The Welder’s Vision: A Guide to Welding Eye Protection

Whether you’re a professional welder or simply need to take care of some DIY repairs, eye protection is crucial. Even the relatively safer fabrication methods require you to wear at least a pair of goggles so that you don’t end up with an arc burn.

With advancing technology, personal protective equipment (PPE) has evolved significantly. Today, you’re presented with a plethora of choices, including welding helmets, hoods, shields, goggles, and more. But what makes these gears indispensable? Let’s find out!

What Happens If You Weld Without Any Eye Protection?

Welding without adequate eye safety for even a short time can leave you with watery, sensitive eyes and blurry vision, a condition known as Photokeratitis or more commonly, flash burn or arc burn. This condition is a severe inflammation of the cornea, similar to the kind of damage caused by staring directly at the sun, a halogen lamp, or a photographer’s floodlight for too long.

I vividly recall the day my father allowed me to try stick welding under his supervision. This was back in 1989 when I was just 9 years old, and at that time, auto-darkening helmets were not yet available widely.

So, guess what? I used a shield equipped with a fixed shade lens. The view through the lens was too dark, and I repeatedly glanced at the workpiece while welding, despite my father’s warning. Little did I realize what was about to happen!

As you might imagine, I ended up with ARC EYES! This experience taught me a valuable lesson, and since that day, I have never compromised on eye protection during welding. Individuals with arc eyes experience a range of symptoms, including:

Pain in the eyes

High sensitivity to light 

Bloodshot eyes

Blurred vision

Watery eyes 

While flash burn or arc burn is common among beginners, PROLONGED EXPOSURE to welding without proper protection can lead to more serious conditions such as keratoconjunctivitis, cataracts, and occasional retinal injuries.

It’s important to note that these symptoms may not appear immediately and could take a few hours to manifest. This means you might not even be aware that you’ve sustained a flash burn until some time after the exposure.

While arc eyes are a compelling reason to use a welding helmet, they are not the only reason. Flying debris and hot metal slags can also pose a significant threat to your eyes.

Here is Dr. Emily Birkholz, MD, Ophthalmology Associates Mankato, explaining welding flash burn and arc eyes in detail:

Are Welding Goggles Safe Enough?

So a pair of welding goggles should be good enough to weld safely, right? Unfortunately, the answer is NO – especially if we are talking about arc welding. It’s true – those goggles do offer some degree of protection against heat and light for cutting jobs. However, that’s only because the exposure wouldn’t be too high. 

But when it comes to heavier projects like the fabrication of heavy machinery, pipes, and vessels, you’re definitely going to need more than a pair of goggles. This is because of three reasons:

FIRSTLY, some of these projects typically call for specialized arc welding processes like Gas Tungsten Arc Welding Gas (GTAW), Gas Metal Arc Welding (GMAW), and shielded metal arc welding (SMAW). These techniques have some of the brightest flashes, which means the UV radiation is significantly more than that from gas welding. 

SECONDLY, such tasks typically take a while to complete, which means you’re exposed to ultraviolet rays for a PROLONGED TIME. This can cause a number of issues if you aren’t wearing adequate protection, and not just for your eyes. 

THIRDLY, welding goggles cannot protect the entire face, leaving the uncovered areas vulnerable to flying debris. Additionally, they offer no protection from gases and fumes, which can still pose a risk to your health.

So, How To PROTECT Your Eyes From Welding Flash?

If you were ever to visit my welding workshop in Utah, you’d find every engineer and technician wearing FULL-FACE HELMETS while working. That’s exactly what you need to protect your face and eyes from prolonged exposure to UV and IR rays. Hoods, especially the auto-darkening ones, offer much better protection. 

In this regard, I’d like to mention that while a pair of goggles only protects your eyes, a helmet also offers coverage for your face and neck. “But why is that relevant?” you might wonder. As you probably know, UV radiation is one of the biggest causes of skin cancer. Considering that arc welding produces the full spectrum of ultraviolet rays, I’m sure you can put two and two together.

This is precisely why you’d often find professionals wearing full-body PPE while welding. Let me guide you through the different types of PPEs you can use to protect your eyes. 

A. Welding Goggles

While welding goggles are easier to use and more portable, they can only protect your eyes, leaving the rest of your face vulnerable. 

B. Hand Shields

You won’t have a hand free to support or hold together the parts being fabricated, either. This makes hand shields best suited for learners rather than professionals like us.

C. Welding Helmets

Here are the two most common welding helmets among different types, based on lens shades:

1. Passive Helmets: Those are the basic welding masks, featuring a dark-tinted lens, typically shade #10. When you lower the hood over your eyes, you can see through the darkened lens, protecting your vision. The issue, however, is that once you stop welding, it becomes too dark to see properly. You would need to remove the hood in order to inspect the weld and then put it back on before restarting.
2. Auto-darkening Helmets: These advanced hoods are as futuristic as they sound. When you start welding, it automatically switches to a pre-selected shade, darkening the lens. The glass returns to a lighter shade as soon as you stop welding, allowing you to inspect the workpiece without removing the helmet.

