HSE INDG297 – Safety in Gas Welding, Cutting and Similar Processes

Essential Safety Guidance for Oxy-Fuel Gas Welding and Cutting Operations

HSE INDG297 provides practical guidance for anyone using compressed gases for welding, flame cutting, heating, brazing, soldering and similar hot-work activities.

The leaflet focuses on the safe use of portable oxy-fuel gas equipment and explains the precautions required to prevent fire, explosion, burns and other serious incidents associated with gas welding and cutting operations.

Although often viewed primarily as a safety document, INDG297 also contains important considerations for occupational hygiene and LEV professionals because many gas welding and cutting processes generate airborne contaminants that require effective exposure control.

The guidance covers:

Oxy-acetylene equipment
Oxy-propane equipment
Gas cylinders
Pressure regulators
Flashback arrestors
Hoses and connections
Fire prevention
Explosion prevention
Hot-work safety
Equipment inspection and maintenance

This resource is relevant to:

Welders/Fabricators
LEV Designers/P601 TExT Engineers
Occupational Hygienists
Maintenance Engineers
Construction Contractors
Health & Safety Professionals
Duty Holders

Source Document

View the HSE guidance here:

View Original HSE Guidance

Source: Health and Safety Executive (HSE)
Document Type: HSE Guidance Leaflet
Status: Current
Last reviewed by LEVCentral: June 2026

LEVCentral Expert Commentary

Gas welding and cutting remain widely used throughout industry despite the growth of alternative technologies such as plasma cutting, laser cutting and mechanised welding systems.

Portable oxy-fuel equipment continues to be used extensively because it is versatile, relatively inexpensive and capable of operating in locations where electrical equipment may be impractical.

However, the hazards associated with gas welding equipment should never be underestimated.

The combination of:

Flammable gases
Oxidising gases
High temperatures
Ignition sources
Pressurised cylinders

creates the potential for serious incidents if equipment is poorly maintained or used incorrectly.

One of the most significant risks addressed by the guidance is flashback.

Flashback occurs when a flame travels back through the welding torch and potentially into the hose assembly or gas cylinder system. Without suitable protection, this can result in catastrophic equipment failure and potentially fatal consequences.

The guidance therefore places significant emphasis on:

Flashback arrestors
Non-return valves
Equipment maintenance
Correct operating procedures
Operator training

From a LEVCentral perspective, the document also provides an important reminder that process safety and occupational hygiene are often closely linked.

Whilst INDG297 focuses primarily on fire and explosion hazards, gas welding and thermal cutting operations frequently generate:

Welding fume
Metal oxides
Nitrogen oxides
Carbon monoxide
Ozone
Combustion products

These contaminants may require effective Local Exhaust Ventilation (LEV) and exposure-control measures in addition to the safety precautions described within the guidance.

Key Learning Points

Oxy-Fuel Equipment Requires Careful Management

Compressed gases and ignition sources create a combination of hazards that must be carefully controlled.

Flashback Protection Is Essential

Flashback arrestors and non-return valves are critical safety devices that help prevent flames travelling back into hoses and gas systems.

Equipment Inspection Prevents Incidents

Regular inspection and maintenance of hoses, regulators, torches and safety devices can significantly reduce the likelihood of accidents.

Hot Work Creates Multiple Hazards

Gas welding and cutting activities can generate fire, explosion and occupational health risks simultaneously.

Exposure Control Should Not Be Forgotten

Many thermal processes generate hazardous airborne contaminants that may require LEV systems or other exposure-control measures.

Topics Covered by the Guidance

Gas Cylinders

Safe storage, handling and transportation of compressed gas cylinders.

Regulators and Pressure Control

Guidance on selecting, fitting and maintaining regulators used with oxygen and fuel gas systems.

Hoses and Connections

Inspection and maintenance requirements designed to prevent gas leaks and equipment failures.

Flashback Arrestors

Use of flashback arrestors and non-return valves to prevent reverse gas flow and flame propagation.

Safe Lighting and Shutdown Procedures

Practical advice on correct operating procedures for welding and cutting equipment.

Fire Prevention

Control measures designed to reduce the risk of fires associated with hot-work activities.

Occupational Hygiene Considerations

Welding Fume Generation

Gas welding and cutting processes can generate airborne contaminants requiring suitable exposure controls.

Local Exhaust Ventilation

LEV systems may be required where welding fume or combustion products are generated.

Confined Space Working

Additional precautions may be required where gas welding or cutting is undertaken within confined or poorly ventilated environments.

Exposure Monitoring

Occupational hygiene assessments may be necessary to evaluate worker exposure to welding fume and combustion products.

Further Resources

Recommended Learning

Thought Leadership

Welding Fume Control Beyond Compliance
Defensible Exposure Control Strategy
Defensible LEV Commissioning
Integrating Process Safety and Occupational Hygiene

LEVCentral Observation

INDG297 serves as an important reminder that welding and cutting operations involve more than exposure to airborne contaminants.

Effective risk management requires consideration of fire, explosion, pressure systems, hot work and occupational health hazards simultaneously.

Whilst modern attention often focuses on welding fume exposure, many of the most serious incidents continue to arise from failures in basic gas safety management.

Organisations that successfully integrate process safety and exposure control are typically best positioned to protect both workers and property.