Blinded by the Arc: What Every Welder Needs to Know About Flash Burn

Symptoms, Prevention, and First Aid Every Worksite Should Know

Whether you’re welding on a construction site in Toowoomba or fabricating farm gear in Goondiwindi, there’s one injury you don’t see coming — until it’s too late.

Welder’s flash, also known as arc eye, is a painful eye condition caused by overexposure to the intense ultraviolet (UV) radiation emitted by welding arcs. And while it might sound minor, untreated arc eye can cause long-term damage and put a serious pause on productivity.

Let’s break down what welder’s flash is, how to prevent it, and the right first aid steps to take if it happens on your watch.

What Causes Welder’s Flash?

Welding produces powerful UV rays — even more intense than the sun. Just a few seconds of exposure without proper protection can cause a burn to the surface of the eye (the cornea). This injury doesn’t show up immediately. Instead, symptoms often begin 4 to 12 hours after exposure, which makes it easy to underestimate the danger.

Even bystanders several metres away can be affected if protective measures like welding screens aren’t in place.

Symptoms of Welder’s Flash

Knowing the signs early can help you act fast:

• 🔴 Pain or burning sensation in the eyes
• 😢 Watery, red, or bloodshot eyes
• 😵 Blurred vision or difficulty seeing in bright light
• 😠 A gritty feeling, like sand in the eyes
• 🌙 Discomfort that worsens at night
• ⚡ Sensitivity to light (photophobia)

If you or a worker is showing any of these signs after a day of welding, it could be welder’s flash — and it’s time to act.

How to Prevent Welder’s Flash

Prevention is simple — but it has to be consistent.

✅ Use the Right PPE

• Welding helmets with the correct lens shade for the type of welding
• Auto-darkening filters that respond instantly to the arc
• Full face shields and safety glasses for grinding and prep work

🛠 Maintain Equipment

• Check helmet lenses for scratches, cracks or worn-out filters
• Make sure the auto-darkening feature is functioning properly before every job

🧱 Set Up Barriers

• Use UV-rated welding screens or curtains to shield others in the area
• Ensure the work area is clearly marked with welding signage

👨‍🏫 Provide Regular Safety Training

• Workers should know the dangers of indirect UV exposure
• Ensure Workers understand the latest Welding processes codes of practice
• Bystanders, apprentices, and non-welding trades need education on why not to “sneak a peek”

First Aid for Welder’s Flash

Immediate care can reduce pain and complications:

1. Remove the person from bright light. Darkness helps reduce pain and further exposure.
2. Apply a cool, damp cloth over closed eyes for comfort.
3. Do NOT rub the eyes — it can worsen irritation.
4. Avoid using eye drops unless prescribed.
5. Seek medical attention ASAP. A GP or eye specialist can confirm diagnosis and provide treatment.

Arc eye is not a “walk it off” injury. Without medical care, it can lead to corneal ulcers, infection, and even vision loss.

Why First Aid Training is Critical for Welders

At Accidental Health and Safety, we’ve seen firsthand how fast welding injuries can escalate — especially in high-risk environments like:

• Fabrication workshops
• Mining operations
• Construction and civil sites
• Agricultural and mechanical workshops
• DIY projects in sheds and garages

Our nationally recognised First Aid and CPR training helps teams respond effectively to injuries like arc eye, chemical splashes, burns, and more. We bring the training to you — across Warwick, Dalby, Toowoomba, Goondiwindi and the wider Darling Downs.

Take Action Today

Don’t wait for a welder’s flash incident to highlight a safety gap. Ensure your team is trained, your PPE is up to standard, and your safety culture is proactive.

👉 Book a First Aid or CPR Course today at accidentalddi.com.au

Share this article with your team, safety officer, or site manager.

Because when it comes to eye injuries, prevention really is better than cure.