Welding & Fabrication Shop Safety Manual

What Should a Welding & Fabrication Shop Safety Manual Include?

The contents of a Welding & Fabrication Shop Safety Manual should reflect the work actually performed.

Depending on operations, the manual may address:

• Welding and fabrication safety responsibilities.
• Hazard assessments.
• Job Safety Analysis (JSA/JHA).
• Safety inspections.
• Welding.
• Cutting.
• Brazing and soldering.
• Hot Work.
• Welding fumes and gases.
• Ventilation.
• Hexavalent Chromium.
• Lead.
• Cadmium.
• Metal coatings.
• Compressed gas cylinders.
• Oxygen and fuel-gas systems.
• Grinding and abrasive wheels.
• Metal saws.
• Press brakes.
• Shears.
• Ironworkers.
• Drills and other machinery.
• Machine Guarding.
• Lockout/Tagout.
• Electrical Safety.
• Cranes and hoists.
• Rigging.
• Forklifts.
• Material Handling.
• Hazard Communication.
• Personal Protective Equipment.
• Respiratory Protection.
• Hearing Conservation.
• Fire Prevention.
• Confined Spaces when applicable.

Programs should be selected according to the company’s processes, machinery, metals, coatings, chemicals, and actual employee exposures.

Welding & Fabrication Shop Safety Program

An effective Welding Safety Program establishes responsibilities and procedures for identifying workplace hazards, controlling employee exposures, preventing injuries and illnesses, and maintaining welding and fabrication equipment in safe operating condition.

Management should provide employees with appropriate equipment, engineering controls, ventilation, PPE, training, supervision, maintenance resources, and safe work procedures.

Managers, supervisors, and designated safety personnel should:

• Identify and evaluate workplace hazards.
• Maintain applicable written safety programs.
• Conduct periodic safety inspections.
• Evaluate welding-fume exposures.
• Maintain machinery and equipment.
• Provide required machine guarding.
• Establish hazardous-energy procedures.
• Maintain ventilation systems.
• Provide appropriate PPE.
• Evaluate hazardous metals and coatings.
• Correct unsafe conditions.
• Investigate workplace incidents.
• Provide employee training.
• Maintain applicable records.

Employees should follow established procedures, inspect equipment, use required guards and PPE, follow Hot Work and Lockout/Tagout procedures, and promptly report unsafe conditions, injuries, exposures, fires, equipment defects, and other workplace hazards.

Hazard Assessments

Hazard assessments should consider:

• Welding processes.
• Base metals.
• Filler metals.
• Coatings.
• Fluxes.
• Chemicals.
• Machinery.
• Material handling.
• Ventilation.
• Noise.
• Employee tasks.
• Work location.

Potential hazards may include:

• Welding fumes.
• Toxic metals.
• Radiation.
• Burns.
• Fire.
• Electrical shock.
• Flying particles.
• Machine points of operation.
• Hazardous energy.
• Crushing.
• Pinch points.
• Noise.
• Heavy material handling.

Assessments should be reviewed when processes, machinery, metals, coatings, or work practices change significantly.

Job Safety Analysis (JSA/JHA)

A JSA/JHA may be used to evaluate higher-risk fabrication activities.

Potential JSAs/JHAs may address:

• Arc welding.
• MIG welding.
• TIG welding.
• Flux-cored welding.
• Torch cutting.
• Plasma cutting.
• Grinding.
• Press-brake operation.
• Shear operation.
• Ironworker operation.
• Material handling.
• Crane and hoist operations.
• Field welding.
• Confined-space welding.

The analysis should identify job steps, hazards, required controls, PPE, and employee responsibilities.

Welding & Fabrication Shop Safety Inspections

Periodic inspections should evaluate:

• Welding areas.
• Cutting areas.
• Grinding stations.
• Fabrication machinery.
• Machine guards.
• Emergency stops.
• Compressed gas cylinders.
• Regulators and hoses.
• Electrical equipment.
• Ventilation systems.
• Cranes and hoists.
• Rigging.
• Forklifts.
• Material storage.
• Chemical storage.
• Fire-protection equipment.
• Walking-working surfaces.

Identified deficiencies should be corrected in a timely manner.

Welding Safety

Welding operations can expose employees to heat, radiation, fumes, gases, electrical hazards, fire, and molten metal.

Employees should receive training appropriate to the welding processes they perform.

Welding equipment should be inspected and maintained in safe operating condition.

Arc Welding

Arc-welding processes may include:

• Shielded Metal Arc Welding.
• Gas Metal Arc Welding.
• Flux-Cored Arc Welding.
• Gas Tungsten Arc Welding.
• Submerged Arc Welding.
• Other specialized processes.

Employees should understand the hazards and controls associated with the specific process being used.

