22._SGW-_Welding_Safety (Importance).pptx

Welding Safety
Prepared By | Safety Professional | www.safetygoodwe.com 1

Welding
• Welding joins two pieces of metal by the use of
heat, pressure, or both
• Brazing or soldering involves a filler metal which
has a lower melting point than the metal pieces
to be joined
• Metal cutting is done by heating the metal with a
flame and directing a stream of pure oxygen
along the line to be cut

Welding
• Arc Welding
• Shielded Metal Arc Welding (SMAW)
• Metal Inert Gas (MIG)
• Tungsten Inert Gas (TIG)
• Plaza Arc Welding (PAW)
• Submerged Arc Welding (SAW)
• And Many More…..more than 80 in all

Health Hazards
• Gases and Fumes…
• Welding “Smoke” is a mixture of very fine particles called fumes and gases
• Welding “Smoke” contains fumes and gases including…
• Chromium, nickel, arsenic, asbestos, manganese, silica, beryllium, cadmium,
nitrogen oxides, phosgene, acrolein, flourine compounds, carbon monoxide,
cobalt, copper, lead, ozone, selenium, and zinc

Health Hazards…Gases & Fumes
• Generally, gases and fumes come from…
• Base material & filler material
• Coatings & paints
• Shielding gases & chemical reactions
• Process & consumables used
• Contaminants in the air

Health Hazards
• It is difficult to list all the health effects of welding exposures because the fumes may
contain so many different substances that are known to be harmful
• The individual components of welding “smoke” can affect just about any part of the body,
including the lungs, heart, kidneys, & central nervous system

Health Hazards
• Exposure to welding “smoke” may have…
• Short-term effects…
• Effects happen at or very soon after
• exposure
• Long-term effects
• Effects may happen after repeated
• overexposures or an extended time
• after the exposure

Short-term exposures
• Exposure to zinc, magnesium, copper and copper oxide can cause metal fume fever
• Symptoms of metal fume fevere may occur 4 to 12 hours after exposure
• Symptoms include…
• Chills, thirst, fever, muscle ache, chest soreness, coughing, wheezing, fatigue, nausea, and
metallic taste in mouth

• Welding “smoke” can irritate the eyes, nose, chest and respiratory tract
• Welding “smoke” can cause coughing, wheezing, shortness of breath, bronchitis,
pulmonary edema, and pneumontis
• Welding “smoke” can cause nausea, loss of appetite, vomiting, cramps, and slow digestion

• Exposure to cadmium can be fatal in a short time
• Ultraviolet radiation can react with oxygen and nitrogen to form ozone and nitrogen oxides
• These gases are deadly at high concentrations and can also cause irritation of nose and
throat and cause serious lung disease

• Ultraviolet rays given off by welding can react with hydrocarbon solvents such as…
• Trichloroethylene; 1,1,1-trichloroethane; methylene chloride; & perchloroethylene to form
phosgene gas
• Even a very small amount of phosgene gas may be deadly
• Early symptoms include dizziness, chills, and cough and usually take 5 – 6 hours to
appear

Short-term
exposures
Arc welding should never be
performed within 200 feet of
degreasing equipment or solvents

Long-term
exposures
Studies of welders, flame cutters, and
burners have shown that welders have an
increased risk of lung cancer…
and…possibly cancer of the larnyx and
urinary tract
Remember… welding “smoke” can include
cancer causing agents such as…cadmium,
nickel, beryllium, chromium, and arsenic

Long-term
exposures
• Welders may experience a variety of
chronic respiratory problems,
including…
• Bronchitis, asthma, pneumonia,
emphysema, pneumoconiosis,
decreased lung capacity, silicosis, and
siderosis

Long-term
exposures
• Other health problems…
• Heart disease, skin diseases, hearing loss, chronic
gastritis, gastroduodentis, and ulcers of the
stomach and small intestine
• Reproductive risks

