Welding

 Welding joins two pieces of metal by the use of

heat, pressure, or both
 Health Hazards
 Welding “Smoke” is a mixture of very fine particles called fumes
and gases
 Include Chromium, nickel, arsenic, asbestos, manganese, silica,
beryllium, cadmium, nitrogen oxides, phosgene, acrolein, flourine
compounds, carbon monoxide, cobalt, copper, lead, ozone,
selenium, and zinc
 come from…Base material & filler material
 Coatings & paints
 Shielding gases & chemical reactions
 Process & consumables used
 Contaminants in the air
 Health Hazards
 smoke” can affect any part of the body, including the
lungs, heart, kidneys, & central nervous system
 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
 Ultraviolet rays given off by welding can react with
hydrocarbon solvents form phosgene gas may be deadly
 Short-term exposures
 irritate the eyes, nose, chest and respiratory tract
 coughing, wheezing, shortness of breath,
bronchitis, pulmonary edema, and pneumontis
 nausea, loss of appetite, vomiting, cramps, and
slow digestion
 Exposure to cadmium can be fatal in a short time
 Long-term exposures
 welders, flame cutters, and burners have shown that
welders have an increased risk of lung cancer…
 welding “smoke” can include cancer causing agents such
as…cadmium, nickel, beryllium, chromium, and arsenic
 Welders may experience a variety of chronic respiratory
problems, Bronchitis, asthma, pneumonia, emphysema,
pneumoconiosis, decreased lung capacity, silicosis, and
siderosis
 Long-term exposures
 Heart disease, skin diseases, hearing loss, chronic
gastritis, gastroduodentis, and ulcers of the stomach and
small intestine
 Reproductive risks
 Heat exposure…
Heat stress, heat stroke
 burns, eye injuries from hot slag, metal chips, sparks, and
hot electrodes
 Other Health Risks…
 Intense light can cause damage to retina
 Infrared radiation may damage the cornea and result in
cataracts
May include sandy or gritty eye, blurred vision, intense pain,
tearing, burning and headache
 Permanent eye damage
 Skin burns and 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
 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 Precautions
Always use dry gloves
Always wear rubber soled shoes
Always use insulating layers
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
 performed in areas free of combustible materials such
as trash, wood, paper, textiles, plastics, chemicals,
and flammable dusts, liquids and gases
 fire inspection
 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 accidently
 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
 A work area with limited access, little or no airflow, not
intended for continuous occupation
 Compressed Gas Hazards
 All cylinders should havecaps 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.
 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
 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
 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
Protective Clothing
 Eye protection
 Fire resistant gauntlet gloves
 Headcap
 High top hard toed shoes
 Leather apron
 Faceshield
 Flame retardant clothing
 Safety Glasses
 Safety helmet
 Ear plugs and/or muffs
 General Precautions
properly trained and qualified
Inspect work area for fire hazards before welding
Compressed gas cylinders should always be secured in
an upright position when not in use and handled with
extreme care
Gas cylinders should be stored at least 20 feet away from
flammable materials and heat sources
Must be specific to the hazard
Must be fitted, cleaned, stored and maintained in
accordance to regulation and manufacturers specs
 Other Precautions
Don’t weld on painted surfaces
Use water table to reduce noise
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