27.19. Welding, Cutting and Brazing Checklist

Are only approved apparatuses purchased for use? AFI 91-203 para. 27.2.1

Do personal protective clothing and equipment meet or exceed the requirements of Chapter 14, Personal Protective Equipment (PPE)? AFI 91-203 para. 27.2.3

Are contractors advised that they must comply with appropriate fire, safety and health requirements when welding, cutting or brazing on Air Force facilities? AFI 91-203 para. 27.2.4

Are acetylene cylinders used and stored in an upright position? AFI 91-203 para. 27.3.1

Is the fuel gas and oxygen supply to the torch shut off when left unattended or not used for extended periods of time, i.e., when left unattended for 30 minutes or more? AFI 91-203 para. 27.3.3

Are welders aware that welding on concrete floors may cause the concrete to spall and produce projectiles? AFI 91-203 para. 27.3.9

Are welders provided appropriate fall protection when working on elevated surfaces? AFI 91-203 para. 27.3.10

Does the welding operation supervisor ensure installed fire protection sprinkler systems are operational before the welding operation begins, or, if not, ensure other means of fire detection, reporting and extinguishing have been approved by the installation FES Flight? AFI 91-203 para.

Are welding hoses visually checked for damage once a shift, before each use? AFI 91-203 para. 27.4.1

Are warning signs posted to prevent personnel from inadvertently touching hot items when left unattended? AFI 91-203 27.4.4

Have workers and other personnel adjacent to the welding areas been protected from radiant energy or spatter by use of noncombustible and/or flameproof screens? AFI 91-203 para.

Are walls, screens, and non-rigid heat and spark barriers finished to limit reflective? AFI 91-203 para.

Have procedures been established to prevent personnel from entering an inside welding area and inadvertently being exposed to welding hazards? AFI 91-203 para.

Where floors have been wet down or damp sand applied, have rigid controls been established to ensure proper grounding of equipment, and are personnel protected from possible electrical shock? AFI 91-203 para.

Is a fully charged and operational fire extinguisher, appropriate for the task, kept in the work area at all times? AFI 91-203 para.

Are welding operations roped off or segregated by physical barriers to prevent unauthorized entry into the area? AFI 91-203 para.

Are outside welding operations placarded to warn bystanders that welding operations are in progress? AFI 91-203 para.

Has a written permit been obtained from the installation FES Flight prior to the start of welding operations? AFI 91-203 para.

Whenever welding activities are within 35 feet of combustible materials, are firewatcher procedures implemented? AFI 91-203 para. and

Has a fire watch been assigned to monitor the operation for 30 minutes after completion of cutting or welding operations, to detect and extinguish possible smoldering fires? AFI 91-203 para. and

Is the welding operation environment free of flammable liquids and vapors? AFI 91-203 para.

While welding and cutting operations are being performed, is fire extinguishing equipment available and ready for use? AFI 91-203 para.

Are approved flash arresters installed between each cylinder and the coupler block when acetylene cylinders are coupled? AFI 91-203 para. 27.6.2

Has back-flow protection been provided that shall prevent oxygen from flowing into the fuel-gas system or fuel from flowing into the oxygen system? AFI 91-203 para. 27.6.3

Has flashback protection been provided by an approved device? AFI 91-203 para. 27.6.4

Has back-pressure protection been provided by an approved relief device, set at a pressure not greater than the pressure rating of the back-flow or flashback device, whichever is lower? AFI 91-203 para. 27.6.5

Are clearly marked master shutoff valves provided for installed systems at points which are readily accessible? AFI 91-203 para. 27.6.7

Does clothing provide sufficient coverage to prevent skin burns? AFI 91-203 para. 27.7.1

Are front pockets and upturned sleeves or cuffs prohibited? AFI 91-203 para. 27.7.1

Are flame resistant gloves, in good condition, used to protect welder‘s hands? AFI 91-203 para. 27.7.2

When additional protection is needed, are durable flame-resistant aprons made of leather or suitable materials provided to protect the front of the body? AFI 91-203 para. 27.7.3

For heavy work, are flame-resistant leggings or other equivalent means used to give added protection to the legs? AFI 91-203 para. 27.7.4

When necessary, are cape sleeves or shoulder covers used during overhead welding, cutting or other operations? AFI 91-203 para. 27.7.5

When necessary, are flame-resistant caps worn under helmets to prevent head burns? AFI 91-203 para. 27.7.6

Is only approved respirator equipment used when working in atmospheres of hazardous concentrations of airborne contaminants? AFI 91-203 para. 27.7.7

Do all welding helmets meet 29 CFR 1910.252, Welding, Cutting, and Brazing - General Requirements, requirements? AFI 91-203 para.

