Welding, Cutting, Brazing & Grinding

Welding and other hot work presents significant opportunity for fire and injury.  Hot work is any temporary operation involving open flames or which produces heat/sparks.  Typical operations include brazing, open flame soldering, grinding, arc welding/cutting, oxy-fuel gas welding, hot taps, and torch applied roofing.  Because of the high temperatures involved and the potential for fire and serious injury, care must be taken to ensure that work is performed safely.

Hazard Avoidance

The hazards associated with hot work are:

• Fires/Explosions (hot surfaces can be ignition sources)
• Burns (both from welding equipment itself and hot surfaces)
• Toxic fumes, particulates and smoke
• Eye injuries (burn and particulates)
• Electric shock
• Noise

Fire/Explosion Precautions

• Do not cut, weld, braze, or grind in the presence of combustible or flammable liquids or atmospheres (gases, vapors, dust).
• Do not cut, weld, braze, or grind on drums, barrels, tanks, or other containers.
• Inspect cracks and holes in floors, walls, and ceilings of the work area to ensure that no combustible materials, or personnel, will be exposed to sparks should they pass through a crack, hole, or penetration.
• If the object to be worked cannot readily be moved to a routine welding area, move all combustible materials at least 35' from where the hot work will take place.
• If any remaining combustibles cannot be moved, ,protect the combustibles with appropriate guards and covers.
• Do not cut,, weld, braze, or grind inside a building if you have reason to suspect the sprinkler system (if present) is not working properly.
• Do not mix aluminum grinding dust and iron or steel grinding dust.  Such a mixture can, under special conditions, explode.  Finely divided aluminum mixed with finely divided ferrous oxide forms thermite, a compound that burns greater than 3,000� C 

Hot Work Safety 

Burns and Personal Injury Precautions

• Using welding curtains and shields.

• Ensure adequate ventilation during the hot work process.

  • Materials such as lead, cadmium, and beryllium generate toxic gases when heated to their vaporization point.

  • Sanding, grinding, or similar activities can release dangerous respirable particles.

• Protect workers from electrical shocks by maintaining electrical welding equipment in good condition.  Repair damaged leads promptly.

• Goggles and face shields that give maximum eye protection for each welding, flame cutting and soldering process shall be worn by personnel performing these operations and helpers assisting in the hot work.  

  • It is not necessary to have a direct view of a welding arc to injure your eyes.  Sufficient light can reflect from nearby surfaces to cause a "welders flash" - especially with prolonged exposure.

• Flame resistant gloves and aprons shall be worn during welding, flame cutting and soldering processes.

• Should protective hard hats be worn, they shall be made of a flame resistant material.  

• Safety shoes with protected tops should be worn to protect the operator from spark hazard.

• Ensure worker protection from high noise levels produced by grinding or cutting activities.

Personal Awareness

• Do not bring combustibles or flammables into an area where welding, cutting, brazing, or grinding occurs.

• Ensure all compressed gas cylinders and fuels are stored and transported properly, and that any regulators, valves, hoses, and fittings are in good condition.

• Thoroughly clean a grinding machine of all aluminum dust before grinding iron or steel.

Options to Hot Work

• Can the job be performed with a handsaw, pipe cutter, or other such equipment?

• Can the all combustibles be removed from the hot work area or can the work be moved?