The earlier modules described the hazards of welding. This final module brings the controls together: the personal protective equipment, or PPE, that welders need, how to check equipment before use, how to protect other people, and the safe system of work and emergency arrangements that tie everything together.

Remember that PPE is the last line of defence in the hierarchy of control. It protects only the wearer, and only when it is the right type, fits properly and is worn correctly.

By the end of this module, you will be able to:

• Select the correct PPE for welding, and explain the employer’s duties under the General Application Regulations 2007.
• Carry out pre-use checks on welding equipment, and deal correctly with defects.
• Protect other people from welding hazards.
• Describe a safe system of work, and basic emergency arrangements.

The essential PPE for protecting your eyes from the arc is a welding helmet or face shield, fitted with a filter of the correct shade for the process and the current. Auto-darkening helmets make this easier, because they switch to the set shade when the arc strikes.

• Check the filter and the cover lens are clean and undamaged.
• Wear safety glasses under the helmet for chipping and grinding.
• Ordinary sunglasses give no protection against the arc.

Where fume cannot be controlled adequately by local exhaust ventilation, or when welding outdoors, suitable respiratory protective equipment, or RPE, is needed.

• A powered air purifying welding helmet is often the best choice, because it does not rely on a tight seal.
• Tight-fitting RPE must be face-fit tested for the wearer.
• Check RPE before each use, and keep filters and batteries in good order.

• Flame-retardant welding clothing, with sleeves down and collar fastened.
• Leather welding gauntlets.
• A leather apron, jacket or sleeves for heavy or overhead work.
• Safety boots, with trousers worn over them so that spatter cannot drop inside.
• Hearing protection, where noise levels require it.

Avoid synthetic clothing, which can melt onto the skin, and remove lighters and matches from your pockets before welding.

Under Part 2, Chapter 3 of the General Application Regulations 2007, employers must provide suitable PPE free of charge, maintain it, and train people to use it.

Workers must wear PPE as instructed, look after it, and report any loss or defect.

PPE must fit the wearer, suit the task, and work together. For example, a respirator must fit under a welding helmet without breaking its seal.

Before starting work, check that:

• Cables, electrode holders and torches are undamaged and fully insulated.
• Connections are tight, and the return lead is clamped close to the work.
• Gas hoses, regulators and flashback arrestors are in good condition and free of leaks.
• The welding set and the extraction are working, and within their inspection dates.
• The work area is clear of combustible materials, and other people are protected.

If you find damaged or faulty welding equipment, stop using it, take it out of use, label it do not use, and report it straight away. Never carry on with a makeshift repair, such as taping a damaged cable or hose.

Part 2, Chapter 2 of the General Application Regulations 2007 requires work equipment to be suitable, maintained in good repair, and inspected where deterioration could cause danger.

Arc radiation, spatter and fume can harm people who are not welding. Before you start:

• Put up welding screens or curtains around the work.
• Keep others out of the area with barriers, and display suitable warning signs.
• Co-ordinate with other trades working nearby.
• Make sure anyone who must be close by wears suitable eye protection.
• Check that fume is not drifting into other work areas.

A safe system of work brings all the controls together. It includes:

• A risk assessment for the task.
• Competent, trained welders.
• Suitable equipment, extraction and PPE.
• Permits for hot work or confined space entry, where needed.
• Adequate supervision.
• Clear communication of the precautions to everyone involved.

Review the system if anything changes, such as a new location, material, process or team, and after any accident or near miss.

Know the emergency procedures before you start:

• Where the fire extinguishers and fire blankets are.
• Where the first aid kit is, and who the nearest first aider is.
• How to raise the alarm, and where the escape routes and assembly point are.
• How to isolate the welding power and close the gas cylinder valves quickly.

Report all accidents and near misses, so that lessons can be learned.

• Burns. Cool the burn under cool running water for 20 minutes. Get medical help for anything more than a minor burn.
• Electric shock. Isolate the power before touching the casualty, then call for help.
• Arc eye. Seek medical advice. Do not rub the eyes.
• Fume or gas exposure. Move the person to fresh air, if it is safe, and get medical help. Never enter a confined space to rescue someone unless you are trained and equipped to do so.