Welding PPE: what to wear before you strike an arc
Before you strike your first arc, you need to know how to choose, inspect and wear personal protective equipment (PPE). In welding there is no such thing as a quick tack without protection: the radiation, spatter, fume and electricity are all there from the first second.
The minimum gear is a welding helmet with the right shade, safety glasses underneath, leather welding gloves, a leather apron or flame-resistant clothing, leather boots with toe protection, a NIOSH-approved respirator with P100 filters and hearing protection for grinding.
The US standards behind the gear
- Eyes and face: look for the ANSI Z87.1 marking on glasses and helmet.
- Lungs: a plain dust mask is not enough, and an N95 alone is not designed for welding fume. Choose a NIOSH-approved respirator with P100 filters or a powered air-purifying respirator (PAPR). At work, OSHA 29 CFR 1910.134 requires a respiratory protection program with medical evaluation and fit testing.
- Fire and general rules: NFPA 51B for hot work, ANSI Z49.1 for safety in welding and cutting, and OSHA 29 CFR 1910 Subpart Q (general industry) and 1926 Subpart J (construction).
The hazards PPE has to stop
- Arc radiation: ultraviolet burns the cornea and skin; infrared can damage the retina with repeated exposure.
- Spatter and sparks: molten spatter can exceed 2,700 °F (1,500 °C) and sparks travel up to 35 ft (11 m). A freshly welded part can look cold and be at 930 °F (500 °C).
- Fume and gases: metal oxide particles and gases such as ozone, nitrogen dioxide and carbon monoxide.
- Electric shock: open-circuit voltage is typically 50 to 90 V, dangerous when you are damp.
PPE by part of the body
| Area | PPE | Avoid |
|---|---|---|
| Eyes and face | Welding helmet with the right shade, plus clear safety glasses underneath | Sunglasses, welding with your eyes shut |
| Hands | Heavy leather gloves for arc welding; thin goatskin or deerskin for TIG | Rubber or nylon gloves, which melt and stick to skin |
| Arms | Long sleeves; leather sleeves or jacket | Rolled-up sleeves |
| Torso and legs | Leather apron or jacket; natural-fiber, flame-resistant clothing | Polyester, nylon, acrylic; cuffed trousers; open pockets |
| Feet | Leather safety boots with steel or composite toe and heat-resistant sole | Sneakers, sandals, trousers tucked into boots |
| Lungs | P100 filtering facepiece, half-mask with P100 filters, PAPR or supplied air | Dust mask, N95 alone, welding without ventilation |
| Ears | Earplugs or earmuffs when noise exceeds 85 dB(A) | Grinding unprotected |
Chapter 2 of the e-book The Welder's Forge.
Eyes and face
The right lens shade depends on the process and current: shade 10–11 for stick up to 160 A, shade 10–12 for MIG/MAG. The full table and a buyer's checklist are in auto-darkening welding helmet. Shop rule: helmet up, glasses stay on. When you grind, add a face shield over the glasses.
Hands, arms and body
For stick and MIG, use heavy leather gloves that resist heat, cuts and abrasion. For TIG, thinner gloves give better feel on the filler rod. Wear natural fibers only: synthetics melt in sparks and make burns worse. Long sleeves, trousers without cuffs (cuffs collect spatter) and no open pockets.
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Feet: boots and trousers outside
Leather safety boots with a steel or composite toe and a heat-resistant sole are a must. Trousers go over the boots: tucked in, spatter drops straight into the boot top.
Respiratory protection: three levels
- Disposable P100 filtering facepiece (NIOSH-approved): filters particles from metal fume but not gases. It suits well-ventilated areas and moderate fume.
- Half-mask elastomeric respirator with P100 filters: add organic vapor or acid gas cartridges when gases are present. For heavy fume and limited ventilation.
- PAPR or supplied-air respirator: comfortable for long days; supplied air is required in confined spaces without ventilation, such as tanks.
A respirator only works if it seals, and facial hair under the seal breaks it. It is also the last line of defense: ventilation and a fume extractor 6–8 in (15–20 cm) from the puddle come first, and you keep your head out of the plume.
Hearing protection
Grinding, plasma cutting and submerged arc can pass 85 dB(A). In a garage, the angle grinder is the loudest thing you will use: wear earplugs or earmuffs whenever you cut or grind.
Look for cracks, holes and torn seams. A holed glove or a cracked lens no longer protects you. Replace damaged items immediately and store PPE clean and dry. Never weld with wet gloves or clothes, and clear flammables from a 35 ft (11 m) radius or cover them with fire-resistant blankets.
Starting from zero? The basic technique is in how to stick weld, and the full path is in the welding for beginners guide. For a free preview of the PPE chapter, grab the free sample.
Frequently asked questions
What PPE do I need for welding?
Does an N95 mask work for welding fume?
Can I wear regular work gloves to weld?
What clothes should I avoid when welding?
Want all of this in one PDF?
The e-book The Welder's Forge covers stick, MIG/MAG and TIG from the first arc to the shop floor, with reference tables and technical figures, in plain American English.
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