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Welding Safety: Protecting Your Future Compensation

What is welding?

Welding is a manufacturing technique that permanently connects two materials, typically metals, by applying sufficient heat to melt the materials being joined. In some cases, pressure, or a combination of heat and pressure, may be employed to fuse materials together. Welding finds widespread applications across various industries for construction, maintenance, repair work, and the production of equipment, machinery, and tools.

What are the hazards associated with welding? 

It is essential to implement controls to either eliminate or mitigate the risks associated with welding, as many of these risks can pose immediate and life-threatening dangers to workers.

Equipment-related risks

  • Electrical equipment that is in bad condition, poorly maintained or has damaged insulation, can expose workers to the risk of electric shock.
  • Poorly maintained personal protective equipment (PPE) can result in burns and vision and hearing damage.

Process-related risks

  • Sparks, excessive heat or radiation may result in burns, welding flashes or fire.
  • Heating metals above boiling point also generates welding fumes.


    • Materials-related risks

    Workers could inhale fume gases and vapours from:

    • the metal being welded
    • coatings such as paint or zinc on the material being welded
    • heating chemical residues.

    Containers that have had flammable or combustible substances in them are a fire and explosion hazard while being welded. Welding these containers must be supervised by a suitably qualified person. Make sure you check all containers before you begin work.

    Containers that have contained:

    • flammable substances like unleaded petrol and acetone may be marked with a flame symbol
    • combustible substances, such as diesel fuel, greases, tar, engine oils, linseed oil or tallow, might not be marked with a flame symbol because they are not normally flammable at normal temperatures and pressures. However, when they’re exposed to the extremely high temperatures and pressures of welding they may create enough vapour to cause an explosion, particularly inside a sealed drum.

    Check AS 1674.1 (1997) Safety in welding and allied processes, Part 1: Fire precautions for guidance on managing and supervising these hazards

    The workspace

    There’s a risk of workers inhaling toxic gases, fumes or getting an electric shock if they’re welding in:

    • a hazardous area
    • a poorly ventilated or confined space
    • a wet environment.

    Welding is hot work that can have fire and explosion risks.


    Level of skill

    Less experienced welders, or those unfamiliar with the tools, may risk injuries from poor work practices.

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