Electrical Safety Issues
The basic principles of welding involve electrical current that is essentially being shorted at the tip of the welding rod to produce the heat needed to melt the rod and the steel long enough for them to bond and create the weld. This means, of course, that we are dealing with electrical current and that certain precautions must be taken in order to work with that current without danger.
- Both the electrode, as well as the work are hot (have electricity running through them) and must never be touched with bare skin or with anything that is wet.
- In semiautomatic or automatic wire melding almost all of the equipment (wire, electrode, reel, welding head and nozzle) is hot and should be treated with caution.
- Always make sure that your work is properly ground and that there is a good electrical connection with the metal being welded. The connection should be as close to the area being welded as possible.
- Make sure that all equipment is in good working condition. Remove and replace any frayed or faulty equipment.
- Never touch equipment from two different welding units as your body could create an electrical bridge and cause electrocution.
- Never work on any of the equipment until it has been disconnect completely. Never try to fix it while it is still hot.
- Always turn off all equipment when not in use.
- Make sure all equipment is installed and running according to code.
Arc Ray Safety
Arc Rays can cause retinal burns and eye injuries. The following chart, available from AWS (The American Welding Society) and available for free download here, outlines the different shades needed for specific types of welding.
The proper eye protection, however, does nothing if not worn when needed and properly.
Auto-darkening lenses (also known as auto-darkening filters or ADFs) are lenses that allow you to see without lifting your helmet but that instantly darken to the preset shade within a millisecond after the arc is struck, allowing the welder to have eye protection at all times. Fixed shade lenses on the other hand mean that the welder must raise his helmet to see whenever there is no arc. This means that the odds of eye and face injury increases.
Heat/Burns/Fire
Welding is hot work! Temperatures can reach 10,000 degrees F. To make matter worse, flux, metal particles and other super heated “bits” can be skipping or flying around as a result of the welding process. This means, of course, that the danger of burns and fires increases dramatically.
Certain precautions therefore have to be taken in order to avoid burns. Bare skin is, of course, not recommended. Flame retardant and fire resistant clothing is necessary. In addition, a certain number of other issues have to be taken into consideration:
- No pockets – With flying super heated debris flying around, pockets are a hazard. Hot pieces can land inside a pocket and burn without being able to fall away.
- Buttoned up collars – Keeping flying debris out of the neck line is essential
- Shirts outside of the pants – Tucking the shirts inside the pants creates the same type of issue that pockets do. Shirts outside of the pants allow the hot particles to fall away rather than simmering.
- Pants without cuffs – Cuffs end up essentially being the same thing as pockets.
- Flammable and combustible material needs to be far from the welding area. Sparks and debris can be projected up to 35 feet or more.
- The rules above about clothing apply to co-workers and others who might be in the immediate vicinity
- Know the location of the fire extinguishers before you start working. Once a fire is blazing, it’s too late to go looking for it. Be prepared.
Heat issues
When dealing with temperatures that can reach 10,000 degrees, and complete skin coverage, especially with FR clothing, we are automatically talking about the possibility of heat stress. Understand the symptoms and treatment of heat related health issues and take the appropriate measures. Make sure that you take frequent breaks away from the heat and stay hydrated at all times.
Burns
If burns do occur, follow the proper burn treatment procedures. Water Jel is a great product for treating minor burns. Keep first aid burn products close by and know where they are.
Yesterday we outlined the 5 areas of safety that need to be addressed in order to make sure that welding stays safe.
We started by looking at one of the least considered ones, noise. Today we are going to look at the most common one, respiratory/Fumes
Fumes/Respiratory
Fumes and gases are the most obvious hazard associated with welding. Many of the metal give off fumes that are immediately noticeable and can cause burning of the eyes, skin irritation and rashes, nausea, vomiting and dizziness.
Other particles, fumes and gases can have a cumulative effect with symptoms not showing up till much later. Pulmonary and respiratory problems can result. Bronchitis, lung fibrosis and emphysema are just three of the possible long-term health problems that can develop over time.
As in all respiratory problems, engineering should always be the first line of defense. Ventilation and/ or exhaust should be used to “suck up” the fumes or circulate the air. A welding fume extractor provides ventilation directly at the source of the fume in order to keep the fumes and gases from dissipating. Because it extracts the fumes and gases right at the source, it substantially extends the life of the respirator cartridge as well as providing better protection for others who might be in the vicinity.
Procedures to protect yourself from welding fumes and gases:
- Keep your face away from the fumes
- Make sure that you can see properly. Don’t lean closer because you can’t see well. Use corrective lenses if necessary.
- Use adequate ventilation. If indoors, use a welding fume extractor or other ventilation. If outdoors, natural ventilation may be adequate.
- Wear respiratory protection where necessary. Powered Air Purifying Respirators (PAPR) are often the preferred form of respiratory protection in areas where fume extraction is not possible or feasible.
- Understand the particular hazards associated with the metal or alloy you are welding. Cobalt, Zinc, Nickel (including nickel plated), Manganese, Copper and Silica all have special hazards that you need to research and be aware of before you start heating them up or welding on them.
- Be aware of oxygen displacement. Even gases which might not be harmful in and of themselves can become hazardous if they are present in large enough quantities to displace oxygen. A basic 4-gas monitor might be necessary in order to adequately warn of oxygen displacement.
The new Hexavalent Chromium standard, as well as other welding related respiratory issues have been at the forefront of safety related issues long enough for most of us to be aware of some of the hazards associated with welding.
Respiratory protection issues, though certainly important, are by no means the only hazards to be aware of when looking at welding. Today and in the next couple of days we are going to be looking at the hazards associated with welding and how to make sure that welding is safe.
The hazards associated with welding include:
- Noise
- Fumes/Respiratory
- Heat/Burns
- Ultraviolet Radiation
- Electrical Safety Issues
Noise
While Noise probably isn’t the first safety hazard most people associate with welding, there are good reasons to consider the issue. Arc welding equipment, as well as the generators and the actual noise generated by the welding process all combine to produce noise levels above the 85 dB threshold. Extended exposure to this high level of noise can and does, result in partial or complete hearing loss over time.
If in doubt, purchase a simple 3M Noise Indicator. It flashes green when noise levels are below 85 dB and red when the noise levels exceed it. Other options include sound level meters and noise dosimeters. You can also opt to have an Industrial Hygienist come in and monitor noise levels for you.
An additional consideration regarding ear plugs or ear muffs is the added protection that they afford for the ear canal. Flying sparks and metal pieces can easily bounce into the ear canal causing substantial pain and injury. Whatever form of hearing protection you use, you are also plugging the ear canal and keeping hot sparks and metal pieces out.