Welding Arc Radiation

Welding arcs generate intense visible, ultraviolet, and infrared radiation.

Employees performing welding should use appropriate welding helmets or hand shields with suitable filter lenses.

Nearby employees should be protected from harmful arc radiation through:

• Welding screens.
• Curtains.
• Barriers.
• Distance.
• Appropriate eye protection.

Screens should be arranged so they do not create additional ventilation problems.

Arc Flash to Nearby Employees

Employees working near welding operations should not look directly at an unshielded welding arc.

Welding areas should be arranged to prevent unnecessary exposure of nearby employees and visitors.

Welding Burns

Hot metal, sparks, slag, and molten material can cause serious burns.

Employees should use appropriate protective clothing and avoid touching recently welded materials until they have cooled or are handled with suitable tools.

Hot materials should be identified or isolated when other employees could unknowingly contact them.

Welding Fumes and Gases

Welding, cutting, and brazing can generate fumes and gases that may be hazardous when inhaled.

The composition and concentration of welding fumes can depend on:

• Base metal.
• Filler metal.
• Coatings.
• Flux.
• Welding process.
• Temperature.
• Ventilation.
• Work location.

Employers should evaluate employee exposure according to the materials and processes used.

Ventilation

Adequate ventilation should be provided to control welding fumes and gases.

Depending on the process and exposure, controls may include:

• General ventilation.
• Local exhaust ventilation.
• Portable fume extraction.
• Fixed extraction systems.
• Process enclosure.
• Respiratory protection when required.

Ventilation systems should capture contaminants as close to their source as practical without interfering with welding quality or employee safety.

Local Exhaust Ventilation

Local exhaust ventilation may be particularly useful for repetitive welding performed at fixed workstations.

Extraction equipment should be:

• Properly positioned.
• Maintained.
• Inspected.
• Kept free of excessive blockage.

Employees should understand how to position extraction equipment effectively.

Welding Fume Exposure Evaluation

The employer should evaluate the metals, consumables, coatings, and processes used to determine whether employee exposure monitoring or additional controls may be necessary.

Employees should not assume welding fumes are harmless because no visible smoke is present.

Base Metal Identification

Before welding, cutting, heating, or grinding, employees should determine what material is being worked on when its composition could affect employee safety.

Information may be obtained from:

• Material specifications.
• Safety Data Sheets.
• Supplier information.
• Previous records.
• Appropriate testing.

Unknown materials should be evaluated before hot work begins when hazardous coatings or metals may be present.

Coated and Painted Metals

Painted, plated, galvanized, or otherwise coated metals may release hazardous contaminants when heated or disturbed.

Before welding or cutting coated material, employees should evaluate the coating and establish appropriate controls.

Coatings should not be assumed safe merely because their composition is unknown.

Galvanized Metal

Heating galvanized steel can generate zinc-containing fumes.

Appropriate ventilation and exposure controls should be used.

Employees should receive information regarding the hazards associated with the metals and coatings they work with.

Stainless Steel Welding

Welding stainless steel and certain chromium-containing alloys can generate hexavalent chromium.

The employer should evaluate potential employee exposure and implement applicable controls.

Hexavalent Chromium — When Applicable

Employees may be exposed to Hexavalent Chromium during:

• Stainless-steel welding.
• Welding chromium-containing alloys.
• Cutting chromium-containing metals.
• Grinding certain chromium-containing materials.
• Work involving chromium-containing coatings.

Where occupational exposure may occur, the employer should evaluate employee exposure and comply with applicable Hexavalent Chromium requirements.

Controls may include:

• Engineering controls.
• Local exhaust ventilation.
• Work-practice controls.
• Regulated areas where applicable.
• Respiratory protection.
• Protective clothing.
• Hygiene.
• Exposure monitoring.
• Medical surveillance where required.

Lead — When Applicable

Employees may encounter lead during welding, cutting, brazing, grinding, or heating of lead-containing metals or coatings.

Where lead exposure may occur, appropriate exposure evaluation and controls should be implemented.

Potential controls may include:

• Ventilation.
• Work practices.
• Housekeeping.
• PPE.
• Respiratory protection.
• Hygiene.
• Exposure monitoring.
• Medical surveillance where required.

Cadmium — When Applicable

Cadmium may be present in certain alloys, filler materials, coatings, or plated metals.

Heating or grinding cadmium-containing material can generate highly hazardous exposure.

Where cadmium may be present, the material should be identified and appropriate exposure controls established before work begins.

Beryllium — When Applicable

Certain specialized metals and alloys may contain beryllium.

Where beryllium-containing materials are welded, cut, ground, or otherwise processed, applicable exposure requirements and controls should be evaluated.

Manganese Exposure

Manganese may be present in welding consumables and welding fumes.

Employee exposure should be evaluated as part of the overall welding-fume assessment.

