Activity 4.1.

1a

WELDING LAB - Hazards & Safety

Precautions

By Mr. STALIN KESAVAN

INDoS- 21ZM7155

VICT Course
Submitted to Cap.MANI RAJAKUMAR
Teaching plan
•Introduction to Welding hazards.

•Lab Layout.

•Briefing on safety precautions.

•Welding Gears.

•Key Points to remember.

Introduction to welding hazards…
• Electric Shock
 In damp conditions.
 While wearing wet clothing.
 On metal flooring or structures.
• Noise Hazards
 Ringing in the ears, known as tinnitus.
 Occasional dizziness, known as vertigo.
 Increased heart rate.
 Increased blood pressure.
• Exposure to UV and IR Radiation
 Burn injury
 cataracts and lead to a loss of vision.

• Exposure to Fumes and Gases

 Pneumonia.
 Occupational asthma
 Cancer
 Throat and lung irritation
 LAB LAYOUT

EXIT

1 2 1 2 1

1
CHANGE
ROOM 2
1- Fire
Extinguisher

2-Sand
1 2 1
3 3 -First Aid kit
Welding Equipment's & Safety Precautions
• Always Wear Appropriate PPE ( Personal Protective Equipment (PPE)
 Welding helmets with side-shields.
 Respirators.
 Fire resistant clothing.
 Ear protection.
 Boots and gloves.
• Receive Appropriate Training
• Ensure Your Workspace is Well Ventilated.
• Ensure Your Workspace is Free of Flammable Material.
 BUTT WELDING

• A butt weld is one of the simplest and

versatile types of weld joint designs.

• The joint is formed simply by placing two

pieces of metal end-to-end and then welding
along the join.

• Thus, workpieces are nearly parallel and do

not overlap
 STEPS IN BUTT WELDING:
 Obtain all necessary equipment. This should be a welding machine, electrode and
workpiece clamps (and their leads), a welding helmet darker than shade 10, welding
gloves, and appropriate safety clothing.
 Prepare the metal to be welded. This includes grinding down rough edges and cleaning the
areas to be welded.
 Bevel the edge of the metal if it is thicker than 1⁄4 inch (0.6 cm). Beveling allows for better
penetration of the root pass and subsequent passes..
 Align your metal to make sure the edges line up well. They should be smooth and align
cleanly.
 Turn your pieces over. This should be the flat side if on or more pieces are beveled, or the
side you don't want to start welding.
 Separate the pieces a little bit and set the amperage on your machine about 10
percent higher than the level you intend to use welding the metal. So, if you are
going to use 100 amps to make your weld(s), set your amperage at 110 amps.
 Make tack welds. These will hold the metal together and prevent it from warping
or bending inward when the weld is finished. To make a tack weld, strike an arc and
let it sit for a few seconds. 
 Flip your metal over to be welded.
 Strike an arc and create your root pass. This is going to be the first and deepest
pass on your weld, and if the metal is thick enough, the only pass you'll need.
 Clean the weld with a hammer and wire brush and make subsequent passes if
needed. These passes should strengthen the weld and fill it in. Make sure to clean
each pass before you start a new one.
KEY POINTS TO REMEMBER

• Be sure the welder is properly installed and grounded.

• Never weld without adequate ventilation.
• Take proper precautions to prevent fires.
• Protect your entire body with fire retardant clothing,
shoes, and gloves.

• Wear eye protection at all times.

• Weld only in a fire safe area.
• Never do any welding, cutting, or hot work on
used drums, barrels, tanks, or other containers.
• Keep a well stocked first aid kit handy.
Remember…
Safety First!

Thank You!!