Welding, Brazing, Cutting =

Hot Work
Bureau of Workers’ Comp
PA Training for Health & Safety
OSHA (PATHS)

29CFR1910.251-255
Subpart Q

PPT-018-01 1
Fire Prevention & Protection
• NFPA 51 B – “Standard for
Fire Prevention in Use of
Cutting and Welding
Processes.”
• Move all fire hazards away
from work area.
• Use guards (fire blankets,
etc.) if fire hazards cannot be
moved.

PPT-018-01 2
• Working on floors with
openings/cracks/grating: fire
blankets to protect lower level from
sparks and slag.
• Have suitable fire extinguishing
agents (extinguisher, water, sand,
etc.) ready near cutting and welding
operations.

PPT-018-01 3
A “fire watch” must be available where there is a fire
potential or where;
• Combustible materials are closer than 35
feet to the point of operation.
• Walls opening within the 35 foot radius,
exposing combustible material.
• Material opposite metal walls and roofs could
catch fire from conduction or radiation.

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• A person acting as a “fire watch” must have
fire extinguishing agents readily available and
be trained in their use.

• A fire watch must be maintained for at least

30 minutes after work ceases.

PPT-018-01 5
• Obtain a “burn permit” (hot work permit)
authorized by the designated responsible person.
• Sweep away all paper clippings, wood shavings
or textile fibers within a radius of 35 feet of
cutting/welding operations.

PPT-018-01 6
PPT-018-01 7
Is a hot work permit required under related
OSHA standards?

NO!

Is a hot work permit a “best practice?”

YES!

PPT-018-01 8
• Areas not authorized by company
management.
• Areas near large quantities of readily-ignitable
materials, such as baled paper or cotton.
• Sprinkler-equipped buildings while sprinklers
are impaired or out of order.
• The presence of explosive atmospheres such
as unclean or improperly-prepared tanks.

PPT-018-01 9
• Recognize safe usage of
welding/cutting/burning equipment on
its property.
• Establish areas for cutting and welding
operations.
• Protect welding leads from
damage by vehicles, slag, etc.

PPT-018-01 10
• Designate a responsible individual to authorize
hot work permits.
• Insist that cutters/welders are trained in safe
work habits for their specific tasks.
• Advise all contractors about flammable or
hazardous materials.

PPT-018-01 11
• Ensure that used containers (drums, barrels,
tanks) have been thoroughly cleaned of
flammable materials including grease, tars and
acids.
• All spaces must be vented and purged before
welding.
• Purging with inert gas is recommended.

PPT-018-01 12
• Keep all cylinders outside of confined spaces.

• Turn off gases at cylinders and purge lines when

away from the confined-space work area.

• Remove electrodes (rods) from electrode holders

(stingers) and disconnect machine
power source.

PPT-018-01 13
• Workers on platforms, scaffolds or open
sided floors must be protected from falls
with:
• A guardrail system or lifeline.
• Safety harnesses with lanyards.
• Welding cable and hoses must be kept
clear of passageways, ladders and
stairways.

PPT-018-01 14
• Welders and welders’ helpers must wear
appropriate eye protection.
• Lens of welding hoods, cutting goggles,
and hand shields must:
• Be arranged to protect face, neck and
ears from radiant energy.
• Be made of tempered glass and free
of bubbles.
• Have lens shade readily identified on
glass.

PPT-018-01 15
Results of excessive exposure to ultraviolet
radiation:
• Causes eyes to feel like they are full of sand.
• Can lead to premature cataracts of the eyes.
Protect against ultraviolet radiation, sparks, fumes
and slag.
• Wear protective clothing and respirators.
• Provide warning signs to warn of hot metal.
• Use ventilation or suitable respiratory
protection.
PPT-018-01 16
• General - mechanical, 2000fpm
• 10,000 ft3 per welder
• ceiling less than 16 feet
• around structural barriers

• Local - mechanical, 100 linear fpm in

weld zone

• When ventilation cannot meet the

needs supplied, air respirators shall be
used.

