Arc welding and cutting processes, as well as other forms of welding, produce radiation. The quantity of radiation could be small, but in some cases ultraviolet or infrared radiation can go undetected. Such radiation can cause eye damage or skin burns. It is therefore necessary to use a welding helmet with the correct shade of filter plate, gloves and the correct clothing. Screen curtains can be used to protect other people in the vicinity. Safety glasses should have UV protective side shields. In addition, noise caused by welding can be hazardous, with temporary or permanent loss of hearing occurring. Ear muffs or ear plugs can be used as protection.

Electric shock from welding and cutting equipment is another danger that can result in injury or even death. When welding there are various components that are electrically energised, such as the welding circuit, the internal circuits, the reel of wire or the drive rolls. Incorrectly installed equipment or equipment which has not been properly grounded is normally the cause of electrical shocks during welding. To avoid electrical shock it is important to follow the instructions of the equipment in use. Employees should be trained on how to avoid electrical injuries. Principles such as not touching live electrical parts, having installations and maintenance done by qualified people, having the equipment grounded at all times and frequently inspecting power cords for open wires should be adhered to. When conditions are less than perfect it is important not to work alone, wear insulating gloves and rubber soled boots, while making use of mats and insulated electrode holders. Of course, water should be avoided under all circumstances.

Further possible hazards of welding include fire and explosions. The main danger comes from flying sparks. According to the American Welding Society, sparks can travel up to 10.7meters from the work area and can pass through or become lodged in cracks, clothing, pipe holes and other small openings in floors, walls or partitions. There are many combustible materials in and around a building which can catch alight from just one spark. Where flammable gases or liquids are present, such sparks can cause an explosion or even multiple explosions. In order to avoid fires and explosions it is necessary to follow the correct processes and procedures, use the correct equipment and remove as many combustible materials as possible – or at least cover such combustible material with fire resistant material. Fire resistant screens and blocking any openings can further protect the welder and the environment. It is important to ensure that the welding object has no combustible coating and no combustible internal structure.