Other Health Risks…
• Heat exposure…
• Heat stress, heat stroke
• burns, eye injuries from hot slag, metal
chips, sparks, and hot electrodes

Other Health
Risks…
• Visible light, and ultraviolet and infrared
radiation
• Intense light can cause damage to retina
• Infrared radiation may damage the cornea
and result in cataracts
• Invisible UV light can cause “arc eye” or
“welders’ flash”
• May include sandy or gritty eye,
blurred vision, intense pain, tearing,
burning and headache

Other Health Risks…
• Permanent eye damage
• Skin burns
• Skin cancer
• Noise
• Can result in stress, increased blood pressure, may contribute to heart
disease, tiredness, nervousness, and irratability

Musculoskeletal Injuries
• Back injuries, shoulder pain, tendonitis, reduced muscle strength, carpal
tunnel syndrome, white finger, and knee joint diseases
• Injuries may be caused by overhead work, vibration and heavy lifting

Electrical
Hazards
• Even though welding generally uses low voltage,
there is still a danger of electric shock
• Wet work areas, Cramped work spaces
• Falls, fractures and other accidents can result
from electrical exposure
• Even small shock can cause brain damage
• Death can occur from large shocks

Electrical Hazards
• Always use dry gloves
• Always wear rubber soled shoes
• Always use insulating layers
• Protect yourself from surfaces that conduct electricity
• When working on electrically powered machinery, make sure the frame is grounded
• Keep insulation on all welding equipment and components dry and in good condition
• Don’t change electrodes with bare hands, wet gloves or while standing on wet or ungrounded
surfaces

Fire and
Explosion
Hazards
Intense heat and sparks can cause fires
or explosions if in the vicinity of
combustible or flammable materials
Welding and cutting should only be
performed in areas free of combustible
materials such as trash, wood, paper,
textiles, plastics, chemicals, and
flammable dusts, liquids and gases

Fire and
Explosion
Hazards
Never weld or cut on containers that have held a
flammable or combustible material unless the
container is thoroughly cleaned or filled with an
inert gas
A fire inspection should be performed prior to
leaving a work area and for at least 30 minutes
after the operation is completed
Fire extinguishers should be nearby, of proper
size, type and number for the hazards involved

Dangerous
Machinery
All machines in the area with
moving parts must be guarded to
prevent worker’s contact
•Hair, clothing, fingers, etc.
When repairing machinery by
brazing and welding, power must
be disconnected, locked out, and
tagged so the machinery cannot be
started up accidentently

Trips and Falls
To prevent trips and falls…
keep work areas clear of equipment, machines,
cables, and hoses
Always properly maintain and use handrails
Always use and maintain safety lines, harnesses
and lanyards
Always make sure that scaffolds are properly
assembled and used

Welding Hazards in
Confined Space
• A work area with limited access, little or no airflow,
not intended for continuous occupation
• May also have dangerous atmospheres,
hazardous configurations, or other hazards
• All employees working in or around confined space
must be trained

Welding
Hazards in
Confined
Space
Never weld or cut in explosive, flammable,
combustible or other dangerous environments
Weld or
cut in
Always use all necessary Personal Protective
Equipment (PPE), including, harness and lanyard,
respiratory protection, eye protection, etc.
Use
Never work in confined space without a trained
attendant
Work in

Welding
Hazards in
Confined
Space
Always leave gas cylinders and
welding power sources outside the
confined space…
Only take hoses or welding leads
into confined space
Always removed hoses and/or leads
when leaving confined space for
breaks, shift or crew changes, etc.