Shields are now considered almost obsolete, and goggles may not provide sufficient protection for certain fabrication processes. A welding mask, helmet, or hood not only protects your face and eyes from intense ultraviolet (UV) rays, infrared (IR) rays, and other harmful radiation but also from flying debris, gases, and fumes.

Using any of the above PPEs? Cast your VOTE to see if your choice is also preferred by others!

Related: Welding Helmet Evolution Over The Years

What Do Colored Lenses In Welding Helmets Protect Against?

If you’ve been researching welding eye protection, you might have noticed that some goggles and helmets come with colored lenses, often GREEN. These lenses are specially designed to reduce scattered light and dim bright flares, which can help reduce eye fatigue.

There are also more advanced options, like gold-plated athermal lenses. One of these goggles was once brought to my workshop by our welder, Liam, and it was quite glamorous. This type of lens is a decent upgrade over the green lenses, as the gold plating reflects 90% of the infrared light.

On the other hand, the lenses of auto-darkening helmets have a PURPLE, metallic look. Ever wondered why? Well, as I eventually discovered, these lenses consist of several metallic layers. The UV/IR filter is made of 5 layers of silver oxide and 6 layers of aluminum oxide, in addition to a thin glass substrate and polarizing filters.

So, that explains the metallic look, but what about the COLOR? These welding lenses are designed to reflect and absorb the two ends of the color spectrum—red (infrared) and blue (ultraviolet). Together, these reflections and absorptions make the lens appear purple from the outside.

Here’s the fun part—when you look through these lenses, the world around you appears green. “Wait… why would everything look green if the lens is purple? That doesn’t sound right!”—you’re probably wondering. Or at least, that’s what I thought when I put on one of these helmets for the first time.

Once again, the answer lies in how the auto-darkening lenses work. As you probably know, the three main colors of light are red, blue, and green. With the red and blue components either reflected or absorbed by the filter, what remains is green! Most of the light making it through the lens is green light, which is why you perceive the world around you that way.

What’s more? There are even modern TRUE-COLOR LENSES, which can show the real color of the workpiece. This makes them an excellent option for professional who spends hours in quality welding.

Purpose of Filter Lenses

The metallic layers I mentioned earlier aren’t the only component of a welding helmet lens that protects your vision. The lenses are made of multiple filters, and metallic layers form only one of them. The filters also help reduce the INTENSITY of the light and are rated by SHADE NUMBERS that indicate the level of protection they offer.

Passive welding hoods come with passive lenses, whereas variable and auto-dimming helmets are designed to switch to a pre-selected shade once activated. 

Are Safety Glasses Required Under A Welding Helmet?

While clear safety glasses keep out sparks and flying debris, they won’t be enough to protect you from flash, fumes, and gases alone- you need a helmet. While this is a matter of debate, with many welders deeming it unnecessary to wear safety glasses under the hood, I would strongly disagree.

In fact, OSHA mandates welders to wear glasses under the helmet for jobs where there are hazards like slag chips, grinding fragments, and bristles. I am quoting:

“Where such hazards exist, workers using a welding helmet with filter lenses would also need to wear glasses with side shields or goggles.”

Occupational Safety and Health Administration (OSHA)

For this reason, I have enforced a STRICT RULE requiring everyone at my workshop to wear safety glasses under their hoods and helmets. Some of my engineers and technicians initially disagreed, but both Liam and Oliver were smart enough to understand my point, and we were able to explain to the rest why it was important.

While a good welding helmet surely offers good protection, there’s no such thing as “too much safety” when it comes to protecting something as vital as your eyes. A pair of clear safety glasses would prevent any flying debris if you had taken your hood off for a moment to inspect the job.

In this case, a pair of clear goggles would certainly offer an additional layer of protection, saving your vision in the event of such mistakes. 

Safety Standards For Welding Headgear

When it comes to welding, nothing surpasses safety as the top priority. After all, the whole purpose of the hood is to protect the welder, isn’t it? Thankfully, this shouldn’t be too hard, as there are legally enforced safety standards.

ANSI Z87.1, CSA Z94.3, and CEN 1/1/1/1 are the most widely accepted safety certifications for welding headgear, used in the US, Canada, and the UK respectively. You can also find other international standards, such as ISO 4007, EN 379, and EN 175, but some of them are now withdrawn. For this reason, we follow mostly CEN and ANSI standards.

Between the two, ANSI Z87.1 is more focused on ensuring that a welder’s face and eyes remain protected even in the event of a lens malfunction. Additionally, ANSI Z87.1-rated welding helmets are also light transmittance-tested at different shade settings to regulate visibility.

CEN 1/1/1/1, on the other hand, is more focused on optical clarity and rates headgear across different classes – uniformity, lens distortion, clarity at sharp angles, and darkness consistency. 

Point of Difference	ANSI Z87.1	CEN 1/1/1/1
Standard Organization	American National Standards Institute	European Committee for Standardization
Scope	Covers eye and face protection	Specifically for welding filters
Requirements	Impact resistance, optical clarity, etc.	Optical class, diffusion of light, homogeneity, angle dependence (1 = best)
Visibility, Clarity, Uniformity, and Consistency	Visibility is regulated, ensuring the darkening effect remains consistent while welding.	The uniformity of the lens and the presence of impurities are evaluated at varying angles.

