Electrical Safety in Arc Welding

Welding, Cutting & Compressed Gas Safety
English (Canada)

The Problem

Arc welding presents serious electrical hazards that can cause severe injury or even death. These risks often stem from damaged equipment, poor grounding, or working in wet or damp environments. Today, we’ll cover how to identify these hazards and apply correct safety practices to prevent accidents and ensure compliance with CCOHS guidance.

Identify the Hazards

  • Electric Shock: Contact with exposed live parts or damaged cables can result in serious shock or electrocution.
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  • Improper Grounding: Using scaffolding, chains, or other unsuitable materials instead of proper grounding increases electrical risks.
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  • Wet or Humid Conditions: Working in damp environments increases the chance of electric shock.
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  • Unsafe Electrode Holder Handling: Leaving electrodes unattended or using unsafe cooling methods creates a significant hazard.
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  • Damaged Equipment: Cables, connectors, or enclosures in poor condition are a major risk if not properly checked before use.

    • Safety Practices and Preventative Measures

    Inspect Welding Equipment Before Use

    • Ensure all protective covers and enclosures are secure and in good condition.
    • If equipment is damp or wet, dry it thoroughly and have it checked by a qualified technician before use.

    Welding Cable and Connection Safety

    • Protect terminal connections with insulated covers or appropriate fittings.
    • Inspect cables for cracks, exposed conductors, or damage—report and tag out any unsafe equipment.
    • Only qualified personnel should repair or replace defective welding gear.

    Proper Cable Size and Grounding

    • Use welding cables correctly sized for the job—ask your supervisor if unsure.
    • Use approved cable connectors for grounding—never use chains, conduit, or scaffolding.

    Safe Handling of Electrode Holders

    • Remove the electrode when the holder is not in use.
    • Switch off the welding machine when moving equipment or stepping away.

    Protect Against Electric Shock

    • Use insulating mats, gloves, and boots when working in damp or humid conditions.
    • Never cool down a hot electrode holder by dipping it in water—this creates a shock hazard.

    Report Equipment Defects

    • Immediately report any damaged or unsafe equipment to your supervisor.
    • Do not use faulty equipment until inspected and repaired by a competent person.

    Real-Life Case or Scenario

    Where possible, use an actual incident that you have experienced or been involved in.

    On a recent job, a welder received an electric shock due to a small tear in the cable insulation. The cable hadn’t been inspected before use, and the damage went unnoticed. A simple pre-use check could have prevented the incident.

    Employee Responsibilities

    • Check all welding equipment and leads before every job.
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    • Wear the correct PPE—especially in wet or damp conditions.
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    • Never make makeshift repairs or use unapproved gear.
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    • Report faulty or unsafe equipment immediately.

    Employer Responsibilities

    • Provide maintained and regularly inspected welding equipment.
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    • Ensure workers are trained in electrical safety specific to welding operations.
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    • Replace or repair any defective equipment without delay.
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    • Provide PPE and take extra precautions for work in damp or hazardous conditions.

    Discussion & Questions

    • “What electrical hazards have you come across while using welding gear?”
    • “What’s your process for checking cables and leads before work?”
    • “Has anyone here experienced or seen an electrical incident during welding? What was the cause, and how could it have been avoided?”

    Encourage your crew to speak up and share knowledge—it helps keep everyone safe.

    Commitment/Action Plan

    Starting today, let’s commit to checking all welding equipment before use. If you spot damaged cables, poor grounding, or missing covers, report them immediately. Electrical incidents are preventable when we’re alert and proactive.

    Wrap-Up

    Electrical hazards in arc welding are no joke—but they are preventable. By inspecting gear, using the correct PPE, and following CCOHS best practices, we can keep ourselves and our team safe. Thanks for your time and for putting safety first.

    Standards Overview

    Under the Canada Labour Code and CCOHS guidance, employers must:

    • Ensure all welding equipment is regularly inspected and maintained.
    • Take extra precautions when welding in wet or confined spaces.
    • Train workers on electrical risks and safe welding practices.
    • Provide fit-for-purpose PPE and safety gear.
    • Refer to CCOHS guidance on managing welding risks, electrical safety, and safe use of plant and equipment.

    Disclaimer

    “The information provided in this toolbox talk is intended for informational and educational purposes only. It is not a substitute for professional legal, safety, or regulatory advice. The content reflects general best practices and industry standards but may not be applicable to all workplace environments or jurisdictions.

    It is the responsibility of employers, supervisors, and workers to ensure compliance with applicable federal, provincial, and territorial laws, regulations, and standards, including but not limited to those set by the Canadian Centre for Occupational Health and Safety (CCOHS) and relevant provincial occupational health and safety authorities. Site App Pro, its affiliates, agents, or representatives—as well as the authors, presenters, and distributors of this toolbox talk—assume no liability for the use or application of the information provided.

    Participants are strongly encouraged to consult appropriate legal, safety, or regulatory professionals regarding specific workplace concerns or questions. Always adhere to your organisation’s policies and procedures for health and safety and hazard management.

    All Rights Reserved Site App Pro 2025

    Last Updated:
    July 10, 2025