A Comprehensive Guide to Welding Masks, Helmets, and PPE for New Zealand

Welding masks and helmets come in a variety of types and styles, each with its own unique features and benefits. Below, we'll explore some of the most common types of welding masks and helmets used by welders in New Zealand.

Auto-Darkening Welding Helmets

Auto-darkening welding helmets are a popular choice among welders in New Zealand and around the world. These helmets feature advanced technology that allows the lens to automatically darken in response to the intense light produced during welding. This provides a high level of protection for the eyes, as the lens will only darken when needed, ensuring clear visibility when not actively welding.

Auto-darkening welding helmets typically include adjustable settings for light sensitivity and darkness, allowing welders to customise the helmet to their specific needs and preferences. Some models also include additional features such as grind mode, which allows the helmet to be used for tasks other than welding, and delay settings to control how quickly the lens darkens and lightens.

While auto-darkening welding helmets may be more expensive than other types of welding masks, their advanced features and the level of protection they provide make them a worthwhile investment for both professional and hobbyist welders.

Fixed Shade Welding Helmets

Fixed shade welding helmets are a more traditional style of welding helmet that are still commonly used by welders in New Zealand. Unlike auto-darkening helmets, the lenses in fixed shade helmets do not automatically adjust to the brightness of the welding arc. Instead, they have a fixed level of darkness that provides protection against the intense light produced during welding.

Fixed shade welding helmets are typically more affordable than auto-darkening helmets, making them a popular choice for welders who are just starting out or who do not weld frequently. However, the fixed shade lens can make it more difficult to see clearly when not actively welding, as the lens will remain darkened at all times. This can make it more challenging to position the electrode and prepare the weld joint before beginning to weld.

Welding Helmets

Welding helmets are a broad category of protective headgear that includes both fixed shade and auto-darkening helmets. Welding helmets provide full coverage of the face and neck, and typically include a window or visor through which the welder can see while working. Welding helmets are typically more durable and reliable than other types of welding masks, making them well suited for extensive or heavy duty welding work.

Welding helmets often include additional features such as adjustable headgear for a more comfortable fit, as well as the ability to attach a respirator or other additional protective equipment. Some welding helmets also include a movable visor that can be flipped up when not in use, allowing the welder to easily switch between welding and inspecting their work without having to remove the helmet.

Air Fed Welding Masks

Air fed welding masks and helmets are a type of welding mask that provide the highest level of respiratory protection for welders. These helmets are closed at the head and are designed to extract fumes via an intake manifold that is connected to an external extraction. Automatic welding helmets with ventilation are among the most advanced technologies currently available. They are connected to a separate fresh air unit, which filters the air before it enters the helmet. This eliminates the risk of inhaling hazardous gases and is ideal for prolonged, professional use.

Air fed welding masks typically include a powered air purifying respirator (PAPR) that supplies the welder with a stream of clean, filtered air to breathe. This provides protection not only against fumes and gases produced during welding, but also against other airborne contaminants in the work environment. The PAPR is typically worn on a belt or backpack, and the air is delivered to the welder through a hose connected to the helmet.

In addition to the respiratory protection they provide, air fed welding masks also include the same features found in other types of welding helmets, such as a window or visor for the welder to see through, and a shield to protect the face and eyes from intense light and flying sparks. While air fed welding masks are typically more expensive and require more maintenance than other types of welding helmets, they are the best choice for welders who need the highest level of protection against both respiratory and other welding hazards.

Welding Glasses and Goggles

In addition to welding masks and helmets, there are also welding glasses and goggles available for welders in New Zealand. Welding glasses and goggles are typically used for more lightweight or low intensity welding tasks, as they provide less coverage and protection compared to full welding masks or helmets.

Welding goggles typically consist of a flexible frame that fits tightly against the face, with one or two lenses that are specially designed to protect against the intense light produced during welding. Some welding goggles also include additional features such as side shields to provide further protection against flying sparks and debris.

Welding glasses are similar to welding goggles, but are typically lighter and more comfortable to wear for extended periods of time. They are often used for tasks that require more precision, as they typically have a smaller and more lightweight design compared to welding goggles. However, welding glasses provide less protection compared to welding goggles, as they typically do not include side shields or other additional protective features.