Appropriate ventilation and work-practice controls should be used.

Metal Fume Fever

Certain metal fumes, particularly those generated from zinc-containing materials, can contribute to acute flu-like illness commonly called metal fume fever.

Employees should report symptoms that may be associated with workplace exposure.

Exposure controls should focus on preventing excessive fume inhalation.

Respiratory Protection

When engineering and work-practice controls do not adequately control applicable respiratory hazards, or respirators are otherwise required, the company should maintain an appropriate Respiratory Protection Program.

Applicable elements may include:

• Hazard evaluation.
• Respirator selection.
• Medical evaluation.
• Fit testing.
• Training.
• Inspection.
• Maintenance.
• Program evaluation.

Employees should not substitute an unapproved dust mask for required respiratory protection.

Welding in Confined Spaces — When Applicable

Welding in confined or enclosed spaces can create serious hazards involving:

• Welding fumes.
• Toxic gases.
• Oxygen deficiency.
• Oxygen enrichment.
• Fire.
• Electrical hazards.
• Restricted escape.

Confined spaces should be evaluated before work begins.

Where a Permit-Required Confined Space exists, applicable entry procedures should be followed.

Confined-Space Ventilation

Ventilation should be provided according to the atmospheric hazards present.

Employees should not introduce oxygen into a confined space for ventilation.

Compressed-gas cylinders should generally remain outside confined spaces unless their presence is specifically addressed and permitted under applicable procedures.

Confined-Space Welding Rescue

Where confined-space entry requires rescue provisions, rescue procedures should be established before entry begins.

Employees should not attempt an unprotected rescue.

Hot Work

Hot Work may include:

• Welding.
• Cutting.
• Brazing.
• Soldering.
• Grinding.
• Torch heating.
• Other spark- or flame-producing activities.

Hot Work should be controlled when fire or explosion hazards are present.

Hot Work Area

Where practical, routine welding and cutting should be performed in designated areas designed for Hot Work.

Designated areas should be maintained to control:

• Combustible materials.
• Flammable liquids.
• Sparks.
• Slag.
• Fire spread.
• Unauthorized access.

Hot Work Permit — When Applicable

Hot Work performed outside designated areas may require authorization or a Hot Work Permit according to company procedures and workplace conditions.

The evaluation should consider:

• Combustible materials.
• Flammable liquids and gases.
• Openings.
• Adjacent areas.
• Fire-protection equipment.
• Atmospheric hazards.
• Fire-watch requirements.

Fire Watch

A fire watch should be provided where required by the conditions or applicable procedures.

Fire-watch personnel should:

• Understand the hazards.
• Have appropriate fire-extinguishing equipment.
• Monitor for fire.
• Know how to activate emergency response.
• Remain for the required period following Hot Work.

Combustible Material

Combustible materials should be removed or appropriately protected before Hot Work begins.

Sparks and molten metal can travel through:

• Floor openings.
• Wall openings.
• Cracks.
• Doorways.
• Other penetrations.

Adjacent areas should be evaluated.

Welding on Containers

Employees should not weld, cut, or heat drums, tanks, vessels, or containers that have held flammable, combustible, toxic, or reactive materials until appropriate cleaning, isolation, testing, and other required precautions have been completed.

An apparently empty container may still contain hazardous vapors or residues.

Oxygen and Fuel-Gas Cutting

Oxy-fuel welding and cutting systems can expose employees to:

• Fire.
• Explosion.
• Burns.
• Compressed gases.
• Hose failure.
• Regulator failure.
• Flashback.

Employees should receive appropriate training before using this equipment.

Oxygen Safety

Oxygen should not be used as a substitute for compressed air or ventilation.

Oxygen equipment should be kept free of oil, grease, and other contaminants that could create a fire hazard.

Employees should handle oxygen systems according to applicable procedures.

Fuel-Gas Safety

Fuel-gas systems should be inspected before use.

Employees should report:

• Leaks.
• Damaged hoses.
• Defective regulators.
• Damaged torches.
• Loose connections.

Leaking equipment should not be used.

Regulators

Regulators should be suitable for the gas and service for which they are used.

Employees should not use adapters or improvised arrangements that defeat the intended connection system.

Damaged regulators should be removed from service.

Welding Hoses

Hoses should be inspected for:

• Cuts.
• Burns.
• Cracks.
• Leaks.
• Damaged fittings.
• Other deterioration.

Hoses should be routed to reduce damage and trip hazards.

Flashback Prevention

Employees using oxy-fuel systems should follow appropriate procedures for equipment setup, lighting, shutdown, and prevention of flashback.

Required check valves or flashback arrestors should be maintained according to the equipment and applicable requirements.

Torch Lighting

Torches should be lit with an approved friction lighter or other suitable device.

Employees should not use matches or cigarette lighters to ignite welding or cutting torches.

