Student Material 001: Plasma Cutting Safety Quick Reference Card¶

Material ID: U5M4-MAT-001 Purpose: Pocket reference for emergency procedures, PPE requirements, and safety checklists Updated: 2026-03-19

Emergency Response Quick Reference¶

UNIVERSAL FIRST ACTION: E-STOP¶

┌─────────────────────────────────────────────────┐
│  ANY EMERGENCY → PRESS E-STOP → THEN RESPOND    │
└─────────────────────────────────────────────────┘

Response by Incident Type¶

Emergency	Action 1	Action 2	Action 3
Electrical Shock	E-stop / Main disconnect OFF	DO NOT touch victim — use non-conductive object	Call 911, CPR/AED if needed
Severe Burn	Remove from source	Cool with running water 20 min	Call 911 if >10% body or 3rd degree
Small Fire	E-stop	P.A.S.S. with extinguisher	Evacuate if fire grows
Large Fire	EVACUATE	Pull fire alarm	Call 911, do NOT re-enter
Arc Eye Flash	Move to dim area	Cool compresses on closed eyes	Seek medical attention (delayed symptoms)
Fume Exposure	Move to fresh air	Call 911 if breathing difficulty	Provide material info to medics
Clothing Fire	STOP-DROP-ROLL	Smother with welding blanket	Cool burns with water

Fire Extinguisher: P.A.S.S.¶

P — Pull the pin
A — Aim at the BASE of the fire
S — Squeeze the handle
S — Sweep side to side

PPE Requirements Checklist¶

HEAD:
[✓] Welding helmet — Shade 8-9 (<40A) or Shade 9-12 (40A+)
[✓] Safety glasses — ANSI Z87.1, UNDER the helmet

BODY:
[✓] FR jacket or heavy cotton shirt — long sleeves, buttoned/snapped
[✓] FR or heavy denim pants — no cuffs
[✗] NO synthetic fabrics (polyester, nylon, rayon) — they MELT into skin

HANDS:
[✓] Leather gauntlet gloves — 14" minimum length

FEET:
[✓] Leather boots — steel/composite toe, 8" shaft
[✓] Pants OVER boot shafts — prevent sparks entering boot

RESPIRATORY:
[✓] Mild steel: P100 half-face minimum
[✓] Stainless/galvanized: P100 + OV cartridge
[✓] Unknown coatings: P100 + OV cartridge (or DO NOT CUT)

HEARING:
[✓] Earmuffs NRR 25+ or earplugs NRR 30+

Pre-Cut Safety Checklist¶

AREA CLEARANCE:
[ ] 35-foot radius cleared of combustibles
[ ] Welding screens deployed
[ ] All personnel alerted and equipped/screened

EMERGENCY EQUIPMENT:
[ ] E-stop tested
[ ] Fire extinguisher within 15 feet, charged, correct type
[ ] Eyewash station accessible
[ ] First aid kit accessible
[ ] Evacuation route clear

MACHINE SAFETY:
[ ] Cables/hoses inspected — no damage
[ ] Work clamp solid contact on workpiece
[ ] Water table at correct level
[ ] Ventilation/fume extraction running

PERSONNEL:
[ ] Full PPE on all operators
[ ] At least 1 other person present in shop
[ ] Fire watch person designated
[ ] Emergency roles assigned (caller, responder)

Emergency Equipment Locations¶

(Fill in your specific lab locations)

Equipment	Location
E-stop button(s)	_______
Main power disconnect	_______
Fire extinguisher (nearest)	_______
Fire extinguisher (backup)	_______
Eyewash station	_______
First aid kit	_______
AED	_______
Fire alarm pull station	_______
Primary exit	_______
Secondary exit	_______
Assembly point	_______
Emergency phone	_______

Prohibited Materials — NEVER Plasma Cut These¶

Material	Hazard	Why
Beryllium copper	Extreme toxic fumes	Carcinogen — requires industrial containment
Cadmium-plated metal	Extreme toxic fumes	Carcinogen — requires industrial containment
Magnesium	Extreme fire	Burns at 5,610°F, cannot be extinguished with water
PVC / plastic-coated metal	Chlorine gas	Immediately dangerous to life (IDLH)
Unknown metals	Unknown hazards	Identify FIRST, then assess
Containers (flammable residue)	Explosion	Must be purged and certified gas-free

Hazardous Material Quick Reference¶

Material	Fume Hazard	Respiratory Protection	Additional Precautions
Mild steel	Iron oxide fumes (moderate)	P100 half-face	Standard ventilation
Stainless steel	Hexavalent chromium (carcinogen)	P100 + OV	Maximum ventilation, exposure log
Galvanized steel	Zinc oxide (metal fume fever)	P100 + OV	Grind coating if possible, maximum ventilation
Aluminum	Aluminum oxide (irritant)	P100	Standard ventilation
Painted metal	Variable (may contain lead)	P100 + OV minimum	Identify paint type, consider supplied air
Brass/Bronze	Copper + zinc fumes	P100	Enhanced ventilation

Fire Watch Duration¶

HOT WORK COMPLETE
        │
        ▼
   FIRE WATCH BEGINS
        │
   Monitor continuously
   for 30 MINUTES
        │
        ▼
   No fire/smoldering
   detected?
   ├── YES → Fire watch ends. Document completion.
   └── NO → Respond to fire. Reset 30-minute clock.

Last Updated: 2026-03-19