Types of Welding Hazards
Arc Radiation
- Produces ultraviolet, infrared, and visible light radiation
- Can cause "welder's flash" (photokeratitis) - painful eye inflammation
- Can burn skin similar to severe sunburn
- Long-term exposure increases risk of cataracts
- Can cause permanent eye damage without proper protection
Fumes and Gases
- Metal fumes from vaporized welding materials
- Shielding gases (argon, helium, carbon dioxide)
- Coating and flux decomposition products
- Base metal contaminants (lead, zinc, cadmium)
- Gases from heat effects on cleaners or degreasers
- Carbon monoxide from incomplete combustion
Electrical Hazards
- Electric shock from welding equipment
- Secondary voltage shock (up to 100 volts)
- Primary voltage shock (230-575 volts)
- Damaged insulation or cables
- Wet conditions increasing shock risk
- Contact with electrically "hot" parts
Fire and Explosions
- Sparks and spatter can travel up to 35 feet
- Hot work on containers that held flammable materials
- Ignition of combustible materials in work area
- Oxygen-enriched atmospheres
- Gas leaks from cylinders or hoses
- Confined spaces with flammable vapors
Physical Hazards
- Burns from hot metal and spatter.
- Cuts from sharp metal edges
- Crushing injuries from falling cylinders
- Trips and falls in work area
- Ergonomic stresses from awkward positions
- Noise from welding and cutting operations
Personal Protective Equipment
Eye and Face Protection
- Welding helmet with proper shade number:
- Shade 10-14 for arc welding (higher for higher amperage)
- Shade 4-8 for gas welding and cutting
- Safety glasses with side shields under helmet
- Face shield for grinding and chipping
- UV-filtering safety glasses when in welding areas
- No contact lenses (can trap particles)
Skin Protection
- Flame-resistant clothing (FR cotton, leather, or wool)
- Leather gloves extending over wrists
- High-top leather boots
- Leather jacket or sleeves for overhead work
- Pant legs over boot tops (no cuffs)
- Head coverings for overhead welding
- No pockets or cuffs that can catch sparks
Respiratory Protection
- Proper ventilation is first line of defense
- N95 minimum for nuisance metal fumes
- Half-face respirator with P100 filters for heavy fume exposure
- Supplied air systems for confined spaces or toxic metals
- Powered air-purifying respirators for long-term work
- Proper fit testing required
- Clean and maintain as directed
Hearing Protection
- Earplugs or earmuffs rated for noise level
- Consider dual protection in very noisy environments
- Ensure hearing protection is compatible with welding helmet
- Fire-resistant hearing protection
- Regular hearing tests for welders
Fire Prevention
Before Welding
- Obtain hot work permit if required
- Inspect area for combustibles within 35 feet
- Cover combustibles that cannot be moved
- Cover or seal floor openings
- Place fire-resistant shields to protect nearby workers
- Have fire extinguishers immediately available
- Assign a fire watch if necessary
- Know location of fire alarms and exits
- Ensure proper ventilation
During Welding
- Maintain fire watch during welding operations
- Keep fire extinguisher within immediate reach
- Don't weld near flammable materials or vapors
- Be aware of where sparks are landing
- Position yourself to direct sparks away from hazards
- Monitor wind direction when working outdoors
- Keep cylinders away from heat sources
After Welding
- Inspect area for smoldering materials
- Maintain fire watch for at least 30 minutes
- Check behind walls, floors, and ceilings
- Look for sparks that may have entered openings
- Verify no hot materials are left unattended
- Document fire watch completion if required
- Return fire prevention equipment
Ventilation and Air Quality
Natural Ventilation
- Only sufficient in large open areas
- Minimum 10,000 cubic feet per welder
- No structural barriers to air movement
- Not adequate for confined spaces
- Not sufficient for toxic metals (lead, cadmium, etc.)
