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Wielding

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Welding Safety Checklist

This checklist is designed to ensure safe welding operations. Complete it before starting any welding work. Mark each item as 'Yes' if compliant, 'No' if not, and 'N/A' if not applicable. Note any corrective actions needed.

I. Pre-Operation Checks

  • [ ] 1.1. Equipment Installation: All equipment is installed by a qualified electrician in conformance with Subpart S of this part [1].
  • [ ] 1.2. Disconnect Switch: A safety-type disconnecting switch or circuit breaker is conveniently located at or near the machine [1].
  • [ ] 1.3. Thermal Protection: Ignitron tubes are equipped with a thermal protection switch [1].
  • [ ] 1.4. Personnel Training: Workmen are properly instructed and competent to operate the equipment [1].
  • [ ] 1.5. Machine Shut-off: Proper switching equipment for shutting down the machines is provided [2].
  • [ ] 1.6. Manufacturer Instructions: Printed rules and instructions covering operation of equipment supplied by the manufacturers are strictly followed [2].
  • [ ] 1.7. Equipment Condition: Inspect the equipment daily to ascertain that it is in good condition [3].

II. Personal Protective Equipment (PPE)

  • [ ] 2.1. Head Protection: Head protection meeting the requirements of ANSI Z89.2-1971 is provided and used where there is exposure to possible high voltage electrical contact [4].
  • [ ] 2.2. Eye Protection: Eye protection meeting the requirements of OAR 437-002-0134(8)(b) is provided and used where foreign objects may enter the eyes [4].
  • [ ] 2.3. Hexavalent Chromium Exposure: Employees are protected from exposure to hexavalent chromium during stainless steel welding process [5].

III. General Safety Measures

  • [ ] 3.1. Shields: The hazard of flying sparks is eliminated by installing a shield guard of safety glass or suitable fire-resistant plastic at the point of operation [6].
  • [ ] 3.2. Additional Shields: Additional shields or curtains are installed as necessary to protect passing persons from flying sparks [6].
  • [ ] 3.3. Foot Switch Guards: All foot switches are guarded to prevent accidental operation of the machine [6].
  • [ ] 3.4. Electrode Holders: Electrode holders when not in use are so placed that they cannot make electrical contact with persons, conducting objects, fuel, or compressed gas tanks [2].
  • [ ] 3.5. Cables: Cables with splices within 10 feet (3 m) of the holder are not used [2].
  • [ ] 3.6. Grounding: Where technically practical, the secondary of all welding transformers used in multispot, projection, and seam welding machines is grounded [6].
  • [ ] 3.7. Ventilation: Flash welding machines are equipped with a hood to control flying flash [7].
  • [ ] 3.8. Fire Safety: Fire-resistant curtains or suitable shields are set up around the machine to protect operators of nearby equipment [7].

IV. Portable Welding Machines

  • [ ] 4.1. Counterbalance: All portable welding guns have suitable counterbalanced devices for supporting the guns, including cables, unless the design makes it impractical [6].
  • [ ] 4.2. Safety Chains: All portable welding guns, transformers, and related equipment suspended from overhead structures are equipped with safety chains or cables [6].
  • [ ] 4.3. Switch Guards: All initiating switches on the portable welding gun are equipped with suitable guards capable of preventing accidental initiation [7].
  • [ ] 4.4. Grounding: The secondary and case of all portable welding transformers are grounded [7].

V. Maintenance and Reporting

  • [ ] 5.1. Periodic Inspection: Periodic inspection is made by qualified maintenance personnel, and a certification record is maintained [7].
  • [ ] 5.2. Defect Reporting: The operator is instructed to report any equipment defects to his supervisor [7].
  • [ ] 5.3. Wet Machines: Machines which have become wet are thoroughly dried and tested before being used [2].
  • [ ] 5.4. Damaged Cables: Cables with damaged insulation or exposed bare conductors are replaced [2].

VI. Resistance Welding

  • [ ] 6.1. Low Voltage: All external weld initiating control circuits operate on low voltage, not over 120 volts, for the safety of the operators [1].
  • [ ] 6.2. Capacitor Welding: Stored energy or capacitor discharge type of resistance welding equipment and control panels involving high voltage are suitably insulated and protected by complete enclosures [1].
  • [ ] 6.3. Interlocks: All doors and access panels of all resistance welding machines and control panels are kept locked and interlocked to prevent access by unauthorized persons [1].
  • [ ] 6.4. Guarding: All press welding machine operations, where there is a possibility of the operator's fingers being under the point of operation, are effectively guarded [1].

VII. Emergency Stop Buttons and Safety Pins

  • [ ] 7.1. Stop Buttons: Two or more safety emergency stop buttons are provided on all special multispot welding machines, including 2-post and 4-post weld presses [6].
  • [ ] 7.2. Safety Pins: On large machines, four safety pins with plugs and receptacles (one in each corner) are provided so that when safety pins are removed and inserted in the ram or platen, the press becomes inoperative [6].

