Safety guide
Welding Safety: The Complete Australian Guide
Two injuries dominate real welding: eyes and lungs. This guide is the control hierarchy for both, plus the fire and electrical rules that keep sheds standing.
PPE: the non-negotiable kit
| Item | Standard/choice | Notes |
|---|---|---|
| Auto-darkening helmet | ASNZS 1338, shade 9–13 | buy from welding suppliers, not gadget stores |
| Gloves | leather, process-matched | TIG gauntlets vs MIG mitts |
| Clothing | FR cotton/leather | synthetics melt into skin |
| Respirator | P2 minimum | PAPR for daily welders |
| Boots | steel cap | spats for heavy spatter work |
Fume: the hazard matrix
| Material | Key hazard | Control priority |
|---|---|---|
| Mild steel | iron oxide, general fume | extraction |
| Galvanised | zinc → metal fume fever | grind coating + extraction + P2 |
| Stainless | hexavalent chromium | extraction + fitted respirator |
| Aluminium | ozone, fume | extraction |
Fire and electrical
- Clear 10 m of flammables; sweep the floor — slag hides in cracks and smoulders for hours
- Fire watch 30–60 minutes after the last arc
- RCD protection on circuits; never file plugs; check leads for damage
- Cylinders chained upright, valves closed when idle, caps on for transport
Arc flash protects bystanders too
Screens aren't courtesy — anyone with line of sight to the arc, including through windows and doorways, needs shielding. 'Arc eye' (photokeratitis) at 3am — gritty, streaming eyes — is the free lesson; repeated exposures accumulate real damage.
Frequently asked questions
Why do welders drink milk after welding?
Milk does nothing to protect you from welding fume — that's a myth with no clinical basis. It dates from the idea that calcium 'binds' toxins. The real fix for fume exposure, including zinc from galvanised steel, is ventilation, extraction and the right respirator — not a milk carton.
What PPE do you need for welding?
Minimum welding PPE: an Australian Standards auto-darkening helmet (ASNZS 1338), leather gloves, flame-resistant clothing (no synthetics), steel-capped boots and enclosed workshop ventilation. Add a P2 respirator for fume-heavy work like galvanised, stainless or aluminium welding.
Can you weld indoors safely?
Yes — with ventilation as the non-negotiable. Weld indoors safely by extracting fume at the arc (local extraction or a strong cross-draft), screening the arc from others, clearing flammables within 10 metres, and never welding near solvents, dust collectors or combustible ceiling voids.
What helmet shade should I use?
Use shade 10–12 for MIG and general stick at hobby amperages, shade 12–13 for 200 A+ stick or heavy fabrication, shade 9–10 for low-amp TIG. All of it assumes an Australian Standards auto-darkening helmet — fixed glass only belongs to dedicated cutting goggles and specific processes.
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