COSH TOPIC NO.

6:
WELDING AND CUTTING SAFETY

WHAT IS “WELDING”?
Welding is a process that joins materials together by melting a metal workpiece along
with a filler metal to form a strong joint. Heat metal parts to a temperature that is high enough to
join the metal parts by coalescence. Welding, soldering, and brazing are commonly known as
“hot work”. Hot work presents increased potential for fire and explosion hazards, especially
when performed in confined and enclosed spaces. You must be aware of these hazards to work
safely and avoid accidents and injuries.

THREE BASIC TYPES OF WELDING

Welding joins pieces of metal by the use of heat, pressure, or both. There are more than
80 different types of welding processes. Three major types of welding processes include:

● Gas – Slower and easier to control than electric arc. Uses gas flame over metals until a
molten puddle is formed.
● Arc – Two metals are joined by generating an electric arc between a covered metal
electrode and the base metal.
● Oxygen and Arc Cutting – Metal cutting in welding is the severing or removal of metal
by a flame or arc.

The most common cutting processes include:

● Oxygen Cutting: Metal is heated by gas flame and an oxygen jet does the cutting.
● Arc Cutting: Intense heat of electric arc melts away the metal.

Examples of common types of welding include: arc welding, plasma welding, welding
processes that use oxy-acetylene gas (SAW), lasers, and electron beams. Welding can
generate toxic fumes and gasses. Brazing or soldering involves a filler metal or alloy
(combination of metals) which has a lower melting point than the metals being joined. The filler
materials (such as lead and cadmium) can be very toxic. Cutting involves heating the metal with
a flame and directing a steam of pure oxygen along the line to be cut.

Factors affecting worker exposure include:

● Type of welding process

● Base metal and filler metals used
● Welding rod composition
● Location (outside vs. enclosed space)
● Welder work practices
● Air movement
● Use of ventilation controls
COMMON HAZARDS

● Air Contaminants - Hot work produces air contaminants. The most common
contaminants include metal fumes and gases. Hazardous fumes may be produced from
heating toxic metals found in common alloys. The fume particles created are small and
can deposit deep in the lungs causing adverse health effects that can range from
systemic poisoning to respiratory tract irritations. Setting up an appropriate work
environment and using the appropriate goggles, face shields, and/or respirators will
protect you from contaminants.

● Radiation - Both visible ultraviolet (UV) and infrared (IR) radiation are produced when
welding and cutting. These types of radiation can cause skin damage (sunburn and
cancer) and eye damage (welder’s flash, cataracts, and burns). You may not be aware of
these injuries until after they occur since UV and IR radiation is NOT detectable by the
senses. Appropriate clothing and filter lenses will protect you from radiation damage.

● Burns and Fires - Hot work can be a fire hazard. Burns, fires, or explosions can result
from flames, arcs, molten metals, heated surfaces, or metal splatters. Sparks from
welding operations have been known to travel as far as 35 feet horizontally from the
welding sight. Be aware of fire hazards when welding and remember that you can cause
fires or be burned when working. Unplug and place soldering irons or guns in holders or
stands when not in use. Always assume that a soldering iron or gun is hot. Give
equipment time to cool down before touching tongs and tips.

● Electrical Shocks - Every year welders die from electric shock. Electric shocks can
occur when proper precautions are not taken. Equipment must meet Underwriters
Laboratories (UL) code and be checked and serviced regularly. Servicing and installation
must only be undertaken by a qualified licensed electrician.

The following are the other hazards that workers may encounter during the process of
welding:

● Potential Explosion when welding in close proximity to closed containers that

have held flammable liquids or other combustible materials
● Potential Flash fire when welding in close proximity to flammable or combustible
vapors at the worksite
● Noise exposure possibly resulting in permanent hearing loss
● Musculoskeletal injuries from posture, heavy lifting

Welding Defects
Common weld defects that you should be familiar with to ensure your safety include:
➔ Incomplete fusion - occurs when the weld fails to fuse one side of the joint in
the root.
 ➔ Inadequate joint and root penetration is cause for rejection of a weld even if it
is sound in all other respects. The strength required in a weldment is achieved
only when the specified joint and root penetration is achieved.
➔ Spatter is the term used to describe metal particles or globules expelled during
welding and that do not form part of the weld. When spatter occurs, small balls of
metal are stuck to the surface of the base metal along the line of weld.
➔ Overlap is a protrusion of the weld metal beyond the bond at the toe of the weld.
➔ An undercut is a groove melted into the base metal adjacent to the toe and not
filled with weld metal
➔ Root cracks are similar to toe cracks except that they occur at the root of the
weld. Root cracks may be in the weld metal or in the base metal.
➔ Toe cracks occur in the base metal, at the toe of the weld.
➔ One common kind of crack is the crater crack. This occurs in the crater or
depression at the termination of a weld bead in gas or arc welding.
➔ Underbead cracks occur in the heat-affected zone underneath a bead and do
not extend to the surface of the metal
➔ Voids, also called gas pockets or blow holes, occur as the result of gas being
absorbed during the welding and then trapped as the metal solidifies.
➔ Slag inclusion is the term used to describe the weld defect in which nonmetallic
solid material is trapped in the weld metal or at the bond between the weld metal
and the base metal.