VIII. Post Welding

  • [ ] 8.1. Cool Down: Allow equipment to cool down before storage.
  • [ ] 8.2. Housekeeping: Ensure the work area is clean and free of flammable materials.

Notes/Corrective Actions: [Space for notes on corrective actions needed]

Inspector: [Inspector Name]

Date: [Date]

Supervisor Signature: [Signature]

7 source record(s)

Sources used for this answer

[1] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1566

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Source excerpt

<!-- image --> 2BDivision 2 Oregon Administrative Rules Oregon Occupational Safety and Health Division - (1) Installation. All equipment shall be installed by a qualified electrician in conformance with Subpart S of this part. There shall be a safety-type disconnecting switch or a circuit breaker or circuit interrupter to open each power circuit to the machine, conveniently located at or near the machine, so that the power can be shut off when the machine or its controls are to be serviced. - (2) Thermal protection. Ignitron tubes used in resistance welding equipment shall be equipped with a thermal protection switch. - (3) Personnel. Workmen designated to operate resistance welding equipment shall have been properly instructed and judged competent to operate such equipment. - (4) Guarding. Controls of all automatic or air and hydraulic clamps shall be arranged or guarded to prevent the operator from accidentally activating them. - (b) Spot and seam welding machines (nonportable). - (1) Voltage. All external weld initiating control circuits shall operate on low voltage, not over 120 volts, for the safety of the operators. - (2) Capacitor welding. Stored energy or capacitor discharge type of resistance welding equipment and control panels involving high voltage (over 550 volts) shall be suitably insulated and protected by complete enclosures, all doors of which shall be provided with suitable interlocks and contacts wired into the control circuit (similar to elevator interlocks). Such interlocks or contacts shall be so designed as to effectively interrupt power and short circuit all capacitors when the door or panel is open. A manually operated switch or suitable positive device shall be installed, in addition to the mechanical interlocks or contacts, as an added safety measure assuring absolute discharge of all capacitors. - (3) Interlocks. All doors and access panels of all resistance welding machines and control panels shall be kept locked and interlocked to p

[2] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1736

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Oregon Occupational Safety and Health Division - (9) Lead work. The wiping of lead joints using melted solder, gas fueled torches, soldering irons or other appropriate heating devices, and the soldering of wires or other electrical connections do not constitute the welding, cutting and brazing described in Subpart Q of this part. When operated from commercial power the metal housing of electric solder pots shall be grounded. Electric solder pots may be used with the power equipment described in paragraph (i)(5) of this section without a grounding conductor. The employer shall ensure that wiping gloves or cloths and eye protection are used in lead wiping operations. A drip pan to catch hot lead drippings shall also be provided and used. ## [redacted phone] (6)(b) Chain saw usage - (A) Chain saws shall be inspected prior to use and kept in good repair at all times. Saws with defective parts shall not be used. - (B) Chain saw engines shall be shut off while being fueled. - (C) Chain saws shall be equipped with an automatic throttle control which will return the engine to idling speed upon release of the throttle. - (D) All employees using chain saws shall wear flexible ballistic nylon pads or other equivalent protection sewn or otherwise fastened to the trousers, which will protect the legs from the thigh to below the knee, except when working from an aerial lift device. - (E) Chain saws shall not be brought into a bucket or work platform of an aerial lift device. Saws shall be carried on the outside of the aerial lift device. Chain saws shall be started and used only outside of the aerial lift device. - 1910.268 (j) Vehicle-mounted material handling devices and other mechanical equipment. - (1) General. - (i) The employer shall ensure that visual inspections are made of the equipment by a competent person each day the equipment is to be used to ascertain that it is in good condition. - (ii) The employer shall ensure that tests shall be made at the beginning of each

[3] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1568

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Source excerpt

<!-- image --> 2BDivision 2 Oregon Administrative Rules Oregon Occupational Safety and Health Division - (4) Switch guards. All initiating switches, including retraction and dual schedule switches, located on the portable welding gun shall be equipped with suitable guards capable of preventing accidental initiation through contact with fixturing, operator's clothing, etc. Initiating switch voltage shall not exceed 24 volts. - (5) Moving holder. The movable holder, where it enters the gun frame, shall have sufficient clearance to prevent the shearing of fingers carelessly placed on the operating movable holder. - (6) Grounding. The secondary and case of all portable welding transformers shall be grounded. Secondary grounding may be by center tapped secondary or by a center tapped grounding reactor connected across the secondary. - (d) Flash welding equipment. - (1) Ventilation and flash guard. Flash welding machines shall be equipped with a hood to control flying flash. In cases of high production, where materials may contain a film of oil and where toxic elements and metal fumes are given off, ventilation shall be provided in accordance with 1910.252(c) of this part. - (2) Fire curtains. For the protection of the operators of nearby equipment, fire-resistant curtains or suitable shields shall be set up around the machine and in such a manner that the operators movements are not hampered. - (e) Maintenance. Periodic inspection shall be made by qualified maintenance personnel, and a certification record maintained. The certification record shall include the date of inspection, the signature of the person who performed the inspection and the serial number, or other identifier, for the equipment inspected. The operator shall be instructed to report any equipment defects to his supervisor and the use of the equipment shall be discontinued until safety repairs have been completed. [39 FR [redacted postal code], June 27, 1974, as amended at 40 FR [redacted postal code

