1910.254(d): Arc Welding Operation and Maintenance
Employers must make sure arc welding operators know this section and 1910.252(a), (b) and (c), check machine connections and grounding before starting, and fix leaks of cooling water, shielding gas or fuel. Welders must follow manufacturer instructions, place electrode holders so they cannot contact people or tanks, not use cables with splices within 10 feet of the holder, report defects and dry and test wet machines before use.
Key takeaways
- 1910.254(d) is part of OSHA's general industry standards (29 CFR Part 1910, Subpart Q).
- OSHA cited it 95 times in the last 3 years, in 91 inspections, with $285,586 in current penalties.
- Most citations: NY (12), VA (7), TN (7).
- Related part: 1910.254(d)(9) Maintenance (83 citations).
- Free 5-minute toolbox talk for your crew below.
In this article
What this rule covers
29 CFR 1910.254(d) ("Operation and maintenance") is one requirement inside 1910.254 Arc welding and cutting, an OSHA general industry standard (Part 1910, Subpart Q). It includes 12 sub-paragraphs. The official text below is copied word for word from the Electronic Code of Federal Regulations (eCFR). The numbers, injury cases and training on this page show how OSHA enforces it on real job sites.
Official text
(d) Operation and maintenance — 95 citations
(1) General. Workers assigned to operate or maintain arc welding equipment shall be acquainted with the requirements of this section and with 1910.252 (a), (b), and (c) of this part. 1 citations
(2) Machine hook up. Before starting operations all connections to the machine shall be checked to make certain they are properly made. The work lead shall be firmly attached to the work; magnetic work clamps shall be freed from adherent metal particles of spatter on contact surfaces. Coiled welding cable shall be spread out before use to avoid serious overheating and damage to insulation.
(3) Grounding. Grounding of the welding machine frame shall be checked. Special attention shall be given to safety ground connections of portable machines.
(4) Leaks. There shall be no leaks of cooling water, shielding gas or engine fuel. 1 citations
(5) Switches. It shall be determined that proper switching equipment for shutting down the machine is provided.
(6) Manufacturers' instructions. Printed rules and instructions covering operation of equipment supplied by the manufacturers shall be strictly followed. 1 citations
(7) Electrode holders. Electrode holders when not in use shall be so placed that they cannot make electrical contact with persons, conducting objects, fuel or compressed gas tanks. 4 citations
(8) Electric shock. Cables with splices within 10 feet (3 m) of the holder shall not be used. The welder should not coil or loop welding electrode cable around parts of his body. 5 citations
(9) Maintenance. Open (d)(9) 83 citations
(i) The operator should report any equipment defect or safety hazard to his supervisor and the use of the equipment shall be discontinued until its safety has been assured. Repairs shall be made only by qualified personnel. 3 citations
(ii) Machines which have become wet shall be thoroughly dried and tested before being used. 1 citations
(iii) Cables with damaged insulation or exposed bare conductors shall be replaced. Joining lengths of work and electrode cables shall be done by the use of connecting means specifically intended for the purpose. The connecting means shall have insulation adequate for the service conditions. Open (d)(9)(iii) 79 citations
[55 FR 13696, Apr. 11, 1990, as amended at 61 FR 9241, Mar. 7, 1996; 70 FR 53929, Sept. 13, 2005]
Source: eCFR, text current as of 2026-10-15. Read all of 1910.254.
Where and how often it was cited
| Year | Citations |
|---|---|
| 2023 | 5 |
| 2024 | 43 |
| 2025 | 33 |
| 2026 | 14 |
Top states: NY (12), VA (7), TN (7), TX (7), MD (7)
Largest penalties
| Employer | Location | Penalty for this rule |
|---|---|---|
| VTCU, CORP. | POCATELLO, ID | $70,938 |
| ZACHRY MAINTENANCE SERVICES, LLC | MANSFIELD, LA | $16,131 |
| HEIDELBERG MATERIALS NORTHEAST LLC | NAZARETH, PA | $14,187 |
| LIEBHERR AMERICA | NEWPORT NEWS, VA | $13,840 |
| POLARIS, INC. | MADISON, AL | $12,905 |
Free toolbox talk
A 5-minute crew talk on 1910.254(d), plus alerts when this rule changes. Free.
OSHA interpretation letters
- OSHA's General Industry standard requires damaged welding leads to be replaced and not to be repaired. (2005-04-05)
Related parts of this rule
- 1910.254(d)(9) Maintenance 83 citations
- 1910.254(d)(9)(iii) 79 citations
Get your crew competent
Trainers on Black Belt Safety: Marc Harvey, Dana Reyes
Trainers and suppliers: feature your business on this rule for $25/month.
Frequently asked questions
What must be checked before starting welding?
All machine connections, the work lead attachment, and grounding of the machine frame.
Can a cable with a splice near the holder be used?
No. Cables with splices within 10 feet (3 m) of the holder shall not be used.
Where should an electrode holder go when not in use?
Where it cannot make electrical contact with persons, conducting objects, fuel or compressed gas tanks.
About this page
Sources
- 29 CFR 1910.254 (eCFR), text current as of 2026-10-15
- U.S. Department of Labor enforcement data: OSHA inspections, citations and accident records, copied nightly; data as of 2026-10-22
3-year window. Federal OSHA only; state-plan rules are not counted. Plain-language text is a summary, not legal advice; the official text controls. Black Belt Safety is not part of OSHA or the Department of Labor.