Helmets, gloves, and leathers are the last line of defense. The best welding in the world does not matter if you cannot see or your hands are fried.
The arc emits intense UV that burns eyes and skin in seconds. The lens shade does the filtering; the helmet does the covering.
| Task | Minimum Shade | Typical Comfort |
|---|---|---|
| TIG / GTAW (under 50 A) | 8 | 9–10 |
| MIG / FCAW light | 10 | 10–11 |
| MIG / FCAW heavy | 11 | 11–12 |
| Stick / SMAW | 10 | 11–13 |
| Plasma cutting | 8 | 9–11 |
| Grinding / chipping | 2–4 | Clear impact lens |
Darkens in a fraction of a millisecond when the arc strikes. Choose switching speed fast enough for your process — TIG needs the fastest.
Glass plate, no batteries, no sensors, never fails at the wrong moment. Still the standard in production stick and heavy MIG.
The helmet comes off, the glasses stay. Impact-rated lenses under the hood protect from spatter when you flip up.
Neck flap, side windows, and throat protection matter — UV bounces off the work and finds every gap.
Gloves are a trade-off between heat protection and dexterity. Match the glove to the process — the wrong glove causes just as many bad welds as a burned hand.
| Glove | Process | Trade-Off |
|---|---|---|
| Thin kidskin / goat TIG | TIG | Maximum feel for the filler rod; low heat rating |
| MIG / FCAW gauntlet | MIG, FCAW | Insulated backs and cuffs; thicker — less feel, more protection |
| Stick welding | SMAW | Heavy leather, cuff support; heat and impact protection |
| TIG/MIG stick gloves (Tillman 24L / 1418) | Shop all-round | The shop standard — MIG and stick workhorse |
Sweat or water on leather conducts electricity and steam-burns. Swap gloves when wet, and keep spares on the bench.
A hole in the palm is a burn waiting. Patch leather gloves or retire them — a $15 glove is cheaper than a burned hand.
Preheating and heavy plate radiate heat into the gloves. Use insulated TIG gloves and thick sidewall protection for hot work.
Spatter sticks, UV burns, and synthetics melt into skin. The rules are simple: natural fiber, covered skin, and nothing that traps a spark.
Cotton or flame-resistant layers over the base shirt. Long sleeves, closed collar, and a fit that does not gap when you reach.
Full leather jackets or bibs for heavy MIG, FCAW, and overhead work. Nothing beats leather where spatter rains down.
A welding cap catches sparks off the head and scalp — and a balaclava covers the neck UV misses when you look down.
Polyester and nylon melt and bond to skin. Everything next to the arc must be cotton, wool, or rated FR fabric.
Leather sleeves cover the forearms for bench work where a jacket is too much. Keep the fabric out of the joint area.
No cuffs that catch spatter, no open pockets facing up, and rolled sleeves are burns waiting to happen.
Welding fume is a known hazard, and ventilation comes first. When ventilation cannot keep up — galvanized steel, stainless, confined spaces — the respirator becomes the control.
Filters coarse fume and dust. Not for heavy fume, galvanized, or prolonged exposure — the first rung, not the answer.
Replaceable P100 cartridges filter the respirable fume fraction. Needs a fit test and clean shave at the seal.
Powered air-purifying respirator blows filtered air under the hood — the professional standard for production and coated metals.
Breathing air from a source — mandatory in confined spaces and where oxygen levels are a concern. Never shop air.
Respirators are regulated: selection, fit testing, and training follow your local authority (OSHA in the US). The filter class matters — P100/N100 for welding fume, not dust masks.
Hot spatter lands on the floor, and heavy plate finds toes. The welding boot is the most under-rated PPE in the shop.
Leather, above-ankle height, and a non-slip sole. All-leather construction so spatter does not melt through to the foot.
Rated impact and compression protection for the inevitable dropped plate. Composite toes stay warm in winter.
Built-in or add-on guards protect the top of the foot — the area spatter and falling parts hit first when bending over the work.
Trousers go OVER the boot shaft, never tucked in. Tucked cuffs funnel sparks and spatter into the boot — one of the oldest burns in the trade.
Grinding, plasma cutting, and heavy fab regularly exceed safe noise levels. Hearing damage is permanent — and entirely preventable.
Cheap, disposable, and effective when rolled and inserted correctly. The default for mixed tasks across the day.
Quick to put on and off between tasks, and bands mount directly to hard hats. Check the NRR rating against your noise levels.
Amplifies voices and blocks harmful noise — lets you hear the crew and the machine while protecting your ears.
A grinding disc sits around 100 dB — safe exposure is minutes, not hours. If you must shout to talk, hearing protection is due.
Auto-darkening helmet with side coverage, plus impact-rated safety glasses underneath.
Process-matched gloves, with spares — TIG gloves for feel, gauntlets for MIG and stick.
100% cotton or FR shirt, leather sleeves or jacket for heavy work, welding cap, boots over the pant leg.
Ventilation first, then P100 or PAPR for fume; plugs or muffs for grinding and plasma noise.
PPE is only PPE when it is rated. These are the marks that prove the gear does what the label claims.
| Standard | Covers | Look For |
|---|---|---|
| ANSI Z87.1 | Eye and face protection | Impact rating on safety glasses and welding lenses |
| ANSI Z49.1 | Welding safety overall | Eye protection, ventilation, and PPE requirements for welding |
| ANSI Z89.1 | Head protection | Hard hat rating when the job calls for head protection |
| ASTM F2413 | Footwear | Impact and compression rating on welding boots |
| ASTM F1891 / NFPA 70E | FR clothing / arc flash | Arc-rated jackets and clothing labels with a rating |
| NIOSH 42 CFR 84 | Respirators | NIOSH approval (e.g. P100) on every respirator cartridge |
| OSHA 29 CFR 1910 | General PPE & welding | Employer obligations — PPE selection, training, and enforcement |
If the gear has no rating mark, it is not PPE — it is a costume. Buy rated, keep the labels, and replace anything that has taken real abuse.
The PPE decision starts with the process and its hazards — arc, heat, sparks, and fume — then builds the kit from the skin out.
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