Welders' Risks: Arc, Burns and Electricity

Why should welder safety be handled with a single risk list?

In most risk assessments, welder safety is split into pieces: arc radiation appears in the PPE section, fire in the emergency section, electricity in the maintenance section and fume in workplace measurements. On site, however, these are risks faced by the same person in the same minute, and they amplify each other. When welding with sweaty gloves, on a wet floor, inside a narrow tank, the risks of electric shock, fume and fire rise at the same time. This article handles the welder's job description with a single risk list.

First, let us clarify two legal links. In the 2025 NACE list, 25.53.01 Machining and welding work is in the hazardous class. In addition, row 22 of the Annex 1 list of the Regulation on the Vocational Training of Persons Employed in Work in the Hazardous and Very Hazardous Classes is "cold smithing and all kinds of welding work"; oxygen, electric, spot and seam welding are listed explicitly. A worker who will do this job must hold a vocational training certificate appropriate to the work before being hired; for the types of certificate, see our vocational training certificate guide.

Arc radiation and welding helmet selection

In addition to visible light, an electric arc emits intense ultraviolet and infrared radiation. Even a few seconds of exposure causes burns to the front surface of the unprotected eye; symptoms (a gritty feeling, watering, sensitivity to light) usually appear hours later, often at night. The welder's exposed skin also burns, much like sunburn. Helpers working next to the welder without a helmet and passers-by are at the same risk.

When choosing a welding helmet, look at three standards:

• TS EN 175: Helmet shell and headgear. Resistance to heat and spatter.
• TS EN 169: Passive welding filters with a fixed shade.
• TS EN 379: Auto-darkening filters. The marking shows the shade numbers in the light and dark states; for example, "4/9–13" means shade 4 in the light state and an adjustable shade between 9 and 13 in the dark state.

The shade number is chosen according to the welding process and the current; the higher the current, the darker the filter required. Determine the correct number from the helmet manufacturer's table by matching the process and the current range you use. For auto-darkening helmets, add a battery and sensor check to the start-of-shift checklist; a dirty or scratched outer cover lens can mislead the sensor.

Welding bays should be separated from the surroundings by light-tight welding curtains or screens. In open-workshop welding, the curtain is a collective protection measure that comes before the helmet.

Spatter burns and fire

Welding spatter and droplets of molten metal both burn the welder and can fly several metres and start a fire. The welder's clothing should therefore not be synthetic, but flame-resistant or flame-retardant; trouser legs should fall over the boots and pockets should have flaps. A leather apron, sleeves and long-cuffed welding gloves are the basic protection against spatter.

Welding is among the jobs involving open flames and sparks, and if it is to be done outside the workshop, during maintenance or where flammable material is present, it should be subject to a hot work permit. Before the permit:

1. Remove flammable material from the area; cover what cannot be moved with a fire-resistant blanket.
2. Close openings in floors and walls so that sparks cannot pass to the floor below or to an adjacent compartment.
3. Place a suitable extinguisher next to the weld point and appoint a fire watch.
4. Keep watching the area for some time after the work is finished; smouldering can start after welding has ended.

For the process, see our permit to work system guide.

Electric shock in welding work

The output of an arc welding machine carries voltage between the electrode holder and the workpiece even when no welding is being done (open-circuit voltage). In a dry environment and with sound equipment this voltage is usually not felt; however, sweat, wet gloves, a damp floor or wide-area body contact with the workpiece inside a metal tank markedly increase the risk of shock. Measures:

• Check the insulation of the electrode holder and cables at the start of the shift; repair damaged cable by replacing it, not with tape.
• Connect the earth (return) cable directly to the workpiece, as close to the weld point as possible. An earth connected at a distant point can cause the current to travel through the building's steelwork or other equipment.
• In wet and confined spaces, use welding machines designed for an increased risk of electric shock and marked with an "S" for that purpose.
• Use dry gloves and insulating soles; keep spare gloves.
• When inserting or changing the electrode, do not hold it with bare hands or wet gloves, and make sure your body is not touching the workpiece at the time.