Compressed Gas Cylinders

Compressed gas cylinders should be:

• Identified.
• Secured.
• Protected from damage.
• Stored appropriately.
• Kept away from excessive heat.
• Handled using suitable equipment.

Valve-protection caps should be used when required.

Cylinder Handling

Employees should not:

• Drag cylinders.
• Roll cylinders horizontally for transportation.
• Lift cylinders by valve-protection caps.
• Drop cylinders.
• Use cylinders as rollers or supports.

Suitable carts or other handling equipment should be used.

Oxygen and Fuel-Gas Cylinder Storage

Oxygen cylinders should be separated from fuel-gas cylinders and combustible materials according to applicable requirements unless an approved protective arrangement is used.

Storage areas should be appropriately ventilated and protected.

Cylinder Valves

Cylinder valves should be opened and closed using appropriate methods.

Employees should not repair cylinder valves or safety devices unless specifically authorized and qualified.

Damaged cylinders should be removed from service and reported to the supplier as appropriate.

Arc Welding Electrical Safety

Arc-welding equipment can expose employees to electrical shock.

Employees should:

• Inspect leads.
• Maintain insulation.
• Use suitable electrode holders.
• Keep equipment dry where practical.
• Avoid contact with energized components.
• Report damaged equipment.

Defective welding equipment should not be used.

Welding Leads

Welding cables and leads should be inspected for:

• Damaged insulation.
• Exposed conductors.
• Damaged connectors.
• Excessive deterioration.

Cables should be routed to reduce trip hazards and damage from vehicles or sharp edges.

Grounding and Work Connections

Welding equipment and work connections should be installed and used according to applicable requirements and manufacturer instructions.

Improvised connections that create electrical or fire hazards should not be used.

Wet Conditions

Electrical welding hazards may increase in wet or damp conditions.

Employees should use appropriate equipment and precautions and should not perform electrical welding under conditions that create uncontrolled shock hazards.

Plasma Cutting

Plasma-cutting operations may expose employees to:

• Intense radiation.
• Fumes.
• Noise.
• Hot metal.
• Sparks.
• Electrical energy.
• Compressed gases.

Appropriate ventilation, PPE, equipment inspection, and fire controls should be used.

Brazing and Soldering

Brazing and soldering may expose employees to:

• Heat.
• Fluxes.
• Fumes.
• Lead or cadmium where present.
• Fuel gases.
• Fire hazards.

Materials should be evaluated before work begins.

Appropriate ventilation and PPE should be provided.

Grinding Safety

Grinding operations can expose employees to:

• Wheel failure.
• Flying particles.
• Sparks.
• Noise.
• Dust.
• Pinch points.

Employees should use grinders only when guards and other required safety devices are in place.

Abrasive Wheels

Abrasive wheels should be appropriate for the grinder and rated for the equipment speed.

Wheels should be inspected before use.

Damaged wheels should not be installed.

Grinder Guards

Required grinder guards should remain installed and properly adjusted.

Employees should not remove guards merely to gain access to a workpiece.

Bench and Pedestal Grinders

Bench and pedestal grinders should be:

• Securely mounted.
• Properly guarded.
• Maintained.
• Equipped with appropriate work rests and protective devices.

Work rests should be maintained at an appropriate distance from the wheel.

Portable Grinders

Portable grinders should be inspected before use.

Employees should verify that:

• The wheel is appropriate.
• The guard is installed.
• Handles are used when required.
• The workpiece is secure.
• The employee is positioned away from the wheel’s potential failure path.

Grinding Sparks

Grinding sparks can ignite combustible materials.

Grinding should be controlled as Hot Work where conditions create a fire hazard.

Employees should evaluate nearby materials before beginning.

Metal Cutting Saws

Fabrication shops may use:

• Band saws.
• Cold saws.
• Chop saws.
• Circular saws.
• Other metal-cutting saws.

Employees should receive equipment-specific training.

Saw Guarding

Required blade guards and point-of-operation protection should remain in place.

Employees should keep hands outside the cutting path and use appropriate material supports.

Material Clamping

Material should be adequately supported and secured before cutting.

Employees should consider movement caused by:

• Cutting force.
• Material weight.
• Released stress.
• Unsupported offcuts.

Press Brakes

Press brakes can create severe crushing and amputation hazards at the point of operation.

Employees should operate press brakes only when required safeguarding is in place.

Safeguarding should reflect the machine, tooling, material, and work being performed.

Press Brake Setup

Setup, adjustment, die changes, and maintenance should be performed according to established procedures.

Hazardous energy should be controlled when required.

Employees should use appropriate handling equipment for heavy dies and tooling.

Shears

Power shears can expose employees to:

• Cutting blades.
• Hold-downs.
• Pinch points.
• Moving material.

