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OSHA Welding Lead Requirements

Welding often requires leads, or cables, to connect machinery or equipment to power sources. OSHA Standards of the CFR 29, 1910.254, regarding cable leads set forth specific regulations to prevent injury or death to workers. Companies that sell welding cables follow OSHA's standards in providing flame-retardant, oil-resistant and durable leads that withstand hot work exposure.

  1. Types of Cables for Leads

    • Cables used for welding and cutting equipment must be insulated with a flexible coating. These leads should be able to resist damage from the current flowing through them, while grounding the worker from shock. Any cable leads must also be durable enough to not melt or catch fire if exposed to arc welding sparks.

    Damaged Leads Not Allowed

    • Cable leads must be free from repair at least 10 feet from the cable end. When the cable becomes worn to the extent of exposing bare conductors, it must be covered with rubber and friction tape.

    Splicing Rules

    • When connecting (splicing) cables together, only insulated connectors should be used. The capacity of the connector must be at least equivalent to that of the cable. Connected cables must main the capacity to give good electrical contact. Any metal lugs or parts shall be completely covered and insulated.

    Ground Return Leads

    • Ground return cable leads must have a safe current-carrying capacity. The capacity must match or exceed the output capacity of the welding equipment for which it is used. If a single ground return cable is connected to more than one piece of equipment, the capacity to carry current shall exceed the total output capacity maximum of all equipment connected to the leads. Workers must inspect ground connections for adequate strength and the capacity for withstanding the electric current.

    Safe Placement of Leads

    • Cable leads should be kept in a way that complies with the OSHA regulations for safe passages. All passageways must be free of cables and other objects that could cause slips, falls or tripping. Workers should remain free of cable leads at all times, as not to become tangled or trapped in case of the need to escape from the area quickly.

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