- Position yourself to avoid breathing fumes
Mechanical Ventilation
- Local exhaust preferred (captures fumes at source)
- General dilution ventilation as backup
- Minimum airflow: 100-150 cubic feet per minute
- Position movable hoods 4-6 inches from work
- Keep your head out of the fume plume
- Ensure exhaust doesn't contaminate other areas
- Regular maintenance of ventilation systems
Special Ventilation Requirements
- Confined spaces require forced ventilation
- Toxic coatings require additional exhaust
- Stainless steel welding needs higher ventilation rates
- Galvanized metal produces zinc oxide requiring extra ventilation
- Degreased metals with chlorinated solvents need special ventilation
- Monitor air quality in confined or enclosed spaces
Cylinder Safety
Storage and Handling
- Secure cylinders upright with chain or bracket
- Keep valve caps in place when not in use
- Transport using proper cart with chains
- Keep cylinders away from heat sources
- Store oxygen and fuel gas cylinders separately
- Never lift cylinders by their valves or caps
- Never use cylinders as rollers or supports
Oxygen Cylinder Safety
- Keep oil and grease away from oxygen equipment
- Never use oxygen as compressed air
- Open valve slowly and stand to the side
- Store at least 20 feet from fuel gases or use barrier
- Use only approved regulators and connections
- Handle with clean gloves free of oil or grease
- Check for leaks with approved leak detection solution
Fuel Gas Cylinder Safety
- Always open acetylene valves less than one full turn
- Use only with approved regulators
- Keep acetylene pressure below 15 psi
- Store upright to keep acetone distributor functional
- Use only approved hoses and fittings
- Purge lines before lighting torch
- Never use copper fittings with acetylene
Safe Welding Practices
Equipment Inspection
- Check cables for exposed conductors
- Verify proper grounding
- Inspect hoses for cracks or leaks
- Test regulators and gauges for function
- Ensure all connections are tight
- Check electrode holder insulation
- Inspect torch tips and valves
Work Area Setup
- Use welding curtains or screens to protect others
- Keep work area dry to prevent shock
- Remove trip hazards from work area
- Ensure adequate lighting
- Position work to prevent awkward postures
- Secure work pieces properly
- Keep cables and hoses organized
Electrical Safety
- Use insulated electrode holders
- Wear dry gloves and clothing
- Never weld in wet conditions
- Use insulating mats when necessary
- Properly ground the work piece
- Turn off power when not in use
- Keep cables away from power cords
Hot Work Permits
- Required for welding outside designated areas
- Document hazard assessment
- Specify required precautions
- List responsible persons
- Include fire watch requirements
- Note time restrictions
- Requires authorization signatures
Special Welding Situations
Confined Space Welding
- Obtain confined space permit
- Test atmosphere before entering
- Ensure continuous ventilation
- Station attendant outside space
- Have rescue equipment available
- Use low-voltage equipment when possible
- Inspect all equipment thoroughly
- Keep gas cylinders outside the space
Overhead Welding
- Wear additional protection (fire-resistant head covering)
- Use screens to protect workers below
- Warn others in area
- Clear area below of combustibles
- Have helper watch for falling sparks
- Take frequent breaks to prevent fatigue
- Use platforms or lifts properly
Welding on Containers
- Never weld on containers that held flammable substances
- Clean and purge thoroughly
- Test atmosphere for explosive gases
- Fill with water when possible
- Use inert gas purging for closed vessels
- Have container certified safe before welding
- Maintain ventilation during work
Welding Different Metals
- Know specific hazards of base metals:
- Zinc (galvanized): Metal fume fever
- Lead: Neurological damage
- Cadmium: Respiratory and kidney damage
- Beryllium: Chronic lung disease
- Chromium (stainless steel): Cancer risk
- Adjust ventilation based on material
- Select proper respiratory protection
- Use correct welding process for metal
First Aid for Common Welding Injuries
Arc Flash (Welder's Flash)
- Remove contact lenses
- Rinse eyes with clean water
- Apply cold compress
- Avoid rubbing eyes
- Seek medical attention
- May take 6-12 hours for symptoms to appear
- Use artificial tears as recommended
Burns
- Cool burn with clean, cool water
- Cover with dry, clean dressing
- Don't apply creams, ointments, or butter
- Don't break blisters
- Remove jewelry near burned area
- Seek medical attention for severe burns
- Watch for signs of infection
Electrical Shock
- Call for emergency help
- Turn off power if possible
- Check breathing and pulse
- Begin CPR if necessary and trained
- Treat for shock (lay flat, maintain body temperature)
- Don't move victim unless necessary
- Seek medical attention even if shock seems minor