Required guards and safeguarding should remain in place.

Employees should keep hands clear of hazardous areas.

Ironworkers

Ironworkers and combination machines may perform:

• Punching.
• Shearing.
• Notching.
• Bending.
• Angle cutting.

Each operating station should have appropriate safeguarding.

Employees should not place hands within hazardous points of operation.

Drill Presses

Drill presses should be maintained and operated safely.

Employees should:

• Secure workpieces.
• Remove chuck keys.
• Keep loose clothing away from rotating parts.
• Avoid gloves where they could become entangled in rotating machinery.
• Stop equipment before removing chips.

Lathes and Mills — When Applicable

Fabrication shops that perform machining should address hazards involving:

• Rotating work.
• Chucks.
• Cutting tools.
• Flying chips.
• Entanglement.
• Machine setup.

Appropriate machine guarding and safe operating procedures should be established.

Machine Guarding

Fabrication machinery should be safeguarded against hazards involving:

• Points of operation.
• Rotating parts.
• Nip points.
• Flying chips.
• Sparks.
• Power-transmission equipment.

Guards and safety devices should not be bypassed.

Safety Devices and Interlocks

Where machinery uses:

• Interlocked guards.
• Light curtains.
• Presence-sensing devices.
• Two-hand controls.
• Other safeguarding systems,

employees should not bypass or defeat those devices.

Defective safety devices should be reported immediately.

Lockout/Tagout

Fabrication machinery may contain electrical, mechanical, hydraulic, pneumatic, gravity, and other hazardous energy.

Applicable Lockout/Tagout procedures should be followed during servicing and maintenance.

Energy-Control Procedures

Before servicing begins, authorized employees should:

• Identify energy sources.
• Shut down equipment.
• Isolate energy.
• Apply required locks or tags.
• Release or restrain stored energy.
• Verify isolation.

Equipment should not be returned to service until appropriate release procedures have been completed.

Stored Energy

Employees should consider stored energy involving:

• Hydraulic pressure.
• Pneumatic pressure.
• Springs.
• Flywheels.
• Elevated machine components.
• Capacitors.
• Gravity.

Stored energy should be released, blocked, restrained, or otherwise controlled.

Clearing Machine Jams

Employees should not place hands or other body parts into hazardous machine areas to clear jams while hazardous energy is present.

Where jam clearing exposes employees to unexpected startup or hazardous energy, applicable Lockout/Tagout procedures should be followed.

Electrical Safety

Fabrication shops may use substantial electrical equipment for welding, machinery, portable tools, ventilation, and material handling.

Employees should report:

• Damaged cords.
• Exposed wiring.
• Broken plugs.
• Missing covers.
• Defective electrical equipment.

Only appropriately qualified employees should perform specialized electrical work.

Extension Cords

Extension cords should be appropriate for the environment and load.

Cords should be inspected and protected from:

• Sharp edges.
• Hot metal.
• Vehicle traffic.
• Water.
• Other damage.

Damaged cords should be removed from service.

Hand and Power Tools

Employees should inspect hand and power tools before use.

Tools should be appropriate for the work and used according to manufacturer instructions.

Damaged tools should be removed from service.

Pneumatic Tools

Pneumatic tools should be connected using appropriate fittings.

Hoses should be protected from damage and routed to reduce trip hazards.

Employees should control stored pneumatic pressure before servicing equipment.

Cranes and Hoists

Fabrication shops may use:

• Overhead bridge cranes.
• Jib cranes.
• Gantry cranes.
• Chain hoists.
• Other lifting equipment.

Only trained and authorized employees should operate lifting equipment as required by company procedures.

Pre-Use Crane Inspection

Operators should inspect applicable crane or hoist components before use according to established procedures.

Defects affecting safe operation should be reported.

Rigging

Slings, hooks, shackles, chains, wire rope, and other rigging equipment should be:

• Suitable for the load.
• Inspected.
• Properly used.
• Protected from damage.

Defective rigging should be removed from service.

Suspended Loads

Employees should avoid standing or working beneath suspended loads.

Loads should be controlled to prevent unintended swinging, shifting, or rotation.

Only employees necessary for the lifting operation should remain within the immediate lifting area.

Sheet and Plate Handling

Sheet metal and plate can create:

• Sharp-edge hazards.
• Crushing hazards.
• Unstable loads.
• Manual-handling injuries.

Mechanical lifting equipment should be used when appropriate.

Employees should wear suitable hand protection and keep body parts away from pinch points.

Steel Storage

Steel stock should be stored to reduce hazards from:

• Rolling.
• Sliding.
• Falling.
• Collapse.
• Vehicle impact.

Racks and storage systems should be suitable for the materials being stored.

Long Stock

Pipe, tube, bar, and other long stock should be supported and stored to prevent uncontrolled rolling or falling.

