Welding — Jaybee Supplies

PPE Knowledge Centre — Welding PPE

PPE Knowledge Centre

Welding PPE

A complete welding PPE ensemble guide — covering welding helmets, shade numbers, EN ISO 11611 clothing, gloves, boots, RPE for welding fume (Group 1 carcinogen), and hearing protection.

CategoryWelding PPE

Version1.0

DateMay 2026

AudienceWorkers · Safety Managers · Procurement

⚠ This document is a knowledge guide only. Always check HSE.gov.uk directly for current requirements. The reader is responsible for compliance.

Contents

Overview & Hazards
Legal & Regulatory Requirements
Types & Classifications
Industry Applications
Selection Guide
Fit, Use & Maintenance
Inspection & Replacement
Common Mistakes & Misuse
Training & Resources
Document Review Log

1Welding PPE — Overview

Welding and allied processes generate a unique combination of simultaneous hazards: arc flash, UV/IR radiation, welding fume (a Group 1 carcinogen), heat, molten metal spatter, and noise. No single item addresses all — a complete ensemble must be assembled and worn correctly for every welding task.

Hazard	Source	PPE Required
Arc flash / UV / IR radiation	The welding arc — all processes	Welding helmet with correct shade filter
Welding fume (carcinogen)	All arc processes — especially MMA, MIG	RPE — FFP3 minimum; TH3 PAPR for regular work
Molten metal spatter	MMA, MIG/MAG, gouging	FR/welding jacket, gloves, face shield
Contact heat and hot metal	Workpiece, spatter, equipment	Welding gloves, FR clothing, safety boots
UV skin exposure (arc burn)	Arc radiation — all processes	FR clothing covering all skin; neck protection
Noise	Grinding, chipping, plasma cutting	Ear defenders where noise assessment requires
Foot injury	Spatter, falling materials	Safety boots with HRO heat-resistant outsole

2Legal & Regulatory Requirements

🔗

HSE: Welding — health and safety overview (includes 2019 WEL revision)Check HSE directly for the latest version.

🔗

HSE: Welding fume — carcinogen reclassification and RPE requirementsCheck HSE directly for the latest version.

🔗

Personal Protective Equipment at Work Regulations 1992 (as amended 2022)Check HSE directly for the latest version.

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COSHH Regulations 2002 — welding fume assessmentCheck HSE directly for the latest version.

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Control of Artificial Optical Radiation at Work Regulations 2010Check HSE directly for the latest version.

3Welding Helmet & Eye Protection

Welding Helmet Standards

EN 175 — welding helmets and hand shields for arc welding
EN 169 — passive welding filter shade numbers
EN 379 — auto-darkening welding filters — electronically darkens on arc strike

Always inspect the filter before use. A cracked or damaged filter provides NO arc protection. Auto-darkening helmets must be tested before every welding session — a failing cartridge provides no protection.

Welding Shade Number Guide

Process	Current / Tip Size	Shade
MMA (stick)	Up to 100A	Shade 10
MMA (stick)	100–200A	Shade 11
MMA (stick)	200–300A	Shade 12
MMA (stick)	300A+	Shade 13–14
MIG / MAG	Up to 250A	Shade 11
MIG / MAG	250A+	Shade 12–13
TIG	Up to 100A	Shade 9–10
TIG	100–200A	Shade 10–11
Plasma cutting	Up to 80A	Shade 9
Gas welding	Light tip	Shade 4–5
Gas welding	Heavy tip	Shade 6–7

