Plasma Cutting Safety Tips and Checklist

Plasma cutting is becoming increasingly popular within many industries, thanks to the ease and precision of the cut offered by plasma cutting machines. There are many different materials which can be cut through without a fuss thanks to a plasma cutter, but they must be conductive. For example, metals like aluminium, mild steel and stainless steel are often cut by a plasma cutter. But while there are huge benefits to plasma cutting, they can be potentially dangerous if certain safety measures are not followed. Plasma cutters create a huge amount of heat, creating potential hazards. That said, if you follow our plasma cutting safety tips, you should be safe and sound while using your plasma cutter.

Plasma Cutting Safety Checklist

A simple way to ensure safety everytime you perform a plasma cutting task is to follow a plasma cutting checklist, ticking off each point before you engage in your project. Doing this each time will safeguard against missing any key safety point and putting yourself at risk. We have put together a plasma cutter safety checklist which you can follow below:

Pre-Plasma Cutting Safety Measures

Work Area:

• Ensure the workspace is free of flammable materials, oil, grease and debris.
• Clear any potential trip and fall hazards.

Equipment:

• Inspect electrical connections for tightness and damage.
• Verify the plasma cutter, power source and work leads are in good working order.
• Check the condition of the plasma torch and nozzles.

Personal Protective Equipment (PPE):

• Confirm proper flame-resistant clothing, gloves and footwear are available and to be worn.
• Choose an appropriate welding helmet with a shade #11 filter for UV/infrared protection. Standard safety glasses are not appropriate as plasma cutting safety glasses.
• Assess the need for respiratory protection based on the material being cut.
• Consider hearing protection like earplugs or ear defenders for extended cutting or thick materials.

Safety Measures During Plasma Cutting

Electrical Safety:

• Only operate the plasma cutter in dry environments.
• Avoid electrical contact with wet gloves or clothing.
• Report any faulty equipment and cease using it until it is fixed.
• Never modify or bypass safety features within the plasma cutter itself.

Fire Safety:

• Always have the appropriate fire extinguisher readily available and ensure all plasma cutter operators know how to use it.
• Maintain a safe distance from flammable materials during cutting.
• Be aware of sparks and molten metal splatter that can ignite fires.
• Use fire curtains or welding blankets to further isolate the work area where possible.

Fume Extraction:

• Use a fume extraction system or exhaust hood when cutting coated or galvanised steel.
• Alternatively, wear an air-supplied respirator or air fed welding helmet for ultimate protection.

General Practices For Plasma Cutting Safely

Important Operating Practices:

• Never operate a plasma cutter without proper training and experience.
• Secure the workpiece firmly in a stable position.
• Maintain a safe distance from the cutting arc and fumes.
• Never lean over or touch the hot metal after cutting.
• Allow the cut metal to cool completely before handling.
• Always turn off the plasma cutting machine when not in use.
• Research the specific safety precautions required for cutting the material in question. Metals like galvanised steel require extra safety measures.
• Dispose of used consumables and waste materials properly.

In Summary

Hopefully by following all of the plasma cutting safety procedures above you will never encounter any issues within your workshop. We have outlined everything you should do before, during and after the plasma cutting process to minimise injury risk and danger to your environment. That said, we would always encourage operators to fully read and digest the manual of their plasma cutter to ensure we have not missed any important details which are unique to that machine. Never take a chance with health and safety when plasma cutting.