RAMS for Welding

The duty to carry out a suitable and sufficient risk assessment sits with the employer under the Management of Health and Safety at Work Regulations 1999 (MHSWR), Regulation 3. For welding work, that assessment feeds directly into your RAMS — a combined method statement and risk assessment that demonstrates how risks are identified and controlled before work begins. Additional legislation bearing on welding operations includes the Electricity at Work Regulations 1989 (EaWR), the Control of Substances Hazardous to Health Regulations 2002 (COSHH), DSEAR 2002 (for gas cylinders and flammable atmospheres), and the Confined Spaces Regulations 1997 where applicable.

Key Hazards and Controls

**Weld fume**

HSE confirmed in 2019 that all welding fume — including mild steel — is a Group 1 carcinogen. There is no safe threshold; the control hierarchy starts with engineering controls, not PPE. Local exhaust ventilation (LEV) is mandatory for all indoor welding and should be the primary control. Practical options include on-torch extraction and low-volume high-velocity (LVHV) capture hoods positioned within 100–150 mm of the arc. Where LEV cannot adequately reduce residual exposure — which is common — respiratory protective equipment (RPE) is required in addition. An air-fed (airline or PAPR) unit with a nominal protection factor up to approximately 2,000 is the standard choice for sustained operations; FFP3 disposable masks (APF ~20) and full-face respirators with P3 filters (APF ~40) may be appropriate for short-duration, lower-risk tasks. Confirm specific WEL figures against EH40 for the base metal and any coatings involved. Stainless steel welding introduces hexavalent chromium; galvanised or painted substrates can produce zinc oxide fume or isocyanate decomposition products — isocyanate exposure requires air-fed RPE specifically.

**Electric shock**

EaWR imposes a duty to prevent danger from electrical systems. RAMS must specify that set leads and return leads are correctly routed and secured, that equipment is inspected and in good condition (PAT where applicable), and that isolation procedures are in place before any work on the welding set itself. Operatives must never attempt DNO or high-voltage (HV) isolation — this is the network operator's responsibility and must be arranged through the correct authority. Wet conditions significantly increase shock risk and must be addressed in the method statement.

**UV radiation and arc eye**

Arc welding produces intense ultraviolet and infrared radiation. Arc eye (photokeratitis) can result from even brief, indirect exposure. Controls include appropriate auto-darkening or fixed-shade welding screens, screens or curtains to protect adjacent workers, and suitable face protection with the correct lens shade for the process.

**Hot works and fire**

A hot works permit is required in virtually all construction and maintenance environments. The method statement must specify pre-work clearance of combustibles, shielding of adjacent materials, a trained fire watch during work, and a post-work inspection period of at least one hour. Fire extinguishers appropriate to the risk must be immediately to hand.

**Gas cylinders**

Cylinders fall under DSEAR 2002. Controls include upright storage and securing, segregation of fuel and oxidant gases, pressure-relief and flashback arrestors fitted to hoses, and no storage in confined or poorly ventilated spaces. Oxygen enrichment is a particular risk — it dramatically lowers the ignition threshold of clothing and materials.

**Confined spaces and fume build-up**

Where welding is performed in a confined space, the Confined Spaces Regulations 1997 apply. A safe system of work and — critically — a suitable rescue arrangement must be established before entry begins (Regulation 5 precondition). Fume and shielding gas (including argon, which displaces oxygen silently) can accumulate rapidly. Continuous atmospheric monitoring, forced ventilation, and a non-entry rescue system are standard requirements.

Common Failings

The most frequent shortcomings seen in welding RAMS documents are: stating RPE as the primary or sole fume control without specifying LEV; omitting weld fume carcinogen classification entirely; failing to address the specific hazards of coated or alloyed base metals; absence of a hot works permit reference; no mention of return-lead routing or electrical isolation authority; and confined-space rescue arrangements noted as "TBC" rather than defined before work commences.

What the Document Must Include

A compliant welding RAMS should set out: the welding process and base materials (including coatings); identification of each significant hazard with the applicable legislation; controls in hierarchy order, collective before personal; specific LEV arrangements and confirmation that RPE selection is fit for purpose with APF recorded; hot works permit procedure and fire watch duration; electrical isolation authority and limitations; gas cylinder handling, storage, and flashback protection; confined-space classification with atmospheric monitoring method and rescue plan if applicable; any COSHH assessment reference for substances involved; competency requirements for operatives; and the name of the person responsible for ensuring controls are in place before work starts.