Welding Leads & Cable Care
Welding leads carry hundreds of amps. A cracked cable, a loose connector or a bad ground clamp can overheat, burn through insulation, start a fire or deliver a shock. Many welding fires and "mystery" shocks start with a lead that was ignored. Good cable care is quick and cheap compared with the damage it prevents.
- Welders
- Fabricators
- Pipefitters
- Maintenance Techs
What the leads do
- The electrode lead (stinger or torch cable) carries current from the welder to the electrode holder or gun.
- The work lead (ground lead) with its clamp carries current back from the workpiece to the welder, completing the circuit. The "ground" is really a return path.
- Cables are rated by gauge and length for the amperage and duty cycle. Long runs and undersized cables overheat and drop voltage.
- Welding machines and cable are covered by OSHA 1910.254 (arc welding) and 1926 Subpart J. See Welding & Cutting and Stick, MIG & TIG Welding.
Main hazards
- Electric shock from damaged insulation, bare conductors and wet conditions. See Wet Locations.
- Fire: overheated or arcing cable and connectors, and cable lying on combustibles. See Fire Prevention.
- Stray current: if the work lead is attached poorly, current can take unintended paths through chains, cranes, bearings, pipes or electrical systems, burning or damaging them.
- Burns from hot cables and connectors.
- Trips and falls over cables, and cables dragged through hazards.
- Cuts and crush damage from sharp edges, vehicles, falling steel and pinch points.
- Back strain from hauling long heavy leads.
Inspecting and caring for leads
- Inspect leads before each use: look for cuts, cracks, burns, worn spots, exposed copper, kinks, loose or hot connectors, and damaged lugs. Feel for hot spots after use.
- Repair or replace damaged cable. Don't tape over exposed conductors on welding leads. Use proper splices and insulated connectors approved for welding cable, and have qualified people do repairs. Remove bad leads from service.
- Use the right size and length. Choose cable for the amperage and duty cycle and keep runs as short as practical. Coil excess cable loosely and fully unroll long leads to avoid heat buildup in coils.
- Tighten connections at the machine, the stinger, the work clamp and any cable joints. Loose connections overheat.
- Attach the work clamp directly to the workpiece or table, on clean bare metal, as close to the weld as practical. Don't route current through chains, hoist hooks, bearings, crane wire rope or structural members you didn't mean to energize. Do not use pipes carrying flammables or electrical conduit as a return path.
- Protect cables: keep them out of water, oil and hot work, away from sharp edges and vehicle paths, and off wet ground. Use cable covers or hang cables overhead where possible.
- Never wrap leads around your body, or hold them in a way that places the lead near your shoulders and neck. Keep both leads from touching while the machine is on.
- Turn off the machine before connecting or disconnecting leads, and before leaving the area.
- Store cables dry, coiled and hung off the floor, away from heat and chemicals.
Welding lead checklist
- Leads are sized for the amperage and free of cuts, burns and exposed copper
- All connections are tight and not hot after use
- The work clamp is on clean metal near the weld, not on chains, bearings or crane gear
- Cables are kept out of water and traffic and are not coiled while welding
- The machine is off when connecting leads, and damaged leads are removed from service
Standards & references
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