enough to lead to
‘hard metal’ respiratory disease. Cobalt (a binder ingredient) is considered a
crucial factor in producing this disease, though this may involve an interaction
with the tungsten carbide itself.
Copper: Fume group B (toxic). Like zinc, Inhalation of copper fume may cause
‘metal fume fever’.
28 Health and Safety in Welding
Iron: Fume group A (least toxic). Prolonged, heavy exposure to fumes from
welding iron articles can result in a condition called siderosis, with visible
changes on an x-ray but no changes in lung function.
Lead: Fume group C (highly toxic). Poisoning generally results from inhalation
of fumes, although the swallowing of dust is also a cause. Lead-based paints
are a source of lead fumes, especially when old steel structures are cut or
welded. Signs and symptoms of lead poisoning may include abdominal pains,
constipation, headaches, weakness, muscular aches or cramps, loss of appetite,
nausea, vomiting, weight loss, and anaemia. In severe cases, it can be fatal.
Magnesium: Fume group B (toxic). The oxide fumes from magnesium can
produce metal fume fever, which is characterised by influenza-like symptoms.
Manganese: Fume group B (toxic). Manganism is a serious occupational disease
but its link to welding is controversial.
Mercury: Mercury vapour can be produced by welding or cutting metals
coated with protective materials containing mercury compounds, such as the
antifouling paints used on ships’ hulls. Nowadays, less toxic substitutes are
used in place of mercury, but there will still be some vessels in service which
are protected with mercury-containing antifouling compounds. Exposure to
mercury vapour may result in abdominal pain, vomiting, diarrhoea, and other
serious problems which, collectively, can result in death.
Nickel: Fume group C (highly toxic). Often used as an undercoating on chrome-
plated parts, nickel and its compounds are generally considered to have low
toxicity.
Silver: Fume group C (highly toxic).
Tin: Fume group A (least toxic).
Titanium: Fume group A (least toxic). Dust may irritate the respiratory tract in
high concentrations.
Tungsten: Fume group B (toxic). Milling tungsten carbide tips (during saw
sharpening) can cause airborne dust concentrations great enough to lead to
‘hard metal’ respiratory disease. Cobalt (a binder ingredient) is considered a
crucial factor in producing this disease, though this may involve an interaction
with the tungsten carbide itself.

Health and Safety in Welding 29

Vanadium: Fume group C (highly toxic). Dust and vanadium pentoxide fumes may
cause severe eye, throat and respiratory tract irritation and pain.
Zinc: Fume group B (toxic). Welding, brazing, or flame cutting of galvanised steel
causes zinc oxide fumes. Inhalation of these may result in metal fume fever.

Fluorides
These and other toxic compounds of fluorine may be found in some welding and
brazing fluxes, electrode coverings and submerged arc fluxes. Containers are
labelled to warn of the presence of fluorides. The fumes will cause chills, fever,
painful breathing, and coughs if inhaled. Over a long period, fluoride can build up
in the bones, causing them to lose calcium and become brittle.

Hazards from gases generated by welding processes

The following gases are generated from welding processes and are particularly
serious hazards that must be protected against.
• Nitrogen dioxide: Formed in the welding arc directly from the air, nitrogen
dioxide is very irritating to the eyes and mucous membranes of the lungs
and throat. Exposure to concentrations between 200 ppm and 700 ppm
(parts per million) can be fatal. Lower concentrations may produce only
mild bronchial irritation, but will be followed several hours later by acute
pulmonary oedema (fluid in the lungs).
• Phosgene: This gas is produced when residues of chlorinated hydrocarbon
degreasers, such as trichloroethylene and perchloroethylene, are left on
metal being welded or flame-cut. The heat and the ultraviolet radiation
cause the degreaser to decay into phosgene gas, which was used as a
poisonous gas in the First World War. Freon gas, which is used in many
refrigeration plants and as a propellant in aerosol cans, will also decompose
to form phosgene when exposed to ultraviolet rays. Phosgene will produce
skin inflammation. Inhalation of high concentrations will cause pulmonary
oedema. Death may result through respiratory or heart failure.
• Phosphine: When steel which has been coated with a phosphate rust-
proofing is welded, phosphine gas is generated. High concentrations will
irritate the eyes, nose and skin. Very high concentrations can result in
severe damage to kidneys and other organs, and perhaps death.

30 Health and Safety in Welding

• Ozone: A gas produced by the ultraviolet radiation in the air in the vicinity
of arc welding and cutting operations, ozone is very irritating to all mucous
membranes. Excessive exposure produces pulmonary oedema. Other
effects of exposure include headache, chest pain, and dryness of the
respiratory tract.

Agents for cleaning and passivating stainless steel

These substances are both very dangerous and will require specialised
methods of storage, use and disposal:
• nitric acid
• hydrofluoric acid.

Health and Safety in Welding 31

Part 12: Metal preparation

The methods used to prepare metals for welding pose a series of specific
hazards, each of which requires control. See TN7 chapter 10 for further details.

