Safe Apparel for Welding, Cutting, and Brazing Operations
The Problem
Welding, cutting, and brazing expose workers to sparks, slag, and intense heat. While gloves, hoods, and shields are essential, inappropriate clothing choices can leave the rest of your body at risk. Clothing made from flammable or synthetic fibres can catch fire or melt, causing severe burns or fatalities. Today, we’ll focus on these risks and how to select proper protective clothing to stay safe on the job.
Identify the Hazards
- Flammable Clothing: Synthetic materials like polyester, nylon, or blended fibres can ignite and melt onto the skin.
- Sparks and Slag: Can lodge in cuffs, pockets, or footwear and cause burns.
- Heat Transfer: Jewellery or inappropriate materials can trap or conduct heat, leading to injury.
- Contaminated Clothing: Grease- or oil-stained garments can act as fuel for a fire.
- Wear and Tear: Damaged or frayed PPE may no longer provide adequate protection.
Safety Practices and Preventative Measures
Avoid Synthetic Materials
- Do not wear clothing made from nylon, polyester, acrylic, or any cotton/synthetic blends—these are flammable and can melt onto the skin.
Choose Fire-Resistant Materials
- Wear clothing made from 100% cotton, wool, or specially designed fire-resistant fabrics.
- Ensure outerwear and undergarments—including shirts, pants, jackets, and socks—are all fire-resistant.
Shirt and Pants Guidelines
- Wear long-sleeved shirts with buttoned cuffs and covered pockets to avoid sparks entering.
- Trousers should not have cuffs and must fully cover boot tops to stop slag from falling in.
Footwear
- Wear fully laced boots or shoes to prevent hot slag or sparks from entering footwear.
Additional Head Protection
- Use a fire-resistant balaclava or skull cap under your welding hood to protect your head and neck from heat and UV radiation.
Clothing Care and Maintenance
- Keep protective clothing clean and free from oil, grease, or other flammable substances.
- Regularly inspect fire-resistant garments for fraying, holes, or other signs of wear—repair or replace as needed.
Remove Ignition Sources
- Empty all pockets of matches, lighters, or other potential ignition items before starting work.
Avoid Jewellery
- Remove rings, necklaces, and other jewellery, as these can trap heat, conduct electricity, or catch sparks.
Real-Life Case or Scenario
A worker wore a polyester-blend shirt while welding. Sparks ignited the shirt, which melted onto their skin, causing third-degree burns. The worker needed months of treatment and rehabilitation. This incident could have been prevented with fire-resistant clothing.
Employee Responsibilities
- Wear only fire-resistant protective clothing that covers your entire body.
- Check your clothing for damage or contamination before each shift.
- Remove jewellery and flammable items before starting work.
- Follow your company’s PPE and apparel safety policies.
Employer Responsibilities
- Provide or recommend compliant, fire-resistant protective workwear.
- Offer training on PPE and safe clothing selection for welding tasks.
- Replace or repair damaged protective gear and ensure PPE complies with WorkSafe NZ requirements.
Discussion & Questions
- “What difficulties have you faced when choosing the right clothing for welding?”
- “Have you seen or experienced any clothing-related incidents during welding tasks?”
Encourage team members to share experiences, concerns, or tips about their PPE and clothing.
Commitment/Action Plan
Let’s commit to inspecting our work clothing daily and ensuring we’re wearing flame-resistant materials. Starting today, take a moment before each job to check your clothing and remind your team to do the same. Safety is everyone’s responsibility.
Wrap-Up
Choosing the right protective clothing for welding could be the difference between staying safe and suffering a serious injury. By following these guidelines, we protect not only ourselves but also our co-workers. Thank you for your attention—let’s continue prioritising safety every day.
Standards Overview
Under the Health and Safety at Work Act 2015 (HSWA) and supported by WorkSafe New Zealand’s guidance, PCBUs (Persons Conducting a Business or Undertaking) must ensure:
- Workers are provided with or have access to appropriate personal protective equipment (PPE)
- Protective clothing minimises the risk of injury from heat, flame, and molten metal
- PPE is maintained in good condition and used correctly
WorkSafe NZ also emphasises:
- Workers must be trained in safe PPE use
- Employers must monitor clothing and equipment for signs of wear or contamination
All PPE must be suitable for the task and compliant with applicable New Zealand standards
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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