PPT-018-01 17
Mostly require local exhaust ventilation or airline
respirators (reference OSHA standard):
• Fluorine compounds
• Zinc
• Lead
• Beryllium
• Cadmium
• Mercury
• Stainless steel
• Chlorinated hydrocarbons

PPT-018-01 18
• Liquefied petroleum gas

• Formed when calcium carbide is submerged in

water or in petrochemical processes.

• Very unstable at pressures over 15 psi.

• Never operate above 15 psi.

• LEL = 2%, UEL=100%

PPT-018-01 19
• Does not require high storage
pressure (the case with most LP
gases). Is usually pressurized
around 250 psi.
• Turns to liquid over 300 psi.
• Acetone liquid in cylinder lying
horizontally takes at least 1
hour to settle to bottom when
cylinder is set up vertically.

PPT-018-01 20
Gases in a typical acetylene cylinder:
• Acetylene gas 36%
• Acetone 42%
• Porous filler 8-10%
• Reserve volume 10-12%
Cylinders are filled with a porous material with
millions of voids to help keep pressure from
building up.

PPT-018-01 21
• Oxygen will not burn but will support
combustion.

• Oxygen is pressurized around 2,200

psi and the cylinder is hollow.

PPT-018-01 22
• Keep oil and grease off oxygen cylinder
valves and fittings (oil and grease will
burn violently).

• Protect valves of oxygen cylinders

(if valves are knocked off, the cylinder
becomes a “bomb”).

• Separate oxygen cylinders from fuel gas

cylinders or combustible materials by a
distance of at least 20 feet.

PPT-018-01 23
 Oxygen = Acetylene =
threads-right-handed threads-left handed
hoses-green hoses-red

• “Crack” cylinders to blow out dirt or dust.

• Open acetylene cylinders no more than 1 ½
turns (3/4 turn recommended).
• Do not stand in front of regulator when turning
it on, the diaphragm in the regulator could
blow outward.

PPT-018-01 24
• Light acetylene first.
• Open acetylene valve.
• Adjust to no more than 15psi (5 to 7psi is
common, depending on size of metal to be
cut).
• Then turn on oxygen.
• Adjust valve at torch head to “fine tune”
flame to where blue flame is about 1/4 inch.
NOTE: Each fuel-gas cylinder lead should
have a back-flow check valve and
flash-back arrestor.
PPT-018-01 25
• Shut oxygen valve off first, then acetylene.
• Oxygen cylinder valves should be opened entirely.
• Turn main valve off and bleed lines.
• Mark empty cylinders “MT” or “Empty” with
railroad chalk.
• When moving cylinders, roll them on their bottom
edges.

PPT-018-01 26
• Welding fumes from zinc, cadmium,
beryllium, lead, mercury and stainless steel
are addressed in OSHA standards.
• Argon gas used in MIG welding operations
must be handled as an inert gas and stored
accordingly.

PPT-018-01 27
• When transporting cylinders, secure vertically and
with gauges unattached.

• Do not pry frozen cylinders - use warm water

because of the fuse plug on the cylinder bottom.

• Do not use valve caps to lift

cylinders.
Improper and
unsafe
storage
PPT-018-01 28
• Clean torch tips with tip cleaners, wires, etc.
• Do not re-light torch tip with hot metal.

Welding Tip Orifice Cleaner Tip Cleaner in Use

PPT-018-01 29
• Only do “hot work” in
designated/authorized areas.
• Ensure permit is in place and all
parties are aware.
• Ensure fire protection equipment is
readily available.
• Ensure “fire watch” is posted for at
least 30 minutes after work is
done.

PPT-018-01 30
• If welding above
openings/gratings ensure
“guarding” is in place.
• Ensure welding gases and
equipment are stored properly and
safely.
• Ensure compressed gas cylinders
are handled correctly.

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PPT-018-01 32