Abrasive blasting
This poses hazards to the eyes, lungs and hearing through noise, vibration and
dust creation. Abrasive blasting needs to be carried out in a blasting cabinet
with ventilation.

Mechanical
preparation
Power tools (grinders and
nibblers) can pose hazards of Nibblers
eye injury, vibration injury and
electric shock.

Use of degreasing chemicals

There may be exposure to the solvent vapour or to its Pedestal grinder
decomposition products (phosgene). Solvent vapours may
be flammable and explosive. Skin contact can result in occupational dermatitis.
See the AS 1627 series.

Cleaning with caustic or acid solutions

These can pose hazards of contact with the solution or its corrosive and/
or irritant fumes. Hydrogen gas can be generated. Hydrofluoric acid poses
extreme dangers and should be used only with specific precautions.

Contaminated surfaces
When coatings on metals are heated it should be assumed that the
decomposition products are toxic.

32 Health and Safety in Welding

Part 13: Welding in confined spaces

TN7 chapter 20 deals with this

topic and refers to AS 2865. A sufficient ventilation

confined space is:

safety harness and rope
any space that is not
gas monitor
intended as a regular qualified
wooden
workplace AND has observer
duck
restricted means of entry/ board emergency
off switch
exit AND has inadequate
ventilation. steel boots
Welding in confined spaces
Key elements of safe welding
in confined spaces include the
following.

Access and emergency rescue

A trained, alert observer must be stationed outside the space.
Safe access is required and pre-planned emergency rescue (including a
safety belt or lifeline) must be assured through the use of suitable emergency
equipment.

Electric shock
Risks of electric shock are increased when working in confined spaces. A range
of measures are described in TN7, including having an observer outside the
space with access to a cut-off switch and rescue equipment. Always site the
welding equipment outside a confined space.

Ventilation
Ventilation for welders in confined spaces is of clear importance. Local exhaust
ventilation will be needed. Don’t enter a confined space unless you are sure the
atmosphere is safe.

Health and Safety in Welding 33

Atmosphere testing
The atmosphere in a confined space may become rapidly depleted in oxygen
content. Check with a monitoring device before entry. As welding proceeds,
inert gases may rapidly displace oxygen – check the atmosphere with a
continuous monitor located near the welder’s breathing zone. Check for toxic
or explosive atmospheres, if appropriate.

Arc flash
Reflected arc flash in a confined space may affect bare skin (e.g. the back of
the neck).

Fire protection
A fire in a confined space will be more serious than a normal fire.

Heat stress
Confined spaces may be hot because of solar load (if outside), or may become
hot during the pre-heating of metals. Take precautions to prevent heat
affecting the worker. Cool air is one option but may not provide sufficient
protection against radiant heat from hot surfaces. Working in a confined
space (especially if hot) can affect a welder, given the level of protective
equipment required and it may be necessary to limit the welder’s working time.

Permit to work
Welding in a confined space may be subject to a permit to work. An example is
shown opposite.

34 Health and Safety in Welding

Health and Safety in Welding 35
Part 14: Hot metals sparks

Hot metal sparks are a constant hazard in many welding processes.

Essential safety measures are to ensure:
• good housekeeping
• training in the selection and use of fire-fighting equipment
• prevention of sparks entering clothing/boots through the use of flame-
resistant personal protective equipment.

36 Health and Safety in Welding

Part 15: Radiation
(ultraviolet, infrared and lasers)

Hazards of ultraviolet
Opaque screens
radiation from arc flash can
affect both the eyes and skin
and are covered elsewhere in
this booklet.
The skin has its own warning
mechanism for thermal
radiation but the eyes do not.
When exposed to heat, the
eyes should be protected. See
AS/NZS 1338.1:1992 Filters
for eye protectors – Filters for
protection against radiation
generated in welding and allied
operations.
Arc flash
The safety of laser cutting/
welding processes will require
specialist advice both in terms
of the safe use of the equipment and personal protection.
See AS/NZS ISO 11553:2004 Safety of machinery – Laser processing machines
- Safety requirements and the AS/NZS 2211 series on laser safety.

Health and Safety in Welding 37

Part 16: Working technique

Keeping the head out of the welding plume is an essential element of welding
safety, as is good housekeeping.

38 Health and Safety in Welding

Part 17: Noise and vibration

Noise
Noise levels can be hazardous during some welding and metal cleaning
processes.
The Department of Labour Approved Code of Practice for the Management
of Noise in the Workplace should be followed to identify noise sources, assess
their significance and apply control measures.
TN7 refers to Australian noise control practices, and should not be referred to
for methods of noise assessment, as the New Zealand methods are different.
Audiometry will be required where employees are exposed to hazardous levels
of noise to ensure that hearing is not damaged by exposure to it.

Vibration
The prolonged use of powered hand tools may expose welders to harmful levels
of vibration, resulting in decreased blood circulation in the fingers. The effect
of vibration is exacerbated when working in the cold. Vibration exposure can be
reduced by:
• selecting the appropriate tool
• selecting a tool designed with ergonomic principles in mind
• regular maintenance
• wearing gloves.

