Why welding needs special protection
Welding produces hazards that ordinary workshop gear does not handle. The arc gives off intense visible light and invisible ultraviolet and infrared radiation. Sparks and molten spatter fly off the work. Hot metal stays dangerous long after the arc stops. Fumes and gases rise from the weld, the flux and any coatings on the metal.
Protection therefore has three jobs: shield the eyes and face, cover the skin, and keep fumes out of your lungs.
Eye and face protection
The helmet
A welding helmet holds a filter lens in front of your eyes and covers your face and neck. The lens is much darker than sunglasses because it must cut down very bright light and radiation. Looking at an arc without a proper filter can cause painful eye injury, sometimes called arc eye, which may not feel obvious until hours afterward. Brief glimpses of someone else’s arc also count, so be careful around other welders.
Common helmet styles include:
- Passive (fixed shade) helmets. The lens is permanently dark. They are simple, durable and usually less expensive. You flip the helmet down with a nod just as you strike the arc, which takes some practice, and you cannot see much with it down before welding starts.
- Auto-darkening helmets. The lens is light until sensors detect the arc, then it darkens in a fraction of a second. This lets you position the work with the helmet already down and often improves accuracy and reduces neck strain. Look for adjustable shade and sensitivity, and keep the sensors clean. Some models use batteries or solar cells, so check how yours is powered.
Neither type is automatically better. The choice depends on the work, budget and personal preference.
Shade numbers
Filter lenses are rated by shade number: higher numbers are darker. The right number depends on the welding process and the current used, and different processes call for different ranges. Charts from lens makers and welding references list recommended shades. When in doubt, follow the manufacturer’s guide, and note that a shade that is too light is hazardous, while one that is too dark makes it hard to see the pool.
Look for a helmet and lens that meet a recognized safety standard for your region, and check the markings. Replace cracked or heavily scratched lenses and covers, and keep clear cover lenses in place to protect the main filter from spatter.
Safety glasses underneath
Wear safety glasses under the helmet. They protect your eyes when you lift the helmet to chip slag or inspect a weld, and when working with grinders and wire brushes. Helmets are not a substitute for glasses or goggles in other tasks.
Protecting people nearby
Anyone close to the arc needs protection too. Welding screens or curtains help contain the light, and other people should avoid looking at the arc or wear appropriate eye protection.
Skin and body protection
Ultraviolet radiation from the arc can burn exposed skin quickly, in a way that resembles sunburn. Spatter and sparks can also burn through clothing, so cover as much skin as practical.
Gloves
Welding gloves are typically made of leather, with long cuffs that cover the wrists and forearms. Thicker, insulated gloves suit stick welding and heavy work. Thinner, more flexible gloves are common for TIG welding, which needs fine touch. Keep gloves dry, since moisture reduces insulation and conducts heat.
Jackets and clothing
- Choose long-sleeved shirts and full-length trousers made from flame-resistant or untreated natural fibers such as heavy cotton or wool. Many people also wear leather jackets or sleeves for overhead work.
- Avoid synthetic fabrics, which can melt and stick to skin.
- Button collars and cuffs. Avoid rolled-up sleeves and trouser cuffs, which catch sparks. Keep pockets covered or empty of lighters and other flammables.
- Fire-resistant treatments can wear off with washing, so follow the garment’s care label.
Footwear and head covering
Wear sturdy leather boots with the trouser legs over the tops, so spatter cannot drop inside. A cap or fire-resistant head cover protects hair and skin under the helmet.
Hearing and other gear
Welding itself is not usually loud, but grinding and chipping are. Earplugs or earmuffs are advisable, and earplugs help keep sparks out of ear canals when you weld overhead.
Fume protection
Weld fumes contain tiny metal particles and gases. Short-term exposure can cause irritation, and some metals and coatings are more hazardous than others. For example, welding galvanized or plated steel without proper controls can release fumes that may make you ill. Paint, oil and degreasing solvents can also create harmful fumes when heated.
General principles include:
- Ventilate. Work in an open, well-ventilated space, or use local exhaust ventilation that draws fumes away from your breathing zone.
- Keep your head out of the plume. Position yourself so rising fumes do not pass your face.
- Clean the metal. Remove coatings and contaminants from the weld area before welding.
- Use a respirator when needed. Where ventilation is inadequate or the metals are hazardous, a respirator rated for welding fumes may be necessary. Fit and filter type matter, and a qualified safety professional can advise.
- Never weld in an enclosed space without proper ventilation and safety procedures.
Shop fans can help, but pointing a fan at the arc can blow away shielding gas and spoil the weld, so use fume extraction or place fans carefully.
Caring for your gear
Inspect helmets, gloves and clothing before use. Look for cracks, holes and burn-through. Replace worn items. Store lenses clean and protected, and follow the manufacturer’s care instructions.
This article is general information, not professional safety advice. For regulated workplaces, follow the applicable safety rules and your employer’s procedures.