Collision Repair Welding Safety and Shop Practices
Hazard control before the arc starts
The SWQT exam tests whether you can set up a safe collision-repair welding zone, not just strike an arc. Collision welding combines electrical, fume, fire, and vehicle-system hazards.
Core rules
- Wear a welding helmet with the correct shade, safety glasses underneath, flame-resistant clothing, leather gloves, and hearing protection. Add a respirator and fume extraction when welding galvanized, painted, or adhesive-contaminated steel.
- Keep combustibles at least 35 ft away or protect them with guards; assign a fire watch and maintain it for at least 30 min after hot work ends. Keep a fire extinguisher at the station.
- Store cylinders upright and secured; separate oxygen and fuel gas by 20 ft or a barrier; keep caps on and keep oil and grease away from oxygen.
- Disable the vehicle: disconnect the battery per OEM, wait for SRS discharge, isolate high-voltage systems, and do not weld a vehicle with a damaged high-voltage battery.
- Inspect cables, grounds, and gun insulation; use GFCI protection and a clean, dry work area.
Worked example
A technician must plug-weld a rocker flange near a fuel line. The correct reasoning is: move or shield the line if the OEM allows, drain or remove the tank if the procedure says so, wet down adjacent trim, use a heat shield, assign a fire watch, and keep the extinguisher within reach. Welding first and watching for smoke is the wrong order.
Traps
Assuming MIG gloves are enough for STRSW; ignoring fume extraction on galvanized steel; leaving the battery connected; missing combustible carpet padding under the weld zone.