Welding is one of the most widely used joining processes in industry, and one of the most hazardous. A single task can combine intense heat, ultraviolet and infrared radiation, toxic fume and gases, electricity, compressed gases, fire risk and hot metal.

Every year, welders and people working nearby suffer burns, eye injuries, lung disease and electric shock. In the worst cases, there are fatal fires and explosions. Most of these incidents can be prevented with proper training, controls and supervision.

This course is for welders, supervisors and managers. By the end of this module, you will be able to:

• Identify the main health and safety hazards of welding.
• Explain the key laws that apply to welding work.
• Describe the legal duties of employers and welders.
• Explain why risk assessment and safe systems of work are essential.

Welding hazards are usually divided into two groups:

• Health hazards, such as fume, radiation and noise. These can cause long-term illness that may not appear for years.
• Safety hazards, such as fire, electric shock and explosion. These can cause immediate, serious injury.

Because several hazards are often present at once, welding risk needs a layered approach, with more than one control working together.

This course looks at each of these hazards in detail:

• Fume and gases. Toxic metal fume and gases damage the lungs, and welding fume can cause cancer.
• Fire and explosion. Sparks, hot metal and flammable atmospheres can start fires and cause explosions.
• Radiation and heat. Ultraviolet and infrared radiation cause eye injuries and skin burns.
• Electricity. The welding circuit can give a dangerous electric shock.
• Compressed gases. Gas cylinders can cause fires, explosions and suffocation.

The welder is most at risk, but not the only one. Others who can be harmed include:

• People working nearby, who can be affected by fume, arc light and sparks.
• Apprentices and new workers, who may not yet recognise the dangers.
• Maintenance staff and contractors carrying out repairs on site.
• People in other areas, if a fire starts after the work has finished.

Welding happens in factories, workshops, shipyards, farms, garages and construction sites, so the risks vary a great deal.

Welding safety in Ireland is governed by the Safety, Health and Welfare at Work Act 2005. It places a general duty on employers to ensure, so far as is reasonably practicable, the safety, health and welfare of employees and others.

More specific duties come from the Safety, Health and Welfare at Work (General Application) Regulations 2007, which cover work equipment, personal protective equipment, electricity, noise and explosive atmospheres. Welding fume is controlled under the Chemical Agents Regulations, and, for cancer-causing substances in the fume, the Carcinogens, Mutagens and Reprotoxic Substances Regulations 2024.

The Health and Safety Authority, or HSA, enforces health and safety law in Ireland. Its inspectors can inspect workplaces, investigate accidents, issue improvement and prohibition notices, and prosecute. Penalties include significant fines and imprisonment.

Ignorance of the law is no defence. Employers and employees both have legal duties, and individuals, as well as companies, can be prosecuted for serious failings.

Employers must, so far as is reasonably practicable:

• Carry out a suitable and sufficient risk assessment of welding work.
• Provide safe equipment, ventilation and a safe place of work.
• Provide information, instruction, training and supervision.
• Provide and maintain suitable personal protective equipment, or PPE, free of charge.
• Monitor exposure, and provide health surveillance where required.
• Consult employees on health and safety.

As a welder, you must:

• Take reasonable care of your own safety, and that of others.
• Use equipment, extraction and PPE as you have been trained and instructed.
• Follow safe systems of work and permits.
• Report defects, damage and unsafe conditions straight away.
• Never interfere with or misuse anything provided for safety.
• Co-operate with your employer on health and safety.

A risk assessment is a careful look at what could cause harm, so you can decide whether enough precautions are in place. The steps are: identify the hazards, decide who might be harmed and how, evaluate the risks and decide on controls, record the significant findings, and review.

For welding, the assessment must consider the process, the materials and any coatings, the location, especially confined spaces and outdoor sites, ventilation, the fire risk, and who else is nearby.

Controls should be chosen in order, starting with the most effective:

• Eliminate the hazard. This is the most effective control, and should be considered first. For example, use bolted joints instead of welding.
• Substitute a less hazardous process or material.
• Use engineering controls, such as local exhaust ventilation.
• Use administrative controls, such as safe systems of work and permits.
• Provide PPE, as the last line of defence.

PPE protects only the wearer, and only when it is the right type, fits and is worn correctly.