Welding and Cutting Safety Training by the University of Southern Mississippi

elding joins two pieces of metal by the use of heat
and/or pressure
razing or soldering involves a filler metal which has a
lower melting point than the metal pieces to be joined
etal cutting is done by heating the metal with a flame
and directing a stream of pure oxygen along the line
to be cut

rc Welding
hielded Metal Arc Welding (SMAW)
etal Inert Gas (MIG)
ungsten Inert Gas (TIG)
laza Arc Welding (PAW)
ubmerged Arc Welding (SAW)

enerally, gases and fumes come from…
 Base material & filler material
 Coatings & paints
 Shielding gases & chemical reactions
 Process & consumables used
 Contaminants in the air

elding “Smoke” is a mixture of very fine particles
called fumes and gases
elding “Smoke” contains fumes and gases including…
 Chromium, nickel, arsenic, asbestos, manganese, silica,
beryllium, cadmium, nitrogen oxides, phosgene, acrolein,
fluorine compounds, carbon monoxide, cobalt, copper,
lead, ozone, selenium, and zinc
 cancer causing agents include: cadmium, nickel, beryllium,
chromium, and arsenic

xposure to welding “smoke” may have…
hort-term effects
 Effects happen at or very soon after exposure
ong-term effects
 Effects may happen after repeated overexposures or an
extended time after the exposure

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

tudies of have shown that welders have an increased
risk of lung cancer and, possibly, cancer of the larynx
and urinary tract
elders may experience a variety of chronic respiratory
problems, including:
 Bronchitis, asthma, pneumonia, emphysema, pneumoconiosis,
decreased lung capacity, silicosis, and siderosis

ther health problems include:
 Heart disease
 skin diseases
 hearing loss
 chronic gastritis
 ulcers of the stomach and small intestine
 other reproductive risks

eat exposure
 Heat stress,
 heat stroke
 Skin burns and skin cancer
Noise
 Can result in stress, increased blood pressure, may contribute to
heart disease, tiredness, nervousness, and irritability

ye damage- More than 5% of all eye injuries in the
construction industry are associated with welding,
cutting, and brazing
 damage to retina
 damage to cornea, resulting in cataracts
 permanent eye damage
nvisible UV light can cause “arc eye” or “welders’
flash”
 May include sandy or gritty eye, blurred vision, intense pain,
tearing, burning and headache

elding booths should be painted with dull finishes so
they don’t reflect UV light
coustic shields between the worker and noise sources
can reduce exposures
oisy machinery can be totally enclosed

se cadmium-free silver solders
se asbestos- free electrodes, gloves, and hot pads
se work area barriers to protect others working in the
same general area

onstruction personnel that is welding should be
properly trained and qualified
nspect work area for fire hazards before welding
ake provisions for ventilation before welding
ompressed gas cylinders should always be secured in
an upright position when not in use and handled with
extreme care

as cylinders should be stored at least 20 feet away
from flammable materials and heat sources
xygen cylinders should be stored at least 20 feet away
from gas cylinders and combustible materials.
 When not possible, use a 5 ft tall noncombustible barrier with a
30 min. fire-resistance rating or better

ll combustible materials should be removed from
welding area or covered with noncombustible material,
prior to welding
 If covered, a worker that has experience using a fire extinguisher
should be posted near as fire watch
orkers should stand to the rear or side of regulators
when opening valves on tanks
roper PPE should be worn, even by workers not
welding

on’t weld on painted surfaces
se water table to reduce noise
roperly maintain equipment
roper housekeeping
se lowest possible amperage
old electrode perpendicular and close to work
surface

PE must be used in conjunction with engineering
controls and safe work practices
 Use of one does not eliminate the need for the other
ye protection should be used in all welding operations
 Wear face shields or helmets and goggles or safety glasses
se appropriate filters on eye protection

ire resistant gauntlet gloves
ead cap
igh top hard toed shoes
eather apron
ace shield
lame retardant clothing

ven though welding generally uses low voltage, there
is still a danger of electric shock
et work areas, cramped work spaces
alls, fractures and other accidents can result from
electrical exposure
ven small shock can cause brain damage
eath can occur from large shocks

lways use dry gloves
lways wear rubber soled shoes
lways use insulating layers
rotect yourself from surfaces that conduct
electricity
hen working on electrically powered machinery, make
sure the frame is grounded
eep insulation on all welding equipment and
components dry and in good condition

ever 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
fire inspection should be performed prior to leaving a
work area and for at least 30 minutes after the
operation is completed
ire extinguishers should be nearby, of proper size, type
and number for the hazards involved

ll machines in the area with moving parts must be
guarded to prevent worker’s contact
e.g. hair, clothing, fingers
hen repairing machinery by brazing and welding,
power must be disconnected, locked out, and tagged
so the machinery cannot be started up accidentally