It's important to note that welding glasses and goggles are only suitable for low intensity or low light welding tasks, as they do not provide the same level of protection as full welding masks or helmets. Welders should always use the appropriate type of eye and face protection based on the specific requirements of the welding task they are performing.

Auto-Darkening Technology

One of the most important features to consider when choosing a welding mask or helmet is auto-darkening technology. Auto-darkening welding masks and helmets are equipped with special sensors that can detect the intense light produced during welding, and automatically adjust the darkness of the lens to provide the right level of protection for the eyes.

Auto-darkening technology ensures that the lens will only darken when needed, allowing for clear visibility before and after the welding process. This can improve safety and productivity by allowing welders to more easily position the electrode and prepare the weld joint before beginning to weld, and to inspect their work without having to remove the helmet.

Welders can typically adjust the sensitivity and darkness settings of the auto-darkening lens to customise the helmet to their specific needs and preferences. Some auto-darkening welding helmets also include additional features such as grind mode, which allows the helmet to be used for tasks other than welding, and delay settings to control how quickly the lens darkens and lightens.

While auto-darkening welding masks and helmets may be more expensive than other types of welding masks, their advanced features and the level of protection they provide make them a worthwhile investment for both professional and hobbyist welders.

Level of Shading

The level of shading on a welding mask or helmet is an important consideration, as it determines the strength of the protection against the intense light produced during welding. The level of shading needed will depend on the specific welding process being used, as well as the intensity of the light.

Welding masks and helmets typically include a shading number that indicates the level of protection provided. Lower shading numbers correspond to lighter shades, while higher shading numbers correspond to darker shades. Welders should choose a shading level based on the specific requirements of the welding process they are performing, as well as their own comfort and visibility preferences.

Welding masks and helmets with auto-darkening technology typically allow for adjustable shading settings, allowing welders to customise the helmet to their specific needs and preferences. This can be a more flexible option compared to fixed shade welding helmets, which have a single, non-adjustable shading level.

Viewing Area

The viewing area of a welding mask or helmet is the size of the window or visor through which the welder can see while working. A larger viewing area provides better visibility and can make it easier for welders to see their work and their surroundings.

The viewing area is typically measured in square inches or square centimetres, and can vary widely between different types and models of welding masks and helmets. Welders should consider the size of the viewing area when choosing a welding mask or helmet, and select a size that provides a comfortable and clear view of their work.

It's important to note that the size of the viewing area is typically larger in traditional welding helmets and larger in fixed shade welding helmets compared to auto-darkening welding helmets. However, the size of the viewing area can vary widely between different models and manufacturers, so it's possible to find auto-darkening welding helmets with larger viewing areas if that is a priority for you.

Weight and Comfort

Welding masks and helmets can be heavy and are worn for extended periods of time, so weight and comfort are important factors to consider when choosing a welding mask or helmet. A good welding mask or helmet should be lightweight and well-padded for comfort, to reduce strain on the neck and ensure that it can be worn for extended periods of time without discomfort.

In addition to the weight of the helmet itself, the headgear and suspension system can also impact the overall comfort of the welding mask or helmet. Look for helmets with adjustable headgear and padding to ensure a secure and comfortable fit. Some helmets also include features such as multiple adjustment points and ergonomic designs to provide a more customised and comfortable fit for the welder.

Respiratory Protection

For welders working with materials that produce fumes or gases, respiratory protection is a critical consideration. While not all welding masks and helmets provide respiratory protection, some types, such as air fed welding masks, can be equipped with additional respiratory protection features.

Air fed welding masks typically include a powered air purifying respirator (PAPR) that supplies the welder with a stream of clean, filtered air to breathe. This provides protection not only against fumes and gases produced during welding, but also against other airborne contaminants in the work environment. The PAPR is typically worn on a belt or backpack, and the air is delivered to the welder through a hose connected to the helmet.

Welders should carefully consider the respiratory protection requirements of their specific welding tasks, and choose a welding mask or helmet with the appropriate features to ensure their safety and well-being.

