Instituting workplace plasma cutting safety measures is critical. Few tools and equipment generate the levels of heat, bright light, and risk of burns or fire as plasma cutting operations. Although the personal protective equipment (PPE) and clothing are similar to those worn by welders, plasma cutting presents a greater danger to workers who do not quite comprehend the risks.

By fully understanding how the process works, workplace dangers, and ways to minimize injuries and ailments, organizations will be in a better position to implement safety policies and provide the best PPE for plasma cutting.

What is Plasma Cutting?

Plasma cutting is an innovative method of cutting through electrically conductive metals using a high-speed and targeted stream of plasma. The plasma reaches temperatures around 28,000 degrees Celsius or 50,400° Fahrenheit. Even the surface of the sun (the photosphere) has "just" around 5,500 °C or 9,930° Fahrenheit.

This method ranks among the most cost-effective ways of cutting through hard metals. It has been likened to water jet and laser cutting applications, although considered less expensive for a variety of tasks.

There’s a misconception that it was created to offset laser cutting. It was initially designed to provide companies with an alternative to oxy-fuel cutting methods. Oxy-fuel uses diesel and petrol to generate the heat needed to pierce metals, but plasma far exceeds its capacity. That’s largely why it stands as a more productive way for manufacturers to complete projects and boost productivity.

How Plasma Cutting Works

Plasma cutting creates what industry insiders sometimes refer to as a hot “cone” that slices through metal efficiently, even allowing users to make curved and angled cuts. This technology has been integrated into a variety of applications, including fixed machines, torches, plasma, and handheld guns.

Its flexible uses make this technique a preference in wide-reaching industries. However, it presents a significant workplace danger due to molten metal and voltages that typically exceed the average welding machine by 5x.

Which Industries Commonly Use Plasma Cutting?

One of the main reasons plasma cutting has been adopted by numerous industries can be attributed to its versatility. Large manufacturing plants can invest tens of thousands of dollars to onboard large capacity cutting equipment. By that same token, a small organization can take advantage of handheld plasma tools for a modest sum. These are industries that routinely use plasma cutting.

  • Aerospace: Many of the unique alloys used in the aerospace niche are best served by using plasma cutting assets.
  • Art:Metal artists have taken advantage of the ability of plasma tools to craft intricate designs and artwork.
  • Automotive: The automotive industry employs fixed and handheld plasma equipment for fabrication, customization, and rebuilding, among others.
  • Construction: Used in construction projects that use steel beams and infrastructure. Plasma tools far exceed other construction sector applications.
  • Farming: Agricultural equipment such as tractors sometimes require spot metal cuts and retooling. Plasma has been a budget-friendly process that has reduced overhead.
  • Military Defense: Many of the military vehicles, aircraft, and ships are constructed with the use of plasma technology.
  • Shipbuilding:The method has been widely adopted to build metal-based hulls and bulkheads, among other ship facets.

This short-list of industries that rely on plasma-cutting equipment could be greatly expanded. If there’s a concern regarding its prevalence, it’s the plasma cutting safety measures that sometimes go unheeded and result in workplace injuries.

What are the Health and Safety Hazards Associated with Plasma Cutting?

This commercial and industrial equipment used to slice through steel and metals generally presents a level of danger that calls for advanced plasma cutting safety measures. It’s necessary that employees know the risks involved and safety supervisors address the hazards while providing as-needed protective clothing for plasma cutting.

These rank among the common health and safety hazards associated with plasma cutting.

  • Fumes and Gases: The process typically releases an abundance of harmful gases and fumes that can be inhaled by plasma cutting tool users, as well as those in the general proximity.
  • Infrared and Ultraviolet Light: Plasma cutting tools emit intense infrared and ultraviolet rays that can harm the eyes.
  • Burns: The extreme heat produced during the cutting process leaves no room for error. Burns and even arc flash are common injuries.
  • Electrocution:Plasma equipment can leverage volts that range from 110 to 240. The presence of electricity can cause electrocution, arc flashes, or fires.
  • Fire Hazard: The molten cone and sparks emitted from the plasma cutting process have been known to start fires when flammable materials are in the area.
  • Pacemakers: It may come as something of a surprise, but the magnetic field created by plasma cutting can interfere with heart-regulating and other medical devices.
  • Hearing Hazard:Plasma cutting equipment typically generates between 90 and 120 decibels. The National Institute for Occupational Safety and Health (NIOSH) advises that workers should not be exposed to more than 85 decibels during an 8-hour shift. Given the higher noise levels created by plasma cutting, it’s essential to provide PPE for plasma cutting that includes ear protection.

Recommended Personal Protective Clothing and Equipment for Plasma Cutting

Because plasma cutting involves intense light, heat, electricity, and handheld devices, it checks just about all of the workplace safety boxes. For those tasked with operating equipment, manipulating sheets of metal, or simply passing by, the use of PPE for workers and those in the immediate area is an absolute must.

These are types of equipment and protective clothing for plasma cutting employers would be well-served to stockpile.

Face Shield and Safety Glasses

Like welding processes, plasma cutting poses a dual threat to the facial area. The intense light generated by the molten cone and sparks can cause damage to the inner eyes. Typically, a welding helmet with an appropriate filter lens is recommended. This protects the eyes, face, and head from sparks, retina burns, and UV rays.

UV and IR glasses are also commonly used PPE for plasma cutting in terms of vision protection. The brightness can also lead to sunburn on the cheeks, lips, forehead, and neck. That’s largely why shields with UV protection are worn. The facial PPE for plasma cutting must also be durable enough to withstand hot splatters and high temperatures.

Respiratory Protection

A respirator provides clean, safe air for workers by filtering out toxic fumes, noxious gases, and metallic dust particles (metallurgic dust) that are generated during the cutting process.  

Hand Protection

Specialized welding gloves must be worn at all times. The heat and electricity used to power the equipment can negatively impact the hands. Once operating a plasma tool, users can anticipate molten splatter raining down on their hands. Without heat and fire-retardant welding gloves, workplace injuries are a near certainty.

Protective Clothing for Sparks and Flames

Technicians who operate these hazardous devices are tasked with wearing protective clothing for plasma cutting at all times. Secondary flame-retardant coveralls with hoods are considered standard PPE. It’s also important to keep in mind that flame- and spark-resistant coveralls should meet or exceed industry standards.

Other Safety/Mitigation Measures

Organizations can create a safer work environment by taking proactive measures. Installing proper ventilation to remove smoke and fumes and replenish fresh air helps reduce the risk of lung-related ailments.

Grounding electrical equipment and keeping the workspace free of flammable debris minimizes the risk of flying sparks setting off a blaze. Flammable materials, pressurized gas, vapors, dust, and liquids need to be placed a minimum of 35 feet away from the plasma cutting equipment.

Stockpile PPE for Plasma Cutting Operations

Maintaining an inventory of certified personal protective disposable clothing is crucial if employers are to minimize potential injuries from plasma cutting. Protective clothing and accessories must resist heat, sparks, and flames while providing breathable comfort for users.