Welding
Hazards in
Confined
Space
No worker should work in an area with less than
19.5% or more than 23.5% oxygen content
Never ventilate with oxygen
Use continuous mechanical ventilation and proper
respiratory protection
All pipes, ducts, power lines, etc. that are not
necessary for the work should be
disconnected/locked out/tagged out

Compressed Gas Hazards
• Gas welding and cutting use a fuel gas and oxygen which are stored in high
pressure cylinders
• Most fuel gases are explosive
• Pure oxygen will increase the flammability of any combustible/flammable
material

Compressed
Gas Hazards
All cylinders should have caps or regulators
Pressure regulators must be designed for gas in use
Check all equipment and components prior to use
Cylinders must be stored upright and secured
Oxygen and fuel gas cylinders must be stored separately
Be aware of flashbacks and backfires??
Close cylinder valves when work is completed or left unattended
during breaks, etc.

Reducing
Noise Hazards
• Identify hazards and potential hazards prior
to beginning hot work
• Read the MSDS sheet to identify the
hazardous material used in welding and
cutting products, and the fumes that may be
generated
• Make sure that you know what you are
welding before beginning
• Cadmium exposure can be fatal in a very
short time

Compressed
Gas Hazards
• After a specific hazard(s) has been
identified…
• you can implement appropriate control
method(s)
• You can use appropriate PPE

Engineering
Controls and
Work Practices
• Substitute less hazardous materials for
hazardous materials
• Use cadmium-free silver solders
• Use asbestos- free electrodes, gloves, and
hot pads
• Use ventilation to move away or dilute
hazards
• Use work area barriers to protect others
working in the same general area

Engineering Controls and Work Practices
Welding booths should
be painted with dull
finishes so they don’t
reflect UV light
Acoustic shields
between the worker
and noise sources can
reduce exposures
Noisy machinery can
be totally enclosed

Engineering
Controls and
Work Practices
• Modify the process or follow safe work practices
so that hazards are eliminated or reduced to the
minimum…
• Don’t weld on painted surfaces; use water table
under plasma arc cutting to reduce noise; Grind
instead of air-arcing; use sub arc; position
yourself away from fumes; remove nearby
flammables/combustibles; properly maintain
equipment; proper housekeeping; use lowest
possible amperage; hold electrode perpendicular
and close to work surface
• Never weld or cut within 200 feet of degreasing
equipment or solvents

Personal Protective
Equipment (PPE)
• PPE must be used in conjunction with engineering
controls and safe work practices
• Use of one does not eliminate the need for the
other
• Eye protection should be used in all welding
operations
• Wear face shields or helmets and goggles or
safety glasses
• Use appropriate filters on eye protection

Filter Lens
Shade
Numbers
SMAW – 1/16 - 5/32 = #10
Gas SAW - 1/16 - 5/32 = #11 (nonferrous)
Gas SAW – 1/16 – 5/32 = #12 (ferrous)
SMAW – 3/16 – ¼ - = #12
5/16 & 3/8 electrodes = #14
Atomic Hydrogen Welding = #10 - #14
Carbon Arc Welding CAW = #14

Filter Lens
Shade
Numbers
Soldering = #2
Torch Brazing = #3 or #4
Light cutting up to 1 inch = #3 or #4
Medium cutting 1 inch to 6 inches = #4 or #5
Heavy cutting over 6 inches = #4 or #6
Light gas welding up to 1/8” = #4 or #5
Medium gas welding 1/8” to ½ “ = #5 or #6
Heavy Gas Welding over ½ “ = #6 or #8

Protective
Clothing
Fire resistant
gauntlet
gloves
Headcap
High top hard
toed shoes
Leather apron Faceshield
Flame
retardant
clothing
Safety Glasses Safety helmet

Hearing Protectors
• Ear plugs and/or muffs should be worn during noisy
operations such as air arcing or grinding
• Most welding operations are noisy

Respirators
• Must be specific to the hazard
• Must be fitted, cleaned, stored and maintained
in accordance to regulation and manufacturers
specs
• NIOSH recommends respirators whenever a
carcinogen is present

Conclusion.. Its just beginning
QUESTIONS

Thank You!

22._SGW-_Welding_Safety (Importance).pptx

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22._SGW-_Welding_Safety (Importance).pptx