Durability and Reliability

As with any piece of safety equipment, durability and reliability are key considerations when choosing a welding mask or helmet. Look for masks and helmets made from high-quality materials that can withstand the demands of the welding environment.

Helmets with a strong, impact-resistant shell and a durable lens are more likely to provide long-lasting protection. Additionally, consider the quality of the headgear and suspension system, as well as the construction of any additional features, such as respiratory protection components.

It's also important to choose welding masks and helmets from trusted manufacturers with a reputation for producing high-quality safety equipment. Investing in a durable and reliable helmet can provide peace of mind and long-term protection for welders in New Zealand.

Auto-darkening welding masks and helmets feature advanced technology that provides welders with a clear view of their work while protecting their eyes from the intense light produced during welding. The key to this technology lies in the auto-darkening filter, which is typically made of a combination of liquid crystal, polarising filters, and sensors.

When the sensors in the welding mask detect the bright light produced by the welding arc, they send a signal to the auto-darkening filter. In response, the filter darkens within milliseconds, shielding the welder's eyes from the intense light. This rapid darkening and light control provide a high level of eye protection, reducing the risk of eye strain, fatigue, and long-term damage.

The sensors in the welding mask continuously monitor the light levels, ensuring that the filter adjusts in real time to provide the optimal amount of protection. When the welding process stops, the filter quickly returns to a lighter shade, allowing the welder to see their work clearly without having to lift the helmet.

Auto-darkening welding masks typically include adjustable settings for light sensitivity and darkness, allowing welders to customise the helmet to their specific needs and preferences. Some models also include additional features such as grind mode, which allows the helmet to be used for tasks other than welding, and delay settings to control how quickly the lens darkens and lightens.

The combination of advanced optics, sensors, and electronics in auto-darkening welding masks provides welders with a safer and more efficient welding experience, improving both productivity and overall safety on the job.

Flying Sparks and Molten Metal

During the welding process, molten metal droplets and hot particles, known as welding spatter, can be ejected with force. These flying sparks and molten metal fragments pose a significant risk of causing burns and skin injuries to welders. In addition to skin protection, the risk of these particles entering the eyes is also a concern.

Welding masks, with their durable and heat-resistant materials, act as a shield against flying sparks and molten metal. The protective visor or lens in the mask provides a clear viewing area for the welder's work while effectively preventing these hazardous materials from reaching the face, eyes, and skin. This protection ensures that welders can carry out their work safely without the risk of burns or injuries from welding spatter.

Fumes, Gases, and Airborne Particles

Welding can produce a variety of airborne contaminants, including metal fumes, gases, and other particles. Inhaling these substances can lead to respiratory issues, lung damage, and long-term health problems. The fumes and gases generated in the welding process, such as ozone and various metal oxides, can be particularly harmful.

Certain types of welding masks, such as air fed welding masks, provide additional protection against respiratory hazards. These specialised masks are equipped with filters and, in some cases, a powered air purifying respirator (PAPR) system. The PAPR supplies the welder with a stream of clean, filtered air, creating a positive pressure environment within the mask to prevent the inhalation of harmful fumes and airborne particles.

In contrast, standard welding masks and helmets, while effective in protecting the respiratory system from larger particles, do not offer the same level of protection as air fed masks. Welders should carefully consider the type of welding they are performing and the specific respiratory hazards present to ensure they have the appropriate respiratory protection in place.

Noise and Arc Sound

Welding can also create a significant amount of noise, including the loud hissing and crackling sounds of the welding arc. Prolonged exposure to high levels of noise can lead to hearing damage and other related health issues for welders.

While not the primary function of a welding mask, the protective coverage of a welding mask can provide some attenuation of noise levels, offering a minimal level of protection for the welder's ears. However, for more comprehensive hearing protection, welders should consider using additional earplugs or earmuffs designed for high-noise environments in combination with their welding masks.

Welding masks play a vital role in safeguarding welders from these hazards, ensuring their well-being and safety as they carry out their work. By providing protection against intense light, flying sparks, and respiratory risks, welding masks are essential tools that enable welders to work safely and confidently in a challenging environment