Welding Safety Guide — Essential PPE and Safe Practices

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Welding is one of the most rewarding skills you can learn — but it comes with genuine hazards that must be respected. Arc flash, UV radiation, toxic fumes, fire risk, and electrical shock are all real dangers that proper safety practices eliminate. This guide covers everything you need to stay safe.

The Hazards of Welding

Understanding the hazards is the first step to managing them effectively:

Arc flash and UV radiation: The welding arc produces intense ultraviolet and infrared radiation — far more intense than direct sunlight. Even a brief glance at an unprotected arc causes arc eye (photokeratitis) — an extremely painful condition similar to severe sunburn on the cornea. Skin exposed to arc radiation burns like severe sunburn.

Welding fumes: Welding produces fumes containing metal oxides, flux vapours, and shielding gas breakdown products — many of which are toxic with prolonged exposure. Manganese from mild steel welding, chromium from stainless steel, and zinc from galvanised steel are particularly hazardous.

Fire and explosion: The welding arc and spatter can ignite flammable materials. Welding near flammable liquids, gases, or materials is extremely dangerous.

Electrical shock: Welding machines operate at voltages that can cause serious injury — particularly in wet or damp conditions.

Burns: Hot metal, spatter, and contact with the electrode holder are all burn risks.

Essential Welding PPE

Welding helmet: The most important piece of welding PPE. Protects eyes and face from arc flash, UV radiation, and spatter.

Fixed shade lens — traditional helmet with a fixed shade glass. Cheap and reliable but you need to flip the helmet to see your workpiece before striking the arc.
Auto-darkening helmet — switches from clear to welding shade in milliseconds when the arc strikes. More expensive but significantly more convenient and generally produces better welds as you can see the joint clearly before starting.

Shade numbers for arc welding:

MMA welding — Shade 10-11
TIG welding — Shade 9-12 depending on amperage

Welding gloves: Heavy leather gauntlet-style gloves that protect hands and forearms from spatter, heat, and UV radiation. MMA welding gloves are thick and heat-resistant. TIG welding gloves are thinner to allow the dexterity needed for feeding filler rod.

Welding jacket or sleeves: Protect arms and torso from spatter and UV radiation. Leather is the traditional material — heavy cotton or flame-resistant synthetic materials are also used. Never weld in synthetic clothing — it melts and fuses to skin.

Welding boots: Steel-capped, leather, with no exposed lacing that spatter can land in. Never weld in trainers or canvas shoes.

Ear protection: Grinding, chipping slag, and some welding processes produce significant noise — wear ear defenders or plugs.

Ventilation — Critical for Health

Welding fumes are serious — long-term exposure causes respiratory disease, and some welding fumes are classified as carcinogenic.

Minimum requirements:

Never weld in an enclosed space without mechanical ventilation
Position yourself to avoid breathing the fume plume — always weld so the fumes rise away from your breathing zone
Use local exhaust ventilation (LEV) — a fume extraction hood positioned close to the arc — for regular welding

Particular hazards:

Stainless steel — produces hexavalent chromium fumes, a known carcinogen. Always use LEV and respiratory protection when welding stainless
Galvanised steel — zinc oxide fumes cause metal fume fever — a flu-like illness. Avoid welding galvanised if possible, or use maximum ventilation
Painted or coated metals — remove coatings from the weld area before welding. Many coatings produce highly toxic fumes

Fire Prevention

Clear the welding area of all flammable materials within a 3-metre radius
Cover flammable items that can't be moved with fire-resistant welding blankets
Never weld near petrol, solvents, or flammable gases
Have a fire extinguisher within reach — CO2 or dry powder extinguisher suitable for electrical fires
Check the area for smouldering after finishing — spatter can lodge in cracks and smoulder for hours before igniting

Electrical Safety

Never weld in wet or damp conditions
Ensure the workpiece is properly earthed — connect the earth clamp directly to the workpiece or the welding table, as close to the weld as practical
Never wrap the welding cable around your body
Inspect cables and connections before each use — replace damaged cables immediately
Switch off the welder when changing electrodes or adjusting connections
The TEH TWT200 and TEH TWA280 both feature IP21 protection — protected against dripping water — but are not rated for use in wet conditions

Setting Up Your Welding Area

Work on a metal welding table or fire-resistant surface — never on wood
Position the welder on a stable, flat surface away from the weld area
Ensure cables are laid out to avoid tripping hazards
Keep the welding area tidy — clutter increases the risk of accidents
Ensure adequate lighting — you need to see what you're welding clearly

For TIG Welding — Additional Considerations

TIG welding uses argon shielding gas:

Store gas cylinders upright and secured — a falling cylinder is extremely dangerous
Always close the cylinder valve when not in use
Never use oxygen instead of argon — this is extremely dangerous
Check connections for leaks before use
Argon displaces oxygen — ensure ventilation even though argon itself is non-toxic

TEH Welding Range: