Welding safety statistics are alarming. According to the Bureau of Labor Statistics, more than five hundred and sixty thousand workers are injured in welding accidents each year, which is about one thousand welding accidents per one hundred million hours worked.
This is a hundred times higher than the average injury rate for other workers, indicating the even greater importance of welding safety. Welding is a very hazardous activity, and there is a lot to be learned to protect workers from welding hazards.
In this article, we will look at the hazards that occur in welding and learn how workers should be protected against these hazards.
What OSHA standards apply to welding safety?
The Occupational Safety and Health Administration (OSHA) has established several welding, brazing, and cutting standards for various industries in 29 CFR – 1910:
- General – 1915;
- Marine – 1926;
Generally speaking, such standards provide safety guidelines for the safe use of personal protective equipment (PPE) and fire protection around the workplace.
- General industrial production (29CFR 1910) – Arc welding/cutting – 254
- Construction Industry (29CFR 1926) – Arc welding/cutting – 35
- Marine (29CFR 1915) – Gas Welding/Cutting – 55; – Arc welding/cutting – 254; – Oxygen gas welding/cutting – 253
For the various fire hazards at each job site, inspect the job site and make a plan to improve the welding safety of both the professional and the protect nearby workers.
What dangers are welders exposed to?
The biggest hazard that welders are exposed to is fire. Such an important point that ensuring fire safety in welding machines(equipment) is a serious problem for a key place in the system of ensuring reliable safe operation.
When performing hot work involving welding, before starting work, remove all combustible items out of the area to be welded. In places in which they cannot be erased, they must be securely protected from penetration by fire or sparks. Employees should also take care that their equipment, and belongings, such as clothing and gas cylinders, are fire prevention.
The possibility of hazardous chemicals being released during welding operations is another hazard. Professional welding safety features dedicated guidelines for working with the possible release of gas emissions when using chromium. While working on these metals, welders are required to use proper breathing apparatus protection.
In addition, welders can cut themselves, injure their eyes, burn themselves or crush their limbs. Using proper PPE is by far the safest way to keep workers safe.
The welders may as well be vulnerable to electrocution. Arc welding is the most common type of injury, with voltages ranging from twenty to one hundred volts. An electrical shock of fifty volts or less can cause injury or death to an employee, subject to the terms of.
How do personal protective measures need to be worn when welding?
Safety and Health Administration Standard Part One, 1910, describes in more detail the use of special protective gear during any welding activities.
The protection of the head, hands, and feet must be provided by employers. The employer should also take the necessary preventative measures to ensure that no hazardous welding fumes are generated in the welding area, such as installing the exhaust ventilation system to eliminate harmful air and providing adequate ventilation.
Safety glasses for eye protection and more
Welders should wear eye and face protection to fire prevention eye injuries. Welding burns are is a widespread state of affairs resulting from exposure to large amounts of ultraviolet radiation. It can lead to temporary blindness and serious eye disease. Normal safety glasses do not offer sufficient protection.
Welding helmets protect the operator from light rays and are classified by the amount of light transmitted. Helmets are classified on a sliding scale according to the DIN classification. The higher the number, the tighter the filter. All employees have a choice of the black class depending on the nature of their work.
The helmet will be protecting the welders as well from splinters and hot metal, and chemicals. Contemporary helmets are made of more lightweight materials for easier handling. This reduces the fatigue and pain that make workers reluctant to wear them.
Many welders use an earplug as it does not disturb other individual protective equipment they wear. Modern hearing aids are comfortable to wear and provide reliable protection.
You need to protect your feet following ASTM F-2412/13-2005, ANSI Z41-1999/91. Workers shall be protected from injuries induced as a result of falling or sliding items, static electricity, and electrocution. It should be noted that the leg guards required for most welding applications are listed in the ASTM standards referenced by OSHA.
OSHA’s general individual protective equipment requirements for construction work also require welding gloves made out of leather, a welding jacket, and sleeves of cotton. Inserts and earplugs may also protect workers from noise.
How Does a Welding Safety Zone Look Like?
To protect the welding environment and the employee himself/herself from dangerous fumes, the danger of heating, and fire, it is recommended to ensure an effectively protected safety zone for the weld.
With this in mind, it is important to remove flammable substances (flammable materials) if possible from the area. Otherwise, it is necessary to apply barriers, if this is not possible. To ensure a high level of protection against light radiation as well as sparks, workers must wear PPE according to safety regulations. In addition, employees must use a mask or a respirator if they can be a risk of hazardous welding fumes.
What are some basic safety tips for ensuring the safety of welders?
1. Need to know your equipment
You must familiarize yourself with the operating and safety manuals for the welding equipment to be used. They contain essential safety information as well as the necessary recommendations to ensure the high performance of the equipment. Safety standards should be followed and the PPE requirements for the activities to be performed should be known.
2. It is important to pay attention to the provision of local exhaust ventilation
To minimize exposure to harmful impurities in the ambient air, it is necessary to use an engineering method of control. The local exhaust ventilation system provides interception of emissions at the source and transports pollutants outside the workspace. This system may include an exhaust hood, ductwork, air transport device, and exhaust disposal site.
If no information is available on the presence of atmospheric hazards, an exposure assessment should be conducted.
3. Secure clothing.
Sparks and other particles can enter open pockets, shirt cuffs, or pant pockets. Be sure to button up your shirt to avoid sparks collar, lapels, and pockets, and cover vulnerable skin areas.
4. Be properly dressed.
Do not dress in shorts or shirts with short sleeves. It is important to wear clothing made of noncombustible, durable material, such as fire-resistant material (another name for “fire-resistant leggings”).
5. Use a protective respirator if necessary.
Toxic fumes may be produced when working in a confined space or using any materials. An exhaust device can be used to remove the fumes from the room. Respirators are often needed for certain types of materials or certain types of areas.
Wear the right welding helmet
To protect against light radiation, it is important to take care that there is sufficient shading. Therefore, remember to make sure that the welding helmet is the right size and provides sufficient protection against light radiation. Automatic blackout helmets were also available that are equipped complete with transducers that switch colors in a split second. Such helmets must comply with ANSI Z87.1-2003.
With these safety tips in mind, you can ensure a high level of safety when welding with flammable materials.
What are specific examples of welding safety violations?
The Connecticut contractor was sued by the court for failing to correct the defects found in the previous inspection and was fined more than hundred and sixty-seven thousand dollars. Violations included: inadequate protective coating during welding, lack of proper fire extinguishers, inadequate information about hazardous chemicals in the workplace, inadequate guardrails, and inadequate machinery safety equipment. The company was also fined for obstructing access to control panels.
There is a famous example of a health and safety violation: On one occasion, a Florida tank manufacturing company was fined one hundred and six thousand dollars for this very reason. This company committed twenty-three violations that exposed employees to poisonous chromium fumes. Chromium hurts humans, affecting their organs. Workers’ exposure to chromium exceeded the OSHA eight-hour exposure limit. The company has also not provided workers with proper medical care, respirators, and protection from the welding arc’s ultraviolet radiation.
Two Mississippi workers died because of an explosion caused by methane gas and hydrogen sulfide. The workers were not trained to recognize the presence of explosive gas in underground tanks, and the four companies were charged with a range of violations, from not training workers to failure to provide the appropriate protective equipment when carrying out welding work.
Smart software for welding safety
The employer and safety manager needs to ensure the proper level of occupational health and safety to eliminate errors and keep workers healthy safe training and individual protective equipment. Keeping track of PPE training and practice will help you prevent violations and avoid possible fines.
SafeSite will help you keep safety records to ensure compliance. For example, hot metal work and weld tracking templates can help you monitor weld safety. In the unlikely event that a problem occurs, it can be reported immediately to the appropriate personnel so that it can be corrected and the production schedule can be maintained. For more information, download the free individual Protective Equipment Management and Maintenance app.
Is welding a dangerous job?
Welding is a dangerous occupation if safety precautions are not taken. Failure to take precautions can expose welders to a variety of hazards, including harmful fumes and gases, electrocution, fires, and explosions.
Is it acceptable for firefighters to refuse to wear helmets or for doctors not to wear gloves during critical operations? Of course not. Even welders must follow certain rules to protect themselves and others.
Why welding safety is important
Welding presents many potential hazards, so it is important to ensure welder safety by taking the following steps:
- Follow all manufacturer’s recommendations
- Analyzing the environment
- Make sure other people are not put at risk while working
- Use tools and equipment as intended
Accidents happen, but many injuries can be avoided by knowing the rules and prohibitions for working in a welding environment. Before starting a project, welders must make sure they know how to work safely. This is the most important thing they can do to protect themselves and their loved ones.
Safety in the welding shop: Risks to Avoid
As mentioned earlier, welders face many potential hazards in the workplace, so safety in the welding shop is extremely important. Some of the most common hazards include:
- Electrical Injury. A sudden electric shock can cause serious injury and in some cases death. An electrical injury can occur when a welder touches two metal objects, creating an electrical circuit between them. The higher the voltage, the greater the amperage, which increases the risk of electric shock to the welder.
- Fume and gas exposure. Welding fumes contain several potentially hazardous metals, including aluminum, beryllium, arsenic, manganese, and lead. In addition, there are gases, such as nitrogen, oxygen, carbon dioxide, carbon monoxide, and hydrogen fluoride, that are commonly generated during welding.
Excessive exposure of welders to these fumes and gases can lead to serious health problems such as speech and motor disorders, respiratory problems, and even cancer.
- Fire and explosion. The welding arc creates very high temperatures and can cause fires and explosions if precautions are not taken. The arc itself can reach as high as 10,000 degrees Fahrenheit, but the commonest cause of the fire is sparks or droplets falling on combustible materials near the work area.
- Physical hazards(injuries). Crushing fingers and toes and other injuries such as burns, cuts, and eye injuries can occur if welders do not use proper PPE (personal protective equipment). These injuries need to be taken seriously because in some cases they can cause the welder to lose his or her job.
A few welding safety rules
How can you prevent such dangers? Here are recommendations for welding safety:
Learn as much as you can
The most successful welders know safety like the back of their hands. They take the time to familiarize themselves with the safety practices of the national organization and the company they work for to ensure a safe and productive workplace for all.
It is also important that welders study the manufacturer’s instructions before working with any equipment. Welders should never assume that they know how to use a piece of equipment before they have read and understood the manufacturer’s recommendations for its safe use.
Protection from fumes and gases
Exposure to fumes and gases can be controlled by ensuring that the work site is properly ventilated. Some employers provide fans, exhaust ventilation, and extraction equipment to remove fumes and gases from welders’ work sites.
If necessary, welders should wear a respirator to prevent inhalation of hazardous substances.
If breathing is difficult, notify the supervisor immediately.
Observe safety precautions in case of electric shock
Electrocution is one of the most important points in welder training because it can result in immediate and serious danger.
Welders should always check that the electrode holder is in good working order before welding to avoid the risk of electrocution. They should also ensure that gloves are dry and in good condition, that wet skin or clothing does not touch the metal parts of the electrode holder, and that dry insulation is maintained between the body and the ground or metal being welded.
Checking the equipment
The proper welder will always check that equipment is properly grounded before using it. Even experienced welders should regularly check equipment for normal wear and tear, which can increase the risk of accidents, such as worn wires or leaking hoses.
If the equipment was in perfect working order the day before, don’t assume that it will be in the same condition today. Also, always inspect the equipment thoroughly before using it.
Avoid clutter
A cluttered work area is one of the most common causes of welding fires and explosions. Sparks from a welding arc can travel up to 10 meters, so it is especially important to keep the work area clear and free of combustible materials.
In general, always keep things tidy and put everything in its place. Place only the tools and equipment used for the project in the work area.
Familiarize yourself with your surroundings
Familiarize yourself with your surroundings before you start the welding process. Knowing the location of tools and equipment not only flame-resistant clothing and increases efficiency, but is also very important from a safety perspective. For example, it is important to know the location of equipment needed to extinguish a fire, such as fire alarms, emergency exits, fire extinguishers, and sand buckets.
Wear appropriate clothing for the job
Welding operators must wear appropriate clothing. Exposed skin is more sensitive to infrared and ultraviolet radiation, so welders should always be fully covered. It’s also important to make sure cuffs and pant pockets are properly cut, as loose clothing can cause sparks to roll off.
What type of clothing is needed? Welders should wear flame-resistant clothing and appropriate PPE.
Wear the right personal protective equipment
Choosing the right PPE for your job is one of the most important decisions you can make to protect yourself as a welder. The following is a brief description of the types of PPE welders should wear.
- Hearing protection: Protective equipment should be used if the measured noise level exceeds 85 dB on average over 8 hours.
- Safety glasses, eye, face, and ear protection. This includes safety glasses, a face shield, and, depending on the project, a helmet.
- Heat and radiation protection: welders must wear flammable material-resistant outerwear, gloves to protect hands and forearms, headgear, and welding goggles.
- Fume protection: using hoods and respirators can protect welders from harmful fumes.
- Electrocution Prevention: In addition to the welding precautions described in item 3, insulating clothing (welding jackets) should be worn to prevent electrocution.
- Foot Protection. Spark and heat-resistant leather shoes with turned ankles provide the best foot protection. Trouser legs should not extend beyond the shoe.
Avoid stress injuries
When welding operation, you are engaged in a hands-on activity that can result in injury if the necessary precautions are not taken. To protect yourself, always use safe lifting techniques, warm up, and take breaks between jobs. This will help you avoid the repetitive micro-injuries that some welders are prone to.
Warning: avoid repetitive stress injuries.
Never forget your safety belts to ensure proper safety measures.
Apply safety procedures
Welders themselves and their co-workers must follow safety procedures. If you notice a safety violation, it is in your best interest and that of your colleagues with whom you work in the same workplace to report it. If you feel that your workplace is unsafe, do not hesitate to say so.
Keep learning
As technology changes, so do the welding industry. As manufacturers introduce new equipment and technology, it is important to keep learning best practices to ensure your competence and welding safety.
Other resources
It is very important to mark the hot metal or provide other ways to notify other employees when the welding operations are complete. When it comes to welding safety, it’s better to take extra precautions. These safety guidelines have been prepared as a starting point, and it is important to continually obtain information from reliable sources in the industry.