Employees should consider the opposite end of long material when moving it through the shop.

Forklift Safety

Fabrication shops may use forklifts to move:

• Steel.
• Pallets.
• Equipment.
• Fabricated assemblies.
• Cylinders.
• Supplies.

Only trained and authorized employees should operate Powered Industrial Trucks.

Forklift Loads

Loads should be stable and within the equipment’s rated capacity.

Long or irregular metal loads should be handled with additional caution.

Operators should consider:

• Load center.
• Visibility.
• Pedestrians.
• Clearance.
• Attachment capacity.

Pedestrian Safety

Employees on foot should remain alert to forklifts, cranes, trucks, and moving material.

Where practical, pedestrian routes should be separated from mobile-equipment traffic.

Employees should avoid walking beneath suspended loads or through active lifting areas.

Manual Material Handling

Employees may manually handle:

• Steel.
• Sheet metal.
• Components.
• Welding leads.
• Gas cylinders.
• Tools.
• Finished products.

Mechanical assistance or team lifting should be used when appropriate.

Ergonomics

Fabrication work may involve:

• Awkward welding positions.
• Repetitive grinding.
• Heavy lifting.
• Overhead work.
• Reaching.
• Bending.
• Prolonged standing.

Work methods, fixtures, positioners, lifting equipment, and workstation design should be evaluated to reduce unnecessary physical stress.

Welding Positioners and Fixtures

Positioners, fixtures, and adjustable worktables can reduce awkward welding postures and manual handling.

Employees should use available equipment where it improves safe access to the work.

Hazard Communication

Fabrication shops may use hazardous chemicals such as:

• Welding consumables.
• Fluxes.
• Solvents.
• Degreasers.
• Paints.
• Primers.
• Metalworking fluids.
• Cleaning products.
• Compressed gases.

An applicable Hazard Communication Program should address:

• Chemical inventories.
• Safety Data Sheets.
• Labels.
• Employee training.
• Non-routine tasks.

Safety Data Sheets

Employees should have ready access to applicable Safety Data Sheets.

SDS information can assist with evaluating:

• Welding consumables.
• Coatings.
• Solvents.
• Gases.
• Surface treatments.
• PPE.
• Ventilation.

Solvents and Degreasers

Employees should understand the hazards of solvents and cleaning products used before welding.

Certain chlorinated solvents can create extremely hazardous decomposition products when exposed to welding arcs or intense heat.

Cleaning products should be evaluated before Hot Work begins.

Painting and Coating — When Applicable

Fabrication shops that paint, prime, or coat products may require additional controls for:

• Flammable liquids.
• Spray operations.
• Hazardous chemicals.
• Ventilation.
• Respiratory exposure.
• Fire prevention.
• PPE.

The safety manual should address these operations when performed.

Abrasive Blasting — When Applicable

Abrasive blasting may expose employees to:

• Respirable dust.
• Silica.
• Toxic coatings.
• Noise.
• Flying material.
• High-pressure equipment.

The blasting media and surface coating should be evaluated before work begins.

Silica — When Applicable

Silica exposure may occur during abrasive blasting or work involving silica-containing materials.

Where respirable crystalline silica exposure may occur, applicable exposure controls should be established.

Personal Protective Equipment

PPE should be selected according to the hazards of the task.

Depending on operations, PPE may include:

• Welding helmets.
• Safety glasses.
• Goggles.
• Face shields.
• Welding gloves.
• Cut-resistant gloves.
• Protective clothing.
• Welding jackets.
• Protective footwear.
• Hearing protection.
• Respiratory protection.
• Hard hats.

Employees should receive training regarding PPE use, care, and limitations.

Eye and Face Protection

Employees should use eye and face protection appropriate to hazards involving:

• Welding radiation.
• Flying particles.
• Grinding.
• Cutting.
• Chemical splash.
• Molten metal.

Safety glasses may still be required beneath welding helmets or face shields depending on the hazard.

Welding Helmets and Filter Lenses

Welding helmets should be maintained in safe condition and equipped with filter lenses appropriate to the operation.

Damaged helmets or lenses should be repaired or replaced.

Hand Protection

Gloves should be selected according to the task.

Potential needs may include protection from:

• Heat.
• Sharp metal.
• Abrasion.
• Chemicals.
• Electrical hazards where applicable.

Employees should understand that gloves can create entanglement hazards around certain rotating machinery.

Protective Clothing

Welding clothing should protect employees from sparks, slag, heat, and molten metal.

Clothing should be selected and worn to reduce trapping of hot material.

Synthetic materials that could melt onto the skin should be evaluated carefully for welding work.

Foot Protection

Appropriate protective footwear should be used where employees may be exposed to:

• Falling steel.
• Sharp material.
• Hot metal.
• Slippery surfaces.
• Heavy components.