eep work areas clear of equipment, machines,
cables, and hoses
lways properly maintain and use handrails
lways use and maintain safety lines, harnesses and
lanyards
lways make sure that scaffolds are properly
assembled and used

work area with limited access, little or no airflow,
not intended for continuous occupation
 May also have dangerous atmospheres, hazardous
configurations, or other hazards
ll employees working in or around confined space
must be trained
dequate ventilation must hold fumes and smoke to
levels within the safe breathing range set forth
in 29 CFR 1926 subpart D

o worker should work in an area with less than 19.5%
or more than 23.5% oxygen content
se continuous mechanical ventilation and proper
respiratory protection
hen adequate ventilation cannot be achieved,
workers must be provided with air supplying
respirators as described in 29 CFR 1926 Subpart E

lways leave gas cylinders and welding power sources
outside the confined space…
nly take hoses or welding leads into confined space
and remove when leaving for breaks, shift or crew
changes
ll pipes, ducts, and power lines that are not necessary
for the work should be disconnected/locked
out/tagged out

hen transporting and handling, valve cap should be
securely in place
ylinders should never be lifted by valve cap
ylinder valve should be closed when cylinder is empty,
being moved or not in use
ylinders should be secured to a pallet, cradle, or sling
board for hoisting
ylinders should not be dropped, bumped, struck or
receive any other huge impact

uel, gas and oxygen hoses must be easily and clearly
distinguishable.
 Oxygen and gas hoses must not be interchangeable
hen oxygen and fuel hoses are taped, no more than 4
inches per foot of hose may be taped
as and oxygen hoses must be inspected before every shift
and removed if defects are found.
orches should be inspected before each shift to detect
leaks

nly use manual electrode holders designed specifically for
arc welding
ll current-carrying parts should be properly insulated for
maximum voltage encountered
ables must be properly insulated, flexible and able to
handle maximum current required
ll equipment and cables should be inspected before each
shift and should be removed if any defects are found

Compressed Gas Cylinder Safety
Subject to damage
from other activities in
the vicinity
Cylinder laying
in a horizontal
position.
Electrical cord in
Contact with the
cylinder

Cylinders are not protected from falling. Note
that the Chain is not secured across.
Chain

1. Cylinder not secured 2. Cylinder should be stored
3. Subject to damage. 4. Electrical cord draped over.
Electrical
Cord

1. Small cylinder not tied off
2. Combustibles stored with cylinders
3. Bad housekeeping
4. Acetylene and Oxygen stored
too close together and no chain.

1. Cylinder with no valve or cap installed 2. Laying horizontal on the ground
3. Subject to damage

Cylinder is damaged. Should be taken out of service immediately!
Electrical arc
damage

Cylinder should be in storage protected from damage and not
laying on the ground regardless if it is full or empty

Old, corroded cylinder that should have been disposed
of a long time ago.

1. Cylinders laying on the ground and improperly stored
2. Subject to damage from forklift operation in vicinity
Forklift

1. Feed line exposed to damage/leak that could cause a fire/explosion
2. Tripping Hazard

1. Inadequate housekeeping
2. Valve caps should be installed.

Acetylene
Cylinder
1. Unsecured acetylene cylinder 2. Exposed to damage

Unsecured cylinders

Regulator left pressurized after useRegulator left pressurized after use

Improper StorageImproper Storage

Tie Off?Tie Off?

Improper storage ofImproper storage of
cylinders- acetylene andcylinders- acetylene and
oxygen stored next to eachoxygen stored next to each
otherother

Evidence of smoking next to acetyleneEvidence of smoking next to acetylene
cylinderscylinders

This cylinder should be
taken to storage and
housekeeping should be
improved.

Unsecured
cylinder

Unsecured Cylinder

Cooking equipment
within 20 ft
of containers

TiedNot Tied

oxy-acetylene torch connected
To bottles without the torch
connected.

No cap installed
Not in use.
Should be
Stored.
Housekeeping

Cylinder not in use
with regulators still
On the cylinder
Free standing
cylinder

Free standing
cylinder

Free standing cylinders
Chain

Cylinder
tied only
With a bungee
cord

Cylinders not
Secured properly

Free standing
cylinders
Exposed to damage
From construction
Activities in area

Free standing
cylinders

Cylinder laying on its sideCylinder laying on its side

oll, R. (2002, October 17). Compressed Gas Cylinder Training Slides.
Retrieved September 10, 2009 from , Web site:
http://siri.uvm.edu/ppt/cgcsafety/sld001.htm
oetsch, D. (2010). Construction safety and the OSHA standards.
Boston: Pearson.
averio (2003). Welding Safety. Retrieved September 10, 2009
from , Web site:
http://www.authorstream.com/Presentation/Saverio-42953-
Welding-Safety-2003-Health-Hazards-HazardsGases-Fumes-Short- term-
Entertainment-ppt-powerpoint/

Welding and Cutting Safety Training by the University of Southern Mississippi

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