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  • Basic Auto Repair Safety

  • Automotive Lift Safety

  • Brake and Clutch Repair Safety

  • Chemicals and Fluids Safety

  • Fire Safety

  • Frame Straightener Safety

  • Fuel Handling Safety

  • Grinder Safety

  • Hand Tool Safety

  • Inspection Pit Safety

  • Ladder Safety

  • Physical Lifting Safety

  • Power Tool Safety

  • Spray Painting Safety

  • Steering and Suspension Repair Safety

  • Tire Removal and Replacement Safety

  • Vehicle Handling Safety

  • Vehicle Jack Safety

  • Welding, Cutting, and Burning Safety

  • OSHA Requirements for Auto Repair Shops

Welding, Cutting, and Burning Safety

Automotive technician welding a body panel

Welding equipment is highly useful when working with automobiles, but it poses a significant risk of injury to the user.

Preparing to weld, cut, or burn safely

All welders must be trained before working with welding equipment in a repair shop. Equipment must be checked by a competent, trained person:

  • According to OSHA, defective oxygen, acetylene, and argon hoses must not be used.
  • Don't try to repair hoses with tape or other materials. The damaged section may be removed to shorten the hose.
  • Always check gauges to make sure they're working properly. Replace gauges if they're defective or the glass is broken.
  • Never use defective welding equipment.

Always wear the appropriate Personal Protective Equipment (PPE) when welding:

  • Welding helmet with filter plates and lenses
  • Welding gloves
  • Long pants, long sleeve shirt, and welding apron

Make sure welding areas are well-ventilated before starting work.

Preparation for Safe Welding

Cylinder storage and handling

Store full and empty cylinders in dry, well-ventilated locations, preferably outside of buildings and away from bulk storage tanks. Don't store cylinders in basements or low-lying areas like work bays. If there's a leak, heavy gases don't disperse easily.

Keep all cylinders upright when in storage. According to the University of Florida Environmental Health and Safety, unused cylinders should be secured with safety chains, and valve caps should be in place where possible.

Check that no sources of ignition are nearby before changing cylinders, and only change cylinders in well-ventilated areas.

Gas and oxygen hoses

When oxy-acetylene welding, always use the red hose for gas fuel and the green hose for oxygen. Keep hoses away from areas where they can be damaged by moving equipment or foot traffic.

Red and green welding hoses.
Red for gas, green for oxygen.

Follow the cylinder manufacturer's guidelines when selecting hoses (and clamps, couplings, and regulators). Selection should also be based on the type of gas and type of welding equipment being used.

Doing the job safely

Avoid standing on wet surfaces when arc welding to avoid the risk of electrical shock. Never perform "hot work" such as welding or metal grinding within fifty feet of combustible materials.

Use an open-ended adjustable wrench when connecting and disconnecting regulators and fittings. Don't try to force connections that don't fit easily, and don't use lubricants or grease on oxygen fittings, hoses, or regulators. They should fit easily. If not, you're probably using the wrong type.

Connecting Regulators and Fittings

Test the fittings on the regulator with liquid soap to check for leaks before lighting a torch. If you see the soap layer bubble, it means there's a leak and you shouldn't light the torch.

When using a torch:

  • Only use a friction lighter. Don't use a match or cigarette lighter.
  • Never operate the torch over oxygen or gas lines.
  • Turn the handle on the regulator clockwise to close the valve before changing torches.

When you're finished working:

  • Turn off the cylinder valves.
  • Bleed the lines.
  • Turn off the valve at the blowpipe.