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Slide 003: PPE Selection, Fire Prevention & Shop Protocols

Slide Visual

PPE Selection, Fire Prevention & Shop Protocols

Slide Overview

This slide covers the complete PPE requirements for plasma cutting, fire prevention protocols, and the administrative procedures that keep the entire shop safe during hot work operations.

Instruction Notes

Complete PPE Ensemble

Plasma cutting requires the most comprehensive PPE of any makerspace operation:

Head Protection - Welding helmet with correct shade lens (8-9 for <40A, 9-12 for 40-80A) - Auto-darkening helmets are recommended — they allow clear vision during setup and darken automatically when the arc strikes - ANSI Z87.1 safety glasses worn UNDER the helmet at all times — the helmet may not be in position when sparks fly during setup

Body Protection - FR (flame-resistant) jacket or long-sleeve shirt rated to ASTM F1506 - The shirt must snap or button closed — no zippers near the arc (metal zippers can arc) - 100% cotton (heavyweight, 9 oz+) is acceptable as minimum — true FR fabric is preferred - Long pants without cuffs (cuffs trap sparks) — FR or heavy denim - NO synthetic fabrics anywhere on the body — they melt and burn into skin

Hand Protection - Leather welding gloves, gauntlet style, minimum 14" length - Split cowhide minimum; grain leather preferred for dexterity - Inspect for holes or worn spots before each use — a tiny hole allows a spark to reach skin

Foot Protection - Leather boots, 8" shaft minimum (protects ankles from sparks) - Steel or composite toe (ASTM F2413) - No laces exposed — tuck under the boot tongue or use lace covers - Sparks can land in boot tops — trouser legs go OVER boot shafts

Respiratory Protection - Minimum: N95 dust mask for mild steel in well-ventilated area - Standard: P100 half-face respirator for general plasma cutting - Enhanced: P100 + OV (organic vapor) cartridge for galvanized, stainless, painted metals - Required: fit testing per OSHA 1910.134 for any tight-fitting respirator

Hearing Protection - NRR 25+ earmuffs OR NRR 30+ earplugs - Must be compatible with welding helmet — earmuffs may interfere with helmet seal

Fire Prevention Protocol

The 35-Foot Rule (NFPA 51B) All combustible materials must be removed from a 35-foot radius around the cutting point: - Paper, cardboard, wood, fabric, foam - Solvents, paints, adhesives - Gas cylinders (except those in active use with proper separation) - If combustibles cannot be removed (structural wood, equipment), cover with fire-resistant blankets or welding curtains

Hot Work Permit System For any plasma cutting outside the designated cutting area: 1. Obtain a hot work permit from the safety officer/lab manager 2. Inspect the area for combustibles within 35 feet 3. Designate a fire watch person 4. Have a fire extinguisher immediately available 5. Post the permit at the work location 6. Maintain fire watch for 30 minutes after work is complete

Fire Watch Duties The fire watch person must: - Have a clear view of the cutting operation and surrounding area - Have a fire extinguisher and know how to use it (P.A.S.S. technique) - Not perform any other duties during fire watch - Remain at the location for 30 minutes after cutting stops - Know the location of the nearest fire alarm and exit

Shop Communication Protocol

  • Before starting: Verbal alert — "Plasma cutting starting at [location]"
  • Verify all personnel have PPE or are behind screens
  • During cutting: no verbal communication possible (noise + helmet). Use pre-arranged hand signals for "stop" (closed fist) and "OK" (thumbs up)
  • After cutting: "All clear — cutting complete"

Key Talking Points

  1. Plasma cutting PPE is non-negotiable — every item serves a specific purpose
  2. Synthetic fabric near plasma operations can turn a minor spark into a severe burn
  3. The 35-foot combustible clearance is a code requirement, not a suggestion
  4. Fire watch is a dedicated role — the fire watch person does nothing else
  5. Shop communication before, during, and after cutting keeps everyone safe

Learning Objectives (Concept Check)

  • [ ] Identify all required PPE items and their specifications
  • [ ] Explain the 35-foot combustible clearance requirement
  • [ ] Describe the fire watch person's duties and duration
  • [ ] Demonstrate proper shop communication protocol for hot work

Last Updated: 2026-03-19