Proper Use and Care of Oxy-Fuel Gas Torch Hoses
The Problem
Oxy-fuel gas torch hoses are essential for safe cutting and welding operations—but if they are damaged, contaminated, or poorly maintained, they can lead to fires, explosions, and serious injury. Today, we’ll look at the hazards associated with oxy-fuel hoses and discuss safe handling, inspection, and maintenance practices to help prevent dangerous incidents.
Identify the Hazards
- Gas Leaks: Damaged hoses or faulty connections can lead to gas leaks, creating a risk of fire or explosion.
- Burns and Injuries: Unexpected gas release or contact with hot surfaces can result in burns.
- Contamination: Hoses exposed to oil, grease, or debris can degrade, increasing the risk of failure.
- Tripping Hazards: Tangled, kinked, or poorly stored hoses can cause serious slips, trips, and falls on site.
Safety Practices and Preventative Measures
1. Use Approved Hoses
- Only use hoses specifically designed for oxy-fuel gas torches.
- Follow colour coding: green for oxygen, red for acetylene—never interchange hoses to avoid confusion.
2. Pre-Use Inspection
- Blow out hoses with clean, dry gas before connecting to remove any foreign material.
- Inspect hoses for cracks, leaks, burns, or wear. Replace damaged hoses immediately—do not use tape or temporary fixes.
3. Leak Detection and Repair
- Use soapy water to test hose connections—bubbles will indicate a leak.
- Never use tape to seal leaks. Repairs must be carried out by authorised personnel using approved fittings.
4. Securing Hose Connections
- Use only crimped fittings or clamps approved for oxy-fuel hose use.
- Do not use general-purpose hose clamps or makeshift fasteners.
5. Protect Hoses from Contamination and Damage
- Keep hoses free from oil, grease, solvents, and metal filings.
- Avoid running hoses over sharp edges, dragging them across rough surfaces, or allowing them to be caught in moving equipment.
6. Protect Hoses from External Hazards
- Keep hoses clear of sparks, open flames, welding slag, and hot surfaces.
- Store hoses in a clean, dry, and well-ventilated area, away from extreme temperatures or heavy objects.
7. Minimal Tape Usage
- if taping hoses together to prevent tangling, use no more than 100 mm of tape for every 300 mm of hose length.
Real-Life Case or Scenario
On a building site, a worker used a hose that had oil residue on it. Under pressure, the contaminated hose deteriorated and leaked acetylene, which ignited and caused a small fire. Luckily, it was quickly controlled, but the event could have been avoided with a proper inspection and cleaning before use.
Employee Responsibilities
- Inspect hoses for damage, leaks, or contamination before every use.
- Use only approved hoses and fittings.
- Keep hoses clear of hazards and avoid creating tripping risks.
- Immediately report any damaged or unsafe hoses to your supervisor.
Employer Responsibilities
- Supply approved oxy-fuel hoses and ensure they are stored and maintained correctly.
- Train workers on proper hose inspection, use, and storage.
- Ensure only authorised personnel carry out hose repairs or replacements.
Discussion & Questions
- “What are the most common hose hazards you’ve seen on site?”
- “How can we better manage hose storage and prevent damage?”
- “Do you have any questions about inspecting hoses or detecting leaks?”
Encourage the team to share practical suggestions or lessons learned.
Commitment/Action Plan
Starting today, let’s all commit to inspecting our oxy-fuel hoses before every use and reporting any damage or improper use right away. Hose safety is non-negotiable—our health and safety depend on it.
Wrap-Up
Safe use of oxy-fuel hoses is a critical part of cutting and welding operations. Fires, explosions, and injuries can be prevented through simple daily checks, proper handling, and correct storage. Let’s all take responsibility and follow these guidelines to protect ourselves and our team.
Standards Overview
Under the Health and Safety at Work Act 2015 (HSWA), PCBUs have a duty to eliminate or minimise risks from plant and equipment, including gas hoses. Key requirements include:
- Inspecting hoses before use for signs of damage or deterioration
- Ensuring only trained and authorised personnel carry out repairs
- Protecting hoses from excessive heat, sharp edges, and mechanical stress
WorkSafe New Zealand provides guidance on safe gas cutting and welding practices, including maintenance of hoses and gas delivery systems.
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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