Apart from these standards, the shade level of auto-darkening welding helmets is often characterized by DIN numbers. DIN stands for “Deutsches Institut für Normung,” which translates to the “German Institute for Standardization.”

The DIN number is used to indicate the level of protection provided by the auto-darkening filter (ADF) in the helmet, typically ranging from 9 to 13. The higher the number, the darker the lens can become, offering greater protection against intense welding arcs.

If you’re from the US, all welding helmets are legally required to be ANSI Z87.1-certified, otherwise, opt for a CEN 1/1/1/1 certified product. Even in case there are no legally enforced safety standards where you live, I’d highly recommend a hood that has one of the two above certifications at the very least.

Welding Helmet Safety Tips

Having a welding helmet that meets safety standards is just the beginning. With my extensive experience in various factories and workshops, including running my own, I’ve learned key strategies for effectively safeguarding your face and eyes.

1. Choose The Right Kind Of Welding Helmet

Besides ensuring your hood is safety-certified, it’s essential to choose one that matches your fabrication requirements. The necessary shade number varies based on the intensity of the arc current. According to OSHA guidelines, the minimum shade number can range from 7 to 11, which is a crucial factor in choosing the best welding helmet for your requirements.

However, ANSI and AWS suggest a slightly higher range, from 10 to 14. It’s important to note that a lens that isn’t dark enough won’t provide adequate protection, while a shade number that’s too high can hinder visibility during welding.

2. Make Sure Your Helmet Fits Perfectly

Proper fit is crucial when choosing your welding mask. It should fit snugly, staying securely against your head at all times and moving only when your head does. Any rattling indicates a LOOSE FIT. When trying on a helmet, be sure to wear a cap or bandanna you’d use while working.

3. Replace Old Lenses Periodically

I’ve frequently observed welders continuing to use helmets with cracked and damaged lenses because they believe, ‘What harm can a small crack do? Replacing the lens for such a minor issue seems like a waste of money.’

However, that is a big misconception. A ‘small crack’ can cause significant harm if the lens shatters or breaks, potentially sending glass shards into your eyes. It’s crucial to replace any damaged lenses promptly.

4. Check For Damage Before Use

It’s worth taking a minute to inspect your helmet for damage or defects before you begin welding. As mentioned earlier, even a thin crack in the lens can be a significant hazard. Vigilance is key to ensuring that your hood is always safe to use.

Watch this video to learn about overall welding safety before you start welding:

Emerging Technologies

As anyone who knows me well enough would tell you, welding protection technologies are absolutely fascinating. Call me a geek if you would, but I’m always rushing to test out newly acquired helmets, glasses, and hoods. I’m sharing my entire resource here. Among the several emerging techs, here are the ones that particularly grabbed my attention. 

Auto-darkening Helmets

The auto-darkening helmets offer unparalleled convenience, significantly reducing time and effort, while increasing safety. This technology has gained immense popularity, evident from the wide array of such hoods available in the market, even under $40.

Extended use of passive masks can lead to neck pain, as welders often have to repeatedly nod their heads to bring them down over their faces. Auto-dimming hoods are a perfect solution to this issue. Moreover, you can configure them for various tasks beyond welding, such as plasma cutting and grinding.

Electromagnetic Arc Sensor

Auto-darkening helmets are highly safe and effective, EXCEPT in very bright environments. For instance, when working under direct sunlight, the sensor may mistake the natural light for the welding arc’s flash, automatically darkening the lens prematurely. This challenge spurred the development of welding hoods with innovative electromagnetic arc sensors.

Unlike optical sensors that rely on detecting bright light, these new helmets use electromagnetic sensors to detect the magnetic frequency generated by the arc.

Arc Tracking 

When exploring welding helmet sensors, it’s crucial to highlight their arc-tracking capabilities. Certain modern hoods can track arc-on time, essentially the duration a welder actively working. This functionality empowers business owners and managers to evaluate worker PRODUCTIVITY and pinpoint opportunities for ENHANCEMENT.

Respiratory Welding Helmets

Welders face multiple hazards beyond bright light, UV radiation, and debris. FUMES, for example, are not only toxic but also classified as a possible carcinogen by IARC since 2017. So, what could be the solution to improve safety?

Respiratory welding helmets address this issue by integrating respirators. They filter out harmful gases and fumes generated during fabrication, providing a convenient, all-in-one solution. This is especially beneficial for individuals with beards, as wearing a separate respirator can be cumbersome.

Underwater Welding Helmets

Underwater helmets are exactly what they sound like – special protective gear designed to help you safely perform hyperbaric welding. They are indispensable in the offshore oil and gas industries, shipyards, dams, and other submerged structures.

Similar in design to helmets used by scuba divers, they are equipped with an air supply system, which can be sourced from either oxygen cylinders or through an umbilical. The filter can be flipped up and down, allowing you to switch between protected and regular vision with ease.