Electrical Safety in Arc Welding
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 WorkSafe New Zealand guidance.
Identify the Hazards
- Electric Shock: Contact with exposed live parts or damaged cables can result in serious shock or electrocution.
- Improper Grounding: Using scaffolding, chains, or other unsuitable materials instead of proper grounding leads to increased electrical risks.
- Wet or Humid Conditions: Working in damp environments increases the chance of electric shock.
- Unsafe Electrode Holder Handling: Leaving electrodes unattended or using unsafe cooling methods creates a significant hazard.
- 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
- Make sure 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 that are correctly sized for the job—ask your supervisor if you’re 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 from it.
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 it has been inspected and repaired by a competent person.
Real-Life Case or Scenario
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.
- Wear the correct PPE—especially in wet or damp conditions.
- Never make makeshift repairs or use unapproved gear.
- Report faulty or unsafe equipment immediately.
Employer Responsibilities
- Provide maintained and regularly inspected welding equipment.
- Ensure workers are trained in electrical safety specific to welding operations.
- Replace or repair any defective equipment without delay.
- 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 WorkSafe NZ best practices, we can keep ourselves and our team safe. Thanks for your time and for putting safety first.
Standards Overview
Under the Health and Safety at Work Act 2015 (HSWA) and WorkSafe New Zealand guidance, PCBUs must:
- Ensure all welding gear is regularly inspected and maintained.
- Take extra precautions when welding in wet or confined areas.
- Train workers on electrical risks and safe practices.
- Provide fit-for-purpose PPE and safety gear.
Refer to WorkSafe’s guidance on Managing Welding Risks, Electrical Safety in the Workplace, and Safe Use of Plant and Equipment.
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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