4Complete Welding PPE Ensemble

Body Area	PPE Item	Standard
Head & face	Welding helmet — passive or auto-darkening	EN 175 + EN 169 / EN 379
Eyes (grinding)	Safety goggles + face shield (when helmet raised)	EN 166
Body / torso	FR welding jacket or coverall	EN ISO 11611 Class 2 (MMA/MIG); Class 1 (TIG/brazing)
Under-layers	FR base layers if worn	All underlayers must be FR — no polyester or nylon
Hands	Welding gauntlets	EN ISO 12477 — heavy (MMA/MIG); thin (TIG)
Feet	Safety boots with HRO sole	EN ISO 20345 S3 HRO — boot tops covered by welding trousers
Respiratory	RPE — FFP3 min; PAPR TH3 for regular welding	EN 149 FFP3 (short duration) or EN 12941 TH3 PAPR
Hearing	Ear defenders — during grinding/chipping/plasma	EN 352-1 or EN 352-2 — based on noise assessment
Neck	Neck flap on helmet or FR balaclava	Prevents UV arc burn to neck — critical for overhead welding

Since 2019, HSE has confirmed all welding fume — including mild steel — is a Group 1 carcinogen. A disposable dust mask does NOT provide adequate protection. FFP3 is the absolute minimum for any welding activity. PAPR TH3 is required for stainless steel, galvanised, or coated metals.

5RPE for Welding Fume

🔗

HSE: Welding fume — RPE and LEV requirementsCheck HSE directly for the latest version.

Short-duration mild steel welding (with LEV) — FFP3 disposable minimum
Regular welding or insufficient LEV — PAPR TH3 class (EN 12941)
Stainless, galvanised, or coated metals — PAPR TH3 mandatory (hexavalent chromium, nickel compounds, zinc oxide)
Confined space welding — airline respirator or SCBA

6Fit, Use & Maintenance

Clothing and Fit

All FR fastenings must be closed before striking the arc
Do not roll up sleeves — eliminates arm protection
Welding trousers must cover boot tops — spatter falling inside a boot causes severe burns
All clothing worn under welding jacket must be FR — no polyester or nylon

Helmet Use

Inspect filter before every use — cracked filter = no arc protection
Lower helmet before striking the arc — never strike with helmet raised
Auto-darkening: test darkening function and check sensor cleanliness and battery every session

7Inspection & Replacement

✓	Inspection Point
□	Welding helmet filter: inspect for cracks or arc damage before every use
□	Auto-darkening helmet: test darkening function, sensor cleanliness, battery level
□	Welding jacket: inspect for burn-through, thinning, missing seam stitching
□	Welding gloves: check for burns, holes, or thinning at fingertips and palm
□	Safety boots: check HRO sole, toe cap, and boot tops for spatter damage
□	RPE: facepiece, valves, filter replacement schedule
□	FR clothing: confirm all garments are FR — no non-FR base layers

Condition	Action Required
Welding filter cracked or arc damaged	Replace immediately — no arc protection
Auto-darkening not working	Replace before welding — arc eye risk is immediate
Welding jacket burn-through	Replace — thermal protection at damaged area is lost
Welding gloves with burn holes	Replace — spatter will reach skin
Non-FR base layer under welding jacket	Replace with FR layer before work continues

8Common Mistakes & Misuse

Common Mistake	Why It Matters / Correct Practice
Not testing auto-darkening helmet before welding	A failed cartridge provides no arc protection. Test before every session without exception.
Non-FR clothing under welding jacket	Synthetic base layers melt in arc flash or heat — severe burns even when the outer jacket survives.
Using FFP2 or a dust mask for welding fume	Welding fume is a Group 1 carcinogen. FFP3 is the minimum — lesser masks do not provide adequate protection.
Raising helmet without switching to goggles + face shield for grinding	Grinding after welding with no eye protection change is a common cause of serious eye injuries.
Using MMA/MIG gauntlets for TIG welding	Thick gauntlets severely reduce dexterity — leading to imprecise work and the temptation to remove gloves. Use TIG-specific thin gloves.
Not using RPE because 'the workshop is ventilated'	General ventilation does not adequately dilute welding fume at the breathing zone. LEV is required at source plus RPE.
Boot tops uncovered by welding trousers	Spatter falling inside a boot causes serious burns. Welding trousers must cover boot tops at all times.