Hearing Conservation

Fabrication shops can have significant noise from:

• Grinding.
• Hammering.
• Plasma cutting.
• Air tools.
• Saws.
• Presses.
• Material handling.
• Ventilation equipment.

Employee noise exposure should be evaluated.

Where exposure reaches applicable thresholds, required Hearing Conservation measures should be implemented.

Housekeeping

Welding and fabrication shops should control accumulation of:

• Metal scrap.
• Welding rod stubs.
• Grinding debris.
• Cords.
• Hoses.
• Oil.
• Packaging.
• Combustible material.

Aisles, exits, electrical equipment, and emergency equipment should remain accessible.

Scrap Metal

Scrap should be placed in designated containers or storage areas.

Sharp or heavy scrap should be handled in a manner that reduces cuts, punctures, and material-handling injuries.

Welding Leads and Hoses

Leads and hoses should be routed to reduce:

• Trip hazards.
• Vehicle damage.
• Contact with hot metal.
• Sharp-edge damage.

Employees should avoid unnecessarily blocking aisles and access routes.

Slips, Trips and Falls

Potential hazards include:

• Welding leads.
• Gas hoses.
• Extension cords.
• Scrap.
• Oil.
• Metal stock.
• Uneven floors.

Hazards should be corrected or controlled promptly.

Walking-Working Surfaces

Floors, platforms, stairs, and elevated work areas should be maintained in safe condition.

Openings and elevated edges should be protected where required.

Ladders

Ladders should be selected, inspected, and used according to applicable requirements.

Employees should avoid using improvised platforms, stacked materials, or fabrication equipment as substitutes for proper access equipment.

Fall Protection

Employees performing elevated fabrication, installation, or repair work should use appropriate fall protection where required.

The method should reflect the work location and applicable regulatory requirements.

Fire Prevention

Welding and fabrication shops contain numerous ignition sources.

Fire-prevention procedures should address:

• Hot Work.
• Sparks.
• Flammable liquids.
• Gas cylinders.
• Combustible materials.
• Electrical equipment.
• Waste accumulation.

Fire extinguishers and other required fire-protection equipment should remain accessible.

Flammable and Combustible Liquids

Flammable and combustible liquids should be stored and handled according to applicable requirements.

Containers should be appropriate, labeled, and kept away from uncontrolled ignition sources.

Quantities at work areas should be limited where appropriate.

Fire Extinguishers

Employees expected or authorized to use portable fire extinguishers should receive applicable education or training.

Extinguishers should be inspected, maintained, and kept accessible.

Emergency Action Plan

The shop should maintain emergency procedures appropriate to its hazards.

Potential emergencies may include:

• Fire.
• Explosion.
• Gas leak.
• Chemical release.
• Serious injury.
• Severe weather.
• Electrical emergency.

Employees should understand alarms, evacuation routes, assembly areas, and reporting procedures.

Compressed Gas Emergency

Employees should know how to respond to:

• Cylinder damage.
• Leaking gas.
• Regulator failure.
• Fire involving cylinders.

Employees should evacuate and obtain specialized emergency assistance when conditions exceed their training and equipment.

First Aid

Appropriate first-aid resources should be available.

Potential fabrication-shop injuries may include:

• Burns.
• Eye injuries.
• Cuts.
• Crush injuries.
• Electrical shock.
• Chemical exposure.
• Strains.

Employees should promptly report injuries and obtain appropriate medical evaluation.

Eye Injury Response

Grinding particles, metal fragments, chemicals, and welding-related exposures can cause eye injuries.

Employees should promptly report eye injuries.

Appropriate eyewash facilities should be provided where corrosive-material exposure requires them.

Burn Response

Thermal and electrical burns should receive appropriate medical evaluation.

Employees should not apply unapproved substances to serious burns.

Incident Reporting

Employees should promptly report:

• Injuries.
• Near misses.
• Fires.
• Equipment damage.
• Chemical exposures.
• Electrical incidents.
• Dropped loads.
• Machine-guarding deficiencies.
• Other unsafe conditions.

Prompt reporting helps identify hazards before similar incidents occur.

Incident Investigation

Significant incidents should be investigated to determine:

• Immediate causes.
• Contributing factors.
• Root causes.
• Corrective actions.

Investigations should consider equipment, guarding, ventilation, maintenance, procedures, training, supervision, material characteristics, and work organization.

Root Cause Analysis

Root Cause Analysis may identify underlying issues involving:

• Equipment design.
• Machine guarding.
• Lockout/Tagout.
• Ventilation.
• Preventive maintenance.
• Employee training.
• Job planning.
• Hazard Communication.
• Production pressure.
• Corrective-action systems.

Corrective actions should address identified causes rather than merely restating the rule that was violated.

