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Safety Protocol 001: Weld Shop Comprehensive Safety & Emergency Procedures

Protocol ID: U6M4-SAFE-001 Context: Master safety protocol for the welding shop covering all hazards, emergency procedures, equipment storage, and administrative controls Hazard Level: Very High — Multiple simultaneous hazards from welding, grinding, cutting, and material handling operations

Potential Hazards

Electrical (FATAL Risk)

  • Open circuit voltage: 60-80V DC (MIG/TIG), potentially lethal in wet or compromised conditions
  • AC TIG welding: alternating polarity prevents muscle release — higher shock risk
  • Damaged cables, exposed conductors, improper grounding

Thermal (CRITICAL Risk)

  • Arc temperatures: 6,000-10,000°F
  • Hot workpieces: 300-1,500°F for minutes after welding
  • Molten spatter: can travel 20+ feet, ignites combustibles
  • Fire: leading cause of welding-related property damage

Radiation (HIGH Risk)

  • UV-A, UV-B, UV-C from welding arc — causes arc eye in seconds of direct exposure
  • Infrared radiation — thermal eye injury from prolonged exposure
  • Reflected UV from shiny surfaces — affects bystanders

Respiratory (HIGH to CRITICAL Risk)

  • Iron oxide fumes from steel welding — respiratory irritant
  • Hexavalent chromium from stainless steel — OSHA-regulated carcinogen
  • Manganese from steel fumes — neurological toxin at chronic exposure
  • Zinc oxide from galvanized steel — causes metal fume fever
  • Ozone generated by UV radiation — respiratory irritant
  • Argon displacement — asphyxiation risk in enclosed spaces

Mechanical (MODERATE to HIGH Risk)

  • Angle grinder injuries — lacerations, disc shatter, entanglement
  • Sharp edges on cut/welded metal — lacerations
  • Heavy material handling — back injuries, crush hazards
  • Compressed gas cylinder hazards — projectile if valve breaks

Required Precautions & Procedures

Daily Shop Opening Checklist

  1. Test all ventilation systems — confirm airflow at each welding station
  2. Inspect fire extinguishers — charged, correct type, accessible
  3. Test eyewash station — 30-second flush
  4. Verify first aid kit and AED are stocked/charged
  5. Inspect gas cylinder security — all chained, caps on storage cylinders
  6. Check shop floor — clean, dry, no tripping hazards
  7. Verify emergency exits are clear and marked
  8. Check welding screens — intact, properly positioned

Before Any Welding Operation

  1. Identify the base metal — verify material type and any coatings
  2. Select appropriate filler and gas for the material
  3. Prepare the joint — grind, clean, fit-up
  4. Select correct PPE for the specific process and material
  5. Position fume extraction 4-6" from the weld zone
  6. Clear combustibles within 35 feet
  7. Deploy welding screens around the station
  8. Verify work clamp makes solid contact
  9. Inspect equipment for damage
  10. Brief any bystanders on staying behind screens

During Welding Operations

  1. Full PPE at all times — no exceptions for "quick tacks"
  2. Never weld alone — at least one other person in the shop
  3. Operator monitoring: sound, pool behavior, spatter pattern
  4. Never leave an energized machine unattended
  5. No food, drink, or tobacco use in the welding area (fume contamination)
  6. Keep the welding area organized — trip hazards cause arc flash incidents

Post-Welding

  1. Fire watch: minimum 30 minutes after last hot work
  2. Mark all hot metal "HOT"
  3. Close gas cylinder valves
  4. Power off all machines
  5. Clean the station — remove spatter from table, sweep floor, empty slag container
  6. Document any incidents, near-misses, or equipment issues

Emergency Response

Response Priority: STOP → ALERT → ACT → REPORT

Electrical Shock 1. Do NOT touch the victim 2. Disconnect power at main breaker 3. Call 911 4. CPR/AED if needed after victim is separated from circuit 5. Hospital evaluation is MANDATORY — cardiac arrhythmia may occur hours later

Burns 1. Remove source of burn 2. Cool with running water 20 minutes (NOT ice) 3. Do not remove stuck clothing or pop blisters 4. Call 911 for 2nd/3rd degree burns covering >10% body or face/hands/joints 5. Cover with sterile dressing, treat for shock

Fire 1. Press E-stop / power off equipment 2. Small fire: P.A.S.S. technique with ABC extinguisher 3. Growing fire: EVACUATE, pull alarm, call 911, close doors 4. Person on fire: STOP-DROP-ROLL, smother with welding blanket 5. Never re-enter until cleared by fire department

Arc Eye / Radiation Burns 1. Move to dim area 2. Cool compress on closed eyes 3. Do NOT rub eyes 4. Seek medical attention (symptoms may worsen 6-12 hours)

Fume Exposure 1. Move to fresh air immediately 2. Call 911 if breathing difficulty 3. Provide material/filler type information to responders 4. Monitor for delayed symptoms (metal fume fever: 4-12 hours)

Argon Asphyxiation 1. Do NOT enter confined space without ventilation 2. Ventilate area first (open doors/curtains) 3. Move victim to fresh air 4. Call 911 5. CPR if not breathing

Grinding Injury 1. Severe laceration: apply direct pressure, elevate, call 911 if deep 2. Eye injury from particle: flush at eyewash 15 minutes, seek medical attention 3. Disc shatter: treat any embedded fragments as impaled objects — do NOT remove

PPE Requirements

PPE Item MIG Welding TIG Welding Grinding Material Handling
Welding helmet Shade 10-12 Shade 8-12 NO — face shield N/A
Face shield N/A N/A ANSI Z87.1 If cutting
Safety glasses Under helmet Under helmet Under face shield Always
FR jacket Required Required Recommended N/A
Leather gloves Heavy gauntlet Thin TIG gloves Heavy leather Heavy leather
Leather boots Steel toe, 8"+ Steel toe, 8"+ Steel toe Steel toe
Hearing protection NRR 25+ As needed NRR 25+ As needed
Respirator P100 minimum P100 minimum N95 minimum N/A
Welding cap FR fabric FR fabric N/A N/A

Last Updated: 2026-03-19