OSHA Standards Related to Welding and Fabrication

The title of this article is a little misleading, because when we think of the kinds of standards that our fabrication shops need to abide by we typically think of OSHA. But there are some other industry standards to pay attention to from organizations like the American Welding Society, National Fire Protection Association, American Conference of Governmental Industrial Hygienists and more. So I’ve provided those relevant standards as well.

This list is LONG and comprehensive. All of these may not apply to your situation, but I had put all of these together for our internal use and figured we could save you the headache of gathering and sorting all of this. Hope it’s of use…

Table of Contents

You can jump directly to a category by selecting from the table of contents.

Welding, Cutting, Brazing

These rules cover how to perform hot work safely, including welding, cutting, and brazing. They require you to remove or protect anything that can burn, have a trained fire watch when needed, and make sure sparks and slag cannot reach combustibles. Equipment must be in good condition, cables and hoses must be intact, and work areas need enough ventilation to keep fumes down.

Be on the lookout for blocked ventilation, missing fire protection, damaged leads or electrode holders, and people welding near flammables without shields. For gas systems, check cylinder storage and regulators. For arc processes, verify proper grounding and return paths. Assign clear hot-work permits if you work outside designated booths.

Compressed Gases, Fuels, and Oxidizers

These rules cover cylinders and systems for oxygen, acetylene, hydrogen, and other gases. They require proper storage, separation of fuel and oxidizer, protection of valves and caps, leak-free connections, and using the correct regulators and flashback protection. Bulk systems have location and clearance rules to reduce fire risk.

Be on the lookout for uncapped cylinders, mixed storage of oxygen and fuel, oil or grease on oxygen equipment, cracked hoses, and makeshift repairs. Keep cylinders secured, move them with proper carts, and train staff on opening valves, purging lines, and shutting down safely.

Ventilation, Fumes, Air Contaminants

These rules set the expectation that you control airborne hazards from welding, cutting, grinding, and machining. You should use local exhaust hoods, extraction arms, and general ventilation to keep exposures below legal limits. Some metals, like stainless with chromium or processes that create hexavalent chromium, have special requirements and lower limits.

Be on the lookout for visible haze, strong odors, and workers lifting shields to “get air.” Measure or sample when you introduce new alloys or processes. Maintain capture hoods, replace filters, and prevent re-entrainment. If you cannot engineer it down, use respirators under a written program.

Noise

These rules require you to control noise exposure and protect hearing. If average exposure hits the action level, you need hearing tests, training, and hearing protection. Very loud tools or extended grinding can push you into that range.

Be on the lookout for long periods of grinding, chipping, impact tools, and loud compressors. Use quieter consumables and tools where possible, isolate noise sources, and enforce consistent earplug or earmuff use. Track who needs annual audiograms.

  • [1910.95] Occupational noise exposure, hearing conservation program at 85 dBA TWA, audiometry, protection.
  • ANSI S1.4, Sound Level Meters
  • ANSI S3.6, Audiometers
  • ANSI S12.6, Measuring Hearing Protector Attenuation
  • ISO 9612, Occupational noise exposure assessment
  • ISO 1999, Estimation of noise-induced hearing loss

Personal Protective Equipment (PPE)

These rules require a hazard assessment, choosing the right PPE, training people to use it, and enforcing it. Eyes and face need protection from sparks and radiation, heads need hard hats under crane work, hands need the right gloves for heat and cuts, feet need safety toes, and respirators require a formal program.

Be on the lookout for wrong shade lenses, worn out gloves, open shoes, and missing PPE in quick jobs. Stock the right gear by process, for example welding helmets and FR jackets at booths, cut-resistant gloves at saws, and face shields at grinders. Replace damaged PPE promptly.

  • [[1910.132] General PPE requirements, hazard assessment, selection, training.
  • [1910.133] Eye and face protection for flying particles, molten metal, radiant energy from welding.
  • [1910.134] Respiratory protection when engineering controls are not sufficient, written program, fit testing.
  • [1910.135] Head protection in areas with falling or overhead hazards such as crane loads.
  • [1910.136] Foot protection for impact, compression, puncture risks.
  • [1910.138] Hand protection selected for specific hazards, abrasions, cuts, chemicals, heat.
  • ANSI/ISEA Z87.1, Eye and Face Protection
  • ANSI/ISEA Z89.1, Industrial Head Protection
  • ASTM F2413, Protective Footwear
  • ANSI/ISEA 105, Hand Protection Classification
  • NFPA 2112 and NFPA 2113, Flame resistant garments and their selection, use, care
  • ANSI/ISEA Z358.1, Emergency Eyewash and Shower Equipment

Hazard Communication and Flammables

These rules require labeled containers, Safety Data Sheets, and training for anyone who uses chemicals like solvents, paints, and welding consumables. Flammable liquid rules cover storage cabinets, proper containers, bonding and grounding for dispensing, and ventilation in spray or cleaning areas.

Be on the lookout for unmarked squeeze bottles, missing SDS access, open cans of solvent, and overfilled cabinets. Keep ignition sources away, manage oily rags in approved containers, and maintain your written HazCom program with an up-to-date chemical list.