When two or more welders are exposed to each other's arc, are filter lens goggles worn under the welders‘ helmets to protect them from the harmful rays? AFI 91-203 para.

Are goggles or other suitable eye protection used during all gas welding or oxygen cutting operations? AFI 91-203 para.

Is eye protection in the form of suitable tinted goggles or spectacles provided for brazing operations? AFI 91-203 para.

Are workers trained to arrange helmets to protect the face, neck and ears from the arc's radiant energy? AFI 91-203 para.

Are ventilated goggles used to prevent fogging of the lenses? AFI 91-203 para.

Are hand-held shields, designed to shield the face and eyes, prohibited from use? AFI 91-203 para.

Does the commander ensure workers who handle, use or are potentially exposed to hazardous materials provided training IAW the Air Force Hazardous Communication Program(AFHCP)? AFI 91-203 para. 27.8.2

Do welders check gas line connections after assembly and before lighting the torch? AFI 91-203 para. 27.9.1

Is the tungsten-arc welding machine's power supply always disconnected before changing electrodes? AFI 91-203 para. 27.10.5

Are welders trained to never change tungsten-arc electrodes with bare hands or wet gloves? AFI 91-203 para.

Is welding on aircraft accomplished outside of hangars whenever possible? AFI 91-203 para.

Does the welding supervisor ensure the senior flight line supervisor is thoroughly briefed on the planned welding operation? AFI 91-203 para.

Prior to the start of welding operations, are fuel tank and engine fuel vents closed/plugged on any aircraft within 50 feet of the welding operation? AFI 91-203 para.

Does the welder rope off or segregate the welding operation by a physical barrier prior to starting the welding operation? AFI 91-203 para.

Is the fireguard informed to stop the welding operation if a hazardous condition develops? AFI 91-203 para.

Do aircraft welding operations performed in hangars conform to the requirements of Chapter 6 of this standard and NFPA 410, Standard on Aircraft Maintenance? AFI 91-203 para.

Has the tank, cylinder, or other container which is to be cut, welded or have other hot work performed on it been purged or inert? AFI 91-203 para.

Are new containers inert or purged prior to cutting, welding or other hot processes being applied to it? AFI 91-203 para.

Are welding or cutting operations only conducted in vehicle maintenance approved by the installation FES Flight? AFI 91-203 para. 27.12

Does maintenance shop supervision evaluate each welding or cutting task to determine if batteries need to be removed or fuel tanks require removal and/or need to be made inert? AFI 91-203 para. 27.12

Do cylinders of compressed gas have pressure-reducing regulators installed? AFI 91-203 para. 27.13.1

Are oxygen cylinders and fittings kept free of grease and oil at all times? AFI 91-203 para. 27.13.4

Have circuits been de-energized before testing? AFI 91-203 para. 27.14.1

Are power cables and electrode holders inspected prior to every use? AFI 91-203 para. 27.14.4

Before starting operations, has the work lead been firmly attached to the work? AFI 91-203 para.

Have cables with damaged insulation or exposed conductors been repaired or replaced? AFI 91-203 para.

Are electrode holders, when not in use, placed where they cannot make electrical contact with personnel, conducting objects, fuel or compressed gas cylinders? AFI 91-203 para. 27.15.4

Does the welding supervisor ensure all welders meet the requirements of Chapter 23, Confined Spaces, prior to entry into confined spaces? AFI 91-203 para. 27.17.1

Has a written permit (AF Form 592) been obtained from the FES Flight, with coordination by the installation Ground Safety office and BE, prior to starting welding operations in a confined space? AFI 91-203 para. 27.17.1

When welding or cutting operations are conducted in confined spaces, is there adequate ventilation to prevent the accumulation of toxic materials or possible oxygen deficiency? AFI 91-203 para. 27.17.3

Before operations are started, is heavy portable equipment mounted on wheels securely blocked? AFI 91-203 para. 27.17.2


Report Routing

Supervisor Signature:


Superintendent Signature:


Commander Signature:


Safety Office Signature:


Wing Commander Signature:


Please note that this checklist is a hypothetical example and provides basic information only. It is not intended to take the place of, among other things, workplace, health and safety advice; medical advice, diagnosis, or treatment; or other applicable laws. You should also seek your own professional advice to determine if the use of such checklist is permissible in your workplace or jurisdiction.