Cutting Hazards and Precautions

Another part of the welder’s job involves cutting operations such as oxyacetylene cutting and
plasma arc cutting. Observe these safety precautions when performing any cutting operation:

➔ Never place hands or fingers between the metal plate and the bed.
➔ Never place hands under the hold-downs or knife.
➔ Ensure all personnel are clear from the piece being cut.
➔ Support the plate to avoid injuries to workers if the cut end of the metal falls away.
➔ When using oxyacetylene cutting equipment, ensure that the work area is gas-free. This
is particularly important when working in bilges and other spaces where dangerous
vapors may collect.
➔ Always post a fire watch to protect the surrounding areas and personnel. The high
pressure oxygen stream used in cutting with an oxyacetylene torch can throw molten
metal for 50 to 60 feet
 ➔ When using oxyacetylene cutting equipment, remove and tag out any interfering
systems, if necessary.
➔ Install all covers, insulators, and handles before attempting to operate the plasma arc
cutting equipment.
➔ When using plasma arc cutting equipment, open all primary disconnect switches before
charging any electrical connections.

Welding and cutting tasks are dangerous, even for the most experienced worker. To avoid
injuries on the job, consider these welding and cutting safety recommendations:

● Always check for fire hazards before you start welding. Wood, paper, and other
flammable materials should be removed from the area. Flammable liquids should be
removed as well.
● Practice welding safety by cleaning wood floors before welding over them. Then, cover
them with metal or some other material that will not burn. It may also be a good idea to
wet the floor, though this can cause an added shock hazard. Guard against these
hazards as necessary.
● Seal cracks so that sparks or slag cannot fall through them, and never allow these hot
materials to fall into machine pits.
● Shield open doorways, broken windows, and similar openings with a welding curtain or
shield made of fire-resistant material. Hot slag may roll along a floor, so be sure the
curtain or shield is in contact with the floor.
● If you must weld near combustible materials, a fire extinguisher, pail of water, fire hose or
a pail of sand should be at hand. It may be necessary to have a worker stand by with a
fire extinguisher to put out sparks as well.
● If you are welding or cutting a tank or drum containing flammable liquids or gas, do not
start your operation until an approved test shows that there is no dangerous vapor
present to ensure it’s safe. Do not rely on another employee’s word that the tank or drum
was tested previously; insist on a new test before you start your work.
● Make sure your work area is properly ventilated. Many of these operations produce
fumes that are harmful in heavy concentrations, and good ventilation is one of the best
methods of protecting yourself against this. Utilize special ventilating equipment if
necessary.
● Wear face and eye protection such as goggles and a helmet to protect against hazards.
Welders working with metal, chipping and cleaning should always have their helmets
 lowered to prevent thrown particles of metal from coming into the eyes. Eye protection,
such as goggles, are worn to protect against sparks, slag and molten metal, and flash
burns caused by radiation from the welding equipment.

Preventive Measures:
Welding and cutting presents the risk of serious burns, electrical shock, and eye
damage. The cutting and welding process emits sparks, which presents a fire hazard. However,
following a few simple safety precautions can keep your welding and cutting activities
injury-free.
• Read the operator’s manual and familiarize yourself with the cutting/welding
equipment.
• Proper training.
• Wear proper personal protective equipment;
➢ welding gloves, long sleeved leathers or apron
➢ welding helmet with appropriate filter shade
➢ safety glasses
➢ leather boots o fire-resistant welding pants
• Ensure the work area is;
➢ free of clutter
➢ free of combustible and flammable materials
➢ ventilated (use engineered ventilation or a respirator)
• Ensure work is performed in a designated hot work area or a hot work permit is
obtained.
• Ensure a fire extinguisher is readily available.
• Ensure the work piece is properly grounded when arc welding.
• When using gas cylinders, chain them securely to a stationary, upright support or cart
at all times.
• Examine hoses/cables regularly for leaks, wear and loose connections.
• Inspect the cylinder valve for damage and/or the presence of contaminants such as oil,
grease or dust before using.
• Handle hot metal with pliers or tongs.
PROTECTIVE CLOTHING AND EQUIPMENT

a. Protective clothing and equipment shall be suitable for the type of work to be
performed, kept in good repair, and kept free of oil and grease.

b. Sleeves shall be kept buttoned at the wrist.

c. Collars shall be kept buttoned.

d. Fire resistant gauntlet gloves, aprons of leather or asbestos, and leggings shall be
used as protection against radiated heat or sparks.

e. Front pockets on overalls and aprons, and cuffs on pants shall be eliminated.

