Loss Control Academy – Field Reference Card
How to Use: Look around the shop from a safe distance—never touch tools or gases. Use a flashlight to check for sparks or leaks. Ask the shop owner: “Last safety check? Fire extinguisher tags?” Mark High (gas leaks, no ventilation), Medium (clutter, old tags), or Low (clean, tagged, trained) risk. Welding causes about $500,000 injuries and 22 deaths each year in the United States (Occupational Safety and Health Administration 2024 data); sparks start 35% of shop fires (National Fire Protection Association). Average fire claim: $35,000+. Prevent with Occupational Safety and Health Administration 1910.252 welding rules and National Fire Protection Association 51B hot work standards.
THE BASICS: HOW WELDING SHOPS WORK
Welding shops join metal using heat to melt and fuse parts. Heat comes from electricity or gas flames.
Simple Types of Welding (What You’ll See):
- Arc Welding (Stick/MIG/TIG): Electric spark melts metal. Stick – uses a coated rod; common for repairs. MIG – feeds wire; fast for cars/frames. TIG – uses gas shield; clean for thin metal.
- Gas Welding (Oxy-Acetylene): Oxygen + fuel gas flame cuts or welds. Why: Old-school, portable, cuts thick steel.
- Plasma Cutting: Super-hot gas jet slices metal. Why: Fast cuts, less mess than torch.
Key Tools:
- Welder Machine: Makes heat.
- Gas Cylinders: Oxygen (green) and fuel (red).
- Helmet/Gloves: Block sparks and UV light.
Why Inspect: Sparks fly 35 feet, fumes hurt lungs, gases explode if mixed. Most issues from clutter or poor setup.
INSPECTION CHECKLIST
WORK AREA SETUP
- Clear space at least 35 feet around welding—no paper or trash Why: Sparks fly far and start fires.
- Floors clean, no oil spills or clutter Why: Slips near hot tools cause burns.
- Fire blankets or screens around work area Why: Stops sparks from spreading.
GAS CYLINDER STORAGE
- Cylinders upright, chained, caps on when not used Why: Tipping causes leaks or explosions.
- Oxygen and fuel gases stored 20 feet apart or with fire wall Why: Mix can explode if leaked.
- No cylinders in tight spaces without air flow Why: Fumes build up fast.
VENTILATION AND FUMES
- Fans or hoods pull fumes away from workers Why: Welding smoke harms lungs over time.
- Air tested in small rooms—no high carbon monoxide Why: Invisible gas makes people pass out.
- Respirators worn if fumes are strong Why: Extra lung protection.
FIRE PREVENTION
- Fire extinguisher (ABC type) within 30 feet, current tag Why: Puts out small fires fast.
- Hot work permit for each job, fire watch for 30 minutes after Why: Checks risks and watches for smoldering.
- No flammable liquids near welding area Why: Vapors catch fire easily.
EQUIPMENT AND MAINTENANCE
- Welder cables no frays, connections tight Why: Bad wires shock or spark.
- Helmets and gloves no cracks, clean lenses Why: Protects eyes and skin from burns.
- Monthly equipment checks logged Why: Spots wear before breaks.
QUESTIONS TO ASK OWNER
- “When was the last full safety check? Can I see the log?”
- “Gas cylinders—chained and separated? Leak tests?”
- “Ventilation system—pulls fumes out? Air tested?”
- “Any fires or close calls last year? What changed?”
- “Staff training—when last? Fire watch rules?”
RISK LEVELS
- High = Gas leaks, no extinguisher → Suggest attention immediately, fix now
- Medium = Clutter, old gear → Clean and check in 30 days
- Low = Clear, tagged, trained → Best practice
LCA Certified Inspector “Vent it. Clear it. Watch it.”
Resources:
- Occupational Safety and Health Administration 1910.252 Welding Rules
- National Fire Protection Association 51B Hot Work Standard
- Safety by Design Welding Checklist
- National Institute for Occupational Safety and Health Welding Guide
Disclosure: This guide highlights common risks but is not exhaustive. Always verify local codes and carrier guidelines.