Welding & Fabrication Shop Safety Training

Employee training should reflect assigned duties and workplace hazards.

Depending on responsibilities, training may address:

• Welding safety.
• Hot Work.
• Welding fumes.
• Compressed gases.
• Grinding.
• Machine Guarding.
• Lockout/Tagout.
• Cranes and hoists.
• Rigging.
• Forklifts.
• Hazard Communication.
• PPE.
• Respiratory Protection.
• Hearing Conservation.
• Fire prevention.
• Emergency procedures.

Task-specific training should be provided before employees independently operate hazardous machinery or perform specialized welding operations.

New Employee Orientation

New employees should receive safety orientation before independently performing assigned duties.

Orientation may address:

• Shop traffic.
• Welding areas.
• Machine hazards.
• Hot Work.
• Compressed gases.
• PPE.
• Hazard Communication.
• Injury reporting.
• Emergency procedures.
• Restricted equipment.

Employees should not operate machinery until appropriately trained and authorized.

Safety Meetings

Periodic safety meetings may reinforce safe work practices and address current shop hazards.

Potential topics include:

• Welding fumes.
• Hexavalent Chromium.
• Grinder safety.
• Compressed gas cylinders.
• Machine guarding.
• Lockout/Tagout.
• Rigging.
• Hand injuries.
• Fire prevention.
• Recent incidents and near misses.

Recordkeeping

Welding and fabrication employers should maintain occupational safety and health records required for their operations.

Records may include:

• Employee training.
• Injury and illness records.
• Safety inspections.
• Equipment inspections.
• Exposure monitoring.
• Respiratory Protection records.
• Hearing Conservation records.
• Medical surveillance records where applicable.
• Incident investigations.

Medical and exposure records should be maintained according to applicable requirements.

Additional Safety Programs

Depending on welding and fabrication operations and employee exposures, additional programs may be necessary for:

• Welding, Cutting & Hot Work.
• Compressed Gas Cylinders.
• Hexavalent Chromium.
• Lead Exposure.
• Cadmium Exposure.
• Beryllium Exposure.
• Respiratory Protection.
• Machine Guarding.
• Lockout/Tagout.
• Hand & Power Tools.
• Grinding Safety.
• Electrical Safety.
• Crane Safety.
• Overhead Cranes.
• Rigging & Material Handling.
• Forklift / Powered Industrial Truck Safety.
• Manual Lifting & Material Handling.
• Ergonomics.
• Hazard Communication.
• Chemical Safety.
• Personal Protective Equipment.
• Eye & Face Protection.
• Hand Protection.
• Hearing Conservation.
• Silica Exposure Control.
• Confined Space.
• Fall Protection.
• Ladder & Stairway Safety.
• Walking-Working Surfaces.
• Slips, Trips & Falls.
• Housekeeping.
• Fire Prevention.
• Emergency Action Plan.
• First Aid.
• Spill Prevention & Response.
• Hazardous Waste Management.
• Incident Reporting & Investigation.
• Root Cause Analysis.

Programs should be included when the company’s welding processes, metals, coatings, machinery, chemicals, and employee exposures make them applicable.

Building a Welding & Fabrication Shop Safety Manual

A useful Welding & Fabrication Shop Safety Manual should reflect the actual work performed.

A small welding shop performing mostly mild-steel MIG welding may require a different combination of programs than a structural fabrication facility using overhead cranes, large plate, press brakes, ironworkers, plasma tables, forklifts, and multiple welding processes.

A stainless-steel fabrication shop may require greater emphasis on Hexavalent Chromium exposure and ventilation.

A sheet-metal fabrication shop may require greater emphasis on sharp material, press brakes, shears, power presses, machine guarding, and material handling.

A company that performs field installation may also require programs for construction activities, aerial lifts, scaffolds, fall protection, portable ladders, cranes, mobile equipment, and customer-site hazards.

The safety manual should therefore be based on the company’s actual welding and fabrication operations rather than automatically assigning every metalworking program to every employer.

Customized Welding & Fabrication Shop Safety Manuals

A Welding & Fabrication Shop Safety Manual can be developed around the company’s welding processes, metals, fabrication machinery, compressed gases, cranes, forklifts, chemicals, coatings, ventilation, field activities, and other occupational hazards.

The finished manual may incorporate applicable programs for Welding and Hot Work, Compressed Gas Cylinders, Hexavalent Chromium, Respiratory Protection, Machine Guarding, Lockout/Tagout, Grinding Safety, Crane and Rigging Safety, Forklift Safety, Hazard Communication, PPE, Hearing Conservation, Fire Prevention, Emergency Action Planning, and other hazards associated with the operation.

This provides welding shops, metal fabricators, sheet-metal shops, structural fabricators, and other metalworking employers with a practical safety manual organized around the work their employees actually perform.