Health and Safety in Welding 39

Part 18: Manual handling

Some welding tasks can involve heavy

and/or repetitive manual handling or
work with sustained awkward postures
for long periods without a break.
The joint Department of Labour/ACC
Code of Practice for Manual Handling
should be used to identify hazards in
manual handling tasks, assess their
significance and devise controls.

Manual handling

40 Health and Safety in Welding

Part 19: Hand tool fitness and safety

Hand tools used during metal preparation and weld treatment can pose several
types of hazard:
• hand tools can create sparks and ignite some welding gases
• electrically-powered tools (grinders) pose the risk of electric shock – check
electrical safety regularly and use RCDs
• tools used for deslagging, grinding and chipping may pose hazards to the
eyes – wear eye protection
• prolonged use of poorly maintained power hand tools can result in injuries
from vibration
• the physical design of hand tools (if not based on ergonomic principles)
can pose the risk of a musculoskeletal disorder. Relevant factors are tool
weight, trigger design, grip/handle diameter and tool shape
• air-powered tools can discharge cold air over the hands
• using tools with wet/sweaty hands may compromise electrical safety and/or
cause the hands to slip
• ensure any electrical or heat insulation on the tool handle remains intact
• grinding wheel hazards – safety principles must be adhered to.
See www.osh.dol.govt.nz/order/catalogue/78.shtml

Health and Safety in Welding 41

Part 20: Specific requirements of the
Health and Safety in Employment Act 1992

The Health and Safety in Employment (HSE) Act 1992 requires employers to
take all the practicable steps open to them in the circumstances to prevent
harm occurring to employees. This requirement is covered in the sections
above and in TN7 and the Fume Minimisation Guidelines.
The HSE Act places some additional obligations on employers, including the
requirements to:
• provide information, training and supervision to employees
• pay for protective equipment – in a range of circumstances
• when employees are exposed to significant hazards, to carry out (with each
employee’s informed consent) health monitoring
• involve employees in health and safety matters.

Information, training and supervision

Basics are covered previously in this booklet. TN7, equipment suppliers and
experienced welders may be consulted for more information.
Information should be given in a manner the employee can understand and
cover the items in this booklet plus what to do in emergency situations, (fire,
explosion, electrocution, confined space collapse, burns, eye injuries and
exposure to fumes).
Training should cover the right way to do the task, the hazards in it, how to
prevent hazards causing harm, incident/damage reporting procedures and how
to use PPE.
Supervision should continue until a welder is competent, and will always be
required in some situations, such as confined space entry.

42 Health and Safety in Welding

Monitoring

Environmental monitoring
This may be required to assess the level of exposure to welding fumes, to
monitor exposure to gases such as ozone or nitrogen oxides produced during
certain welding processes or to monitor oxygen content or the build up of
explosive gases in confined spaces.

Personal health monitoring

This must be carried out, with the person’s informed consent, if they are faced
with a significant hazard. The decision as to whether a significant hazard is
faced rests with the employer.
Hearing, vision and lung function testing are typically monitored in welders.
Biological monitoring to establish the absorption of substances such as lead or
manganese will be appropriate if welders are exposed to these substances.
Exposure to welding fumes has been shown to cause a number of
respiratory conditions, including fume fever, chemical pneumonitis, reversible
bronchospasm and occupational asthma.
Biological monitoring may be necessary to follow the health of people exposed
to welding fumes. See www.cdhb.govt.nz/chlabs/testsframe.htm.
Respiratory conditions arising as a consequence of welding fume exposure are
best monitored by the following:
• a respiratory questionnaire given to the exposed employees and either
self-administered or administered by an occupational health nurse. (See
the Department of Labour website at www.dol.govt.nz.)
• the use of serial peak flows. Peak flows measure the amount of air forcibly
expelled from the lungs in one second. Various values or patterns are
evident when the lungs are not functioning properly
• a peak flow meter is required (available from the occupational health nurse)
and the recordings are usually done for a period of time at work and away
from work (to give normal values)
• the Department of Labour recommends recording the best of three blows,
repeated four times a day (before work, in the middle of work, at the end
of work and as the person goes to bed at night) for two weeks, with some

Health and Safety in Welding 43

 period of this two weeks being away from work. (Peak flow charts are
available on the Department’s website.)
• if the respiratory questionnaire or the peak flow recordings suggest
a problem then more specific lung function testing and x-rays may
be appropriate. This would be undertaken at the discretion of the
investigating doctor or occupational health nurse (under the advice of the
treating doctor).

Employee participation
Employees must be involved in the development of health and safety
procedures.

44 Health and Safety in Welding

Part 21: WeldIng fume Control summary
Worksheet
This worksheet can be used to obtain an idea of the level of protection
required for different welding processes.

The Welding Fume Control Tool is currently being reviewed.

Health and Safety in Welding 45

Notes

46 Health and Safety in Welding