Faults on the supply side of the welding machine are a matter of general electrical safety. Earthing of the socket and wiring supplying the machine is part of the periodic inspection of the internal electrical installation; maintenance for an internal fault in the machine is done with the power isolated. For these steps, see our guide to the 5 rules of electrical safety.

Gas cylinders

In oxy-acetylene welding and cutting, a flammable gas and oxygen are used together; in gas-shielded welding there are shielding gases such as argon and carbon dioxide. The basic rules:

• Cylinders are kept upright and secured against falling with a chain or clamp; a cylinder trolley is used for moving them.
• Oxygen cylinders, valves and regulators are not allowed to come into contact with oil or grease; an oxygen valve is never opened with oily gloves.
• Flashback arrestors are used on the hose line.
• Leak checks are done with soapy water, never with a flame.
• Empty and full cylinders are marked and stored separately; cylinder valves are closed at the end of work.
• Although argon and carbon dioxide are not toxic, they can cause asphyxiation by reducing the oxygen in the air; this risk is assessed separately in enclosed and confined spaces.

Welding fume and ventilation

Welding fume is a fine mixture of metal oxides and gases. The International Agency for Research on Cancer (IARC) has classified welding fume as carcinogenic to humans (Group 1). The composition of the fume varies with the material being welded: chromium and nickel compounds with stainless steel, zinc oxide with galvanised sheet ("metal fume fever", which resembles a cold), and additional decomposition products on painted or oily surfaces.

The order of measures is: first extraction at source (on-torch extraction or a mobile extraction arm brought close to the weld point), then general ventilation, and lastly respiratory protection of a suitable class. Adjusting the welder's working position so that their head stays out of the fume plume is also an effective and cost-free measure. Where exposure needs to be measured, we plan the measurements with authorised laboratories and health institutions. For obligations relating to dust and fume, see our guide to the Regulation on Dust Control.

Welding in confined spaces

Welding inside a tank, boiler, pipe or silo brings together all the risks above. Confined space welding is always subject to a work permit and includes the following measures:

1. The atmosphere is measured before entry: oxygen level, flammable gas and toxic gas.
2. Gas cylinders are left outside the confined space; only hoses and cables go inside. During breaks, the torch is taken out.
3. The space is never ventilated with oxygen. Oxygen enrichment can cause clothing to ignite from a single spark.
4. Mechanical ventilation and extraction at source are used together.
5. There is an attendant outside in constant communication with the person inside; a rescue plan and equipment are ready.
6. Additional measures are taken against electric shock because of the wet and conductive environment.

Welder PPE and risk summary

Selecting PPE, ensuring it is CE marked and teaching workers how to use it are the employer's obligations; details are in our PPE use guide. The 2026 base administrative fine for not providing PPE is 8,980 TL per worker.

In our OHS specialist service, we inspect welding bays under these headings and monitor on site how hot work and confined space permits are working. For sector-specific risks, see our metal and machinery and automotive supply industry pages.

Frequently Asked Questions

Is a vocational training certificate mandatory for welders?

Yes, in workplaces in the hazardous or very hazardous class. Welding work is on row 22 of the Annex 1 list of the vocational training regulation; a worker who will actually do this job must hold a vocational training certificate appropriate to the work before being hired.

What should be considered when choosing a welding helmet?

Check that the helmet shell complies with TS EN 175, and the filter with TS EN 169 if passive or TS EN 379 if auto-darkening. Select the shade number from the manufacturer's table according to the welding process and the current.

Why is welding fume dangerous?

Welding fume has been classified by IARC as carcinogenic to humans and, depending on the material welded, contains oxides of metals such as chromium, nickel or zinc. Extraction at source and ventilation come before respiratory protection.

What is the most critical rule when welding inside a narrow tank?

Leaving gas cylinders outside and never ventilating the space with oxygen. In addition, gas measurement before entry, continuous ventilation and an attendant outside are indispensable parts of the work permit.