Common Dangers of Welding and How to Avoid Them

Posted On: July 30, 2018
Dangerous Causes of Arc Flash
Welding is a process whereby different metal parts are joined together by heating the surfaces to their respective melting points. Welders face a range of potential hazards that can cause severe injuries and even death. However, welding can be made quite safe if best practices are followed. These guidelines will help mitigate the risk of accidents and injuries and allow workers to avoid any potential hazards. Employers should provide appropriate training to employees and ensure compliance with safety guidelines. A vital component of such training is awareness of the most common dangers and knowledge of how to avoid them.

Common Injuries

Burns are the most common welding injury. They are caused by a lack of, or improper, personal protective equipment (PPE). Eye damage from exposure to arc rays is another common hazard. Other common injuries include bruises and cuts to toes and fingers. Use of proper PPE not only protects against such injuries but allows freedom of movement as well. Recommended clothing for welding includes flame-resistant treated cotton and leather. Avoid using synthetic materials such as rayon or polyester as they melt when exposed to extreme heat. Flame-resistant leather gloves, hearing protection, and helmets with side shields are also highly recommended.

Electric Shock

One of the most immediate risks faced by a welder is electric shock. It is a severe threat that can lead to serious injury or death. It occurs when a welder is placed into an electrical circuit by touching together two metal objects that have a voltage between them. An arc welding circuit’s secondary voltage shock is the most common electric shock. It ranges from 20 to 100 volts. Note that a shock of 50 volts or even less can prove fatal in certain conditions. Injuries are caused either by the shock itself or by a fall in reaction to the shock. Electric shocks can be avoided by:
  • Avoiding skin contact with the electrode or metal parts
  • Wearing dry gloves and clothing
  • Insulating yourself from the metals being welded
  • Using dry insulation between the body and the ground

Fumes and Gases

Welding fumes contain complex metal oxide compounds which can be severely hazardous to your health.
  • Acute exposure to welding fumes can cause irritation in the eyes, nose, and throat, nausea, and dizziness.
  • Prolonged exposure could cause lung damage, kidney damage, stomach ulcers, nervous system damage, and cancers of the larynx, lung, and urinary tract.
It is important, therefore, to have sufficient exhaust and ventilation in the welding area. Respirators, fans, and exhaust systems control exposure to harmful substances in welding fumes and gases.

Fire and Explosions

Extreme temperatures created by welding arcs constitute an unavoidable fire and explosion hazard. The arc emits intense infrared, ultraviolet (UV), and visible radiation. The UV radiation is particularly dangerous as it burns unprotected skin and causes skin cancer with long term exposure. The arc also produces extreme heat, sparks, and spatter which can reach up to 35 feet away. All flammable materials should thus be removed from the welding area before work is begun. Examples include oil, gasoline, paint, cardboard, paper, wood, acetylene, hydrogen, and propane. Welders also need to be aware of unique potential hazards within their work environment, such as when working in confined spaces or in an elevated area.

Safe Welding with

Welders should be educated to be aware of the environment in which they work. Confined spaces or elevated areas, for example, may require different or unique equipment and safety considerations. Managers, supervisors, and workers should, therefore, be trained to identify, prevent, and protect against all potential hazards at the workplace. The OSHA 10 and OSHA 30 Hour Training Programs offered by are designed to help keep workers safe. The courses will help you:
  • Understand OSHA standards and requirements
  • Identify hazardous conditions and practices
  • Understand the types, need, and use of different PPE
  • Identify critical health and safety hazards
  • Implement preventative and protective measures
The courses can be taken and completed online, at your own pace and schedule. You will receive a certificate of completion at the end of the course which you can download and print.  


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Welding can prove to be a highly dangerous occupation, particularly if safety measures are ignored. Click To Tweet

The Occupational Safety and Health Administration [OSHA] and the American Conference of Governmental Industrial Hygienists [ACGIH] provide safety guidelines which help mitigate the risks of welding hazards.  

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