f. Capes or shoulder covers made of leather or other flame and heat-resistant material
shall be worn during overhead welding or cutting operations. Leather skull caps worn
under helmet provide protection against head burns. When working in a confined space
or an overhead location, ear plugs shall be worn or the ears covered with wire screen
protectors.

g. Hard hats or other types of head protectors shall be used where there is exposure to
falling objects.

h. Low cut shoes shall not be worn unless the ankles are covered with protective
leggings.

i. Employees required to wear respirators shall keep them clean and sterilized. When not
in use, such equipment shall be stored in closed containers.

j. The air line to supplied-air respirators shall be provided with a filter which will remove
pipe scale, water, oil, mist, and noxious vapors. It shall also be equipped with a pressure
reducing valve to prevent the supplied-air pressure from exceeding 25Psi.

k. Insulating mats of sufficient size shall be used when sitting on the same metal which is
being welded. Rubber gloves shall be worn under welding gloves when welding in wet or
damp locations.

l. After a welding job is completed, the material shall be chalk marked “HOT,” or a
warning sign shall be posted to caution other employees.
TYPICAL PERSONAL PROTECTIVE EQUIPMENT FOR WELDING

a. Protective clothing and equipment shall be suitable for the type of work to be performed, kept
in good repair, and kept free of oil and grease.

b. Sleeves shall be kept buttoned at the wrist.

c. Collars shall be kept buttoned.

d. Fire resistant gauntlet gloves, aprons of leather or asbestos, and leggings shall be used as
protection against radiated heat or sparks.

e. Front pockets on overalls and aprons, and cuffs on pants shall be eliminated.

f. Capes or shoulder covers made of leather or other flame and heat-resistant material shall be
worn during overhead welding or cutting operations. Leather skull caps worn under helmet
provide protection against head burns. When working in a confined space or an overhead
location, ear plugs shall be worn or the ears covered with wire screen protectors.

g. Hard hats or other types of head protectors shall be used where there is exposure to falling
objects.

h. Low cut shoes shall not be worn unless the ankles are covered with protective leggings.

i. Employees required to wear respirators shall keep them clean and sterilized. When not in use,
such equipment shall be stored in closed containers.
j. The air line to supplied-air respirators shall be provided with a filter which will remove pipe
scale, water, oil, mist, and noxious vapors. It shall also be equipped with a pressure reducing
valve to prevent the supplied-air pressure from exceeding 25Psi.

k. Insulating mats of sufficient size shall be used when sitting on the same metal which is being
welded. Rubber gloves shall be worn under welding gloves when welding in wet or damp
locations.

l. After a welding job is completed, the material shall be chalk marked “HOT,” or a warning sign
shall be posted to caution other employees.

Protective Shade Chart for Welding Operations

Why is Welding Safety Important?

Welding is a hazardous workplace activity which exposes over half a million workers to
health and safety risks each year in the United States alone. Welding safety measures are
designed to protect employees from welding hazards. Welding safety can be implemented by
conducting proper training, inspecting welding equipment, and ensuring workers are aware of
safety precautions before performing welding activities to minimize the risk of health and safety
injuries.

Precautions and Tips

 Safety precautions in welding are action steps welders can take to prevent
welding-related incidents or injuries such as burns, eye injuries, and other skin injuries and even
deaths due to explosions, electrocutions, and asphyxiation. In order to eliminate or reduce the
most common welding hazards, welders should practice the following safety precautions and
tips accordingly:

● Provide adequate ventilation and local exhaust to keep fumes and gases from the
breathing zone and the general area.
● Report concerns to a supervisor so your exposure to substances of the welding fumes
can be checked.
● Fire and electricity resistant clothing, hand shields, welding gloves, aprons, and boots
can be worn to protect workers from heat, fires, electrocution, and burns. Take note that
flame retardant treatments become less effective with repeated laundering. Pant legs
must not have cuffs and must cover the tops of the boots. Cuffs can collect sparks.
● Earmuffs and earplugs can also protect workers against noise.
● Perform lockout and tag out procedures when performing repairs. Only qualified repair
technicians should service or repair welding equipment.
● Keep a suitable Class ABC fire extinguisher nearby while welding. Make sure the
extinguisher gauge is full. If an extinguisher is not available, be sure to have access to
fire hoses, sand buckets, or other equipment that houses a fire.
● If welding within 35 feet of flammable materials, put a piece of sheet metal or
fire-resistant blanket over the flammable material and have a fire watcher nearby to keep
track of sparks.

REFERENCES:

● https://manoa.hawaii.edu/opf/documents/safety/29%20OPF%20Safety%20Program%20
Manual%20-%20Welding%20and%20Cutting.pdf
● https://threesixtysafety.com/welding-and-cutting-safety/
● https://www.lsu.edu/ehs/references/university-safety-manual/4J_Welding_cutting.php
● https://www.osha.gov/welding-cutting-brazing
● https://www.ehs.iastate.edu/sites/default/files/uploads/forms/Toolbox%20Talks%20-%20
Welding%20and%20Cutting.pdf
● https://safetyculture.com/topics/welding-safety/