  • [1910.1200] Hazard Communication aligned with GHS, SDS, labels, training for chemicals, welding consumables, solvents.
  • [1910.106] Flammable liquids storage, dispensing, ventilation, containers, Class I to III.
  • [1910.107] Spray finishing using flammable and combustible materials if you spray coat parts in-house. (Index)
  • [1910.157] Portable fire extinguishers selection, spacing, inspection, training, including Class D for combustible metal fines.
  • UN GHS, Globally Harmonized System for classification and labeling
  • ANSI Z400.1 and Z129.1, Legacy SDS and labeling guidance often referenced
  • NFPA 704, Hazard diamond system
  • NFPA 33, Spray Application Using Flammable or Combustible Materials
  • NFPA 34, Dipping and Coating Processes
  • NFPA 77, Recommended Practice on Static Electricity

Machines, Machining, and Hand or Portable Tools

These rules require guards on points of operation, rotating parts, and nip points. Grinders need tool rests and tongue guards set very close to the wheel. Mechanical power presses and forming equipment need proper safeguarding and inspections. Portable tools need guards in place and safe cords.

Be on the lookout for removed guards, missing or loose grinder rests, foot pedals without covers, and taped cords. Keep chuck keys out of drills, use only rated wheels, and lock out machines before maintenance. Train operators on safe setups and use jigs or fixtures to keep hands out of danger.

  • [1910.212] Machine guarding, general guarding point of operation, nip points, rotating parts, flying chips.
  • [1910.215] Abrasive wheel machinery grinders, work rests set within 1/8 inch, tongue guards within 1/4 inch, wheel guards.
  • [1910.217] Mechanical power presses safeguarding, controls, inspections, injury reporting. Relevant for some stamping or forming.
  • [1910.218] Forging machines maintenance, splash guards, housekeeping, tongs and tools.
  • [1910.241–1910.244] Hand and portable powered tools definitions, general, guarding of portable tools. (Index)
  • ANSI B11 series, Machine tool safety and guarding
  • B11.0, Risk assessment
  • B11.19, Performance of safeguarding measures
  • B11.1, Mechanical power presses
  • B11.3, Press brakes
  • B11.9, Grinding machines
  • ISO 12100, Safety of machinery, Risk assessment
  • ISO 13849-1, Safety-related parts of control systems
  • IEC 60204-1, Electrical equipment of machines
  • RIA/ANSI R15.06, Industrial robots and robot systems

Energy Isolation and Electrical

Lockout and tagout rules require a written program, machine-specific procedures, training, and periodic audits. Before servicing, you must shut off and isolate energy, apply locks, verify zero energy, and control stored energy. Electrical rules require approved equipment, correct wiring methods, and protection from damage and moisture.

Be on the lookout for employees “just reaching in” to clear jams, shared keys, or missing lockout points. Standardize procedures for your lasers, press brakes, saws, and compressors. For electrical, avoid extension cords as permanent wiring, protect cords from pinch points, and keep panels accessible with labeled circuits.

  • [1910.147] Control of hazardous energy, lockout tagout written program, procedures, training, periodic inspection.
  • Subpart S Electrical, including [1910.303] General equipment approval and safe installation, and [1910.305] Wiring methods cable trays, flexible cords, protection from damage.
  • ANSI/ASSP Z244.1, Control of Hazardous Energy
  • ISO 14118, Prevention of unexpected startup
  • NFPA 70, National Electrical Code
  • NFPA 70E, Electrical Safety in the Workplace
  • UL 508A, Industrial Control Panels
  • IEC 60529, Ingress protection ratings

Material Handling, Cranes, and Forklifts

These rules require operator training and inspections for forklifts, safe rigging practices, and documented inspections for cranes and slings. Rated capacities must be visible, loads must be stable, and travel paths must be clear.

Be on the lookout for overloaded forks, damaged fork tips, missing daily checks, and homemade slings. Tag out damaged slings, store rigging off the floor, and keep clear communication between operators and spotters. Mark travel lanes and pedestrian areas.

  • [[1910.178] Powered industrial trucks operator training, rated capacities, fueling or charging, maintenance.
  • [1910.179] Overhead and gantry cranes clearances, inspections, load rating, maintenance records.
  • [1910.184] Slings selection, inspection, use of alloy steel chain, wire rope, synthetic web slings. (Standards page)
  • ANSI/ITSDF B56.1, Powered Industrial Trucks
  • ASME B30 series, Cranes, Hoists, Slings and Rigging Hardware
    • B30.2, Overhead and Gantry Cranes
    • B30.9, Slings
    • B30.10, Hooks
    • B30.26, Rigging Hardware
  • ASME BTH-1, Design of Below-the-Hook Lifting Devices
  • CMAA 70, Top Running Bridge and Gantry Cranes

Walking Surfaces, Exits, and Emergencies

These rules require clean, dry, and unobstructed floors, safe stairs and platforms, and clear exit routes. You must maintain emergency action and fire prevention plans, train employees, and keep extinguishers accessible and inspected.

Be on the lookout for cords across aisles, slippery floors, blocked exits, and missing guardrails on platforms. Post exit signs, light the routes, keep doors unlocked during business hours, and run periodic drills so everyone knows where to go and who to check in with.

Medical and First Aid

These rules require prompt access to first aid, trained personnel, and suitable supplies. If you have corrosives, you need an eyewash within quick reach. The goal is to stabilize injuries until professional care.

Be on the lookout for empty first aid kits, expired supplies, and eyewash units blocked by boxes. Assign and train first aid responders, restock kits on a schedule, and make sure everyone knows where to find help and how to report incidents.

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John P.
John P.
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