[4] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1567

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Source excerpt

<!-- image --> Oregon Occupational Safety and Health Division 2BDivision 2 - (5) Shields. The hazard of flying sparks shall be, wherever practical, eliminated by installing a shield guard of safety glass or suitable fireresistant plastic at the point of operation. Additional shields or curtains shall be installed as necessary to protect passing persons from flying sparks. (See 1910.252(b)(2)(i)(C) of this part.) - (6) Foot switches. All foot switches shall be guarded to prevent accidental operation of the machine. - (7) Stop buttons. Two or more safety emergency stop buttons shall be provided on all special multispot welding machines, including 2-post and 4-post weld presses. - (8) Safety pins. On large machines, four safety pins with plugs and receptacles (one in each corner) shall be provided so that when safety pins are removed and inserted in the ram or platen, the press becomes inoperative. - (9) Grounding. Where technically practical, the secondary of all welding transformers used in multispot, projection and seam welding machines shall be grounded. This may be done by permanently grounding one side of the welding secondary current circuit. Where not technically practical, a center tapped grounding reactor connected across the secondary or the use of a safety disconnect switch in conjunction with the welding control are acceptable alternates. Safety disconnect shall be arranged to open both sides of the line when welding current is not present. - (c) Portable welding machines. - (1) Counterbalance. All portable welding guns shall have suitable counterbalanced devices for supporting the guns, including cables, unless the design of the gun or fixture makes counterbalancing impractical or unnecessary. - (2) Safety chains. All portable welding guns, transformers and related equipment that is suspended from overhead structures, eye beams, trolleys, etc., shall be equipped with safety chains or cables. Safety chains or cables shall be capable of supporting the to

[5] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 303

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Source excerpt

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ ## WAC 296-24-680 Welding, cutting, and brazing. You must protect employees from exposure to hexavalent chromium during the stainless steel welding process. See WAC 296-62-[redacted postal code], Hexavalent chromium for specific criteria. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), § 296-24-680, filed 12/01/2015, effective 01/05/2016. Statutory Authority: RCW 49.17.010, .040, .050, and .060. 06-16-106 (Order 06-13), § 296-24-680, filed 08/12/06, effective 09/01/06. Statutory Authority: RCW 49.17.010, .040, .050, and .060. Order 73-5, 296-24-680, filed 5/9/73 and Order 73-4, 296-24-680, filed 5/7/73.] ## WAC 296-24-[redacted postal code] Definitions. Welder and welding operator . Any operator of electric or gas welding and cutting equipment. Approved . Listed or approved by a nationally recognized testing laboratory. Refer to WAC 296-24-[redacted postal code](19) for definitions of listed and approved, and federal regulation 29 CFR 1910.7 for nationally recognized testing laboratory. All other welding terms are used in accordance with American Welding Society-Terms and Definitions-A3.0-1969. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), § [redacted identifier], filed 12/01/2015, effective 01/05/2016. Statutory Authority: Chapter 49.17 RCW. 88-23-054 (Order 88-25), 296-24-[redacted postal code], filed 11/14/88; Order 73-5, 296-2468001, filed 5/9/73 and Order 73-4, 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-682 Installation and operation of oxygen fuel gas systems for welding and cutting. [Order 73-5, 296-24-682, filed 5/9/73 and Order 73-4, 296-24-682, filed 5/7/73.] ## WAC 296-24-[redacted postal code] General requirements. - (1) Flam

[6] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1734

Open source document

Source excerpt

Oregon Occupational Safety and Health Division - (1) Head protection. Head protection meeting the requirements of ANSI Z89.2-1971, 'Safety Requirements for Industrial Protective Helmets for Electrical Workers, Class B' shall be provided whenever there is exposure to possible high voltage electrical contact, and the employer shall ensure that the head protection is used by employees. ANSI Z89.2-1971 is incorporated by reference as specified in 1910.6. - (2) Eye protection. Eye protection meeting the requirements of OAR 437-0020134(8)(b) shall be provided and the employer shall ensure its use by employees where foreign objects may enter the eyes due to work operations such as but not limited to: - (i) Drilling or chipping stone, brick or masonry, breaking concrete or pavement, etc. by hand tools (sledgehammer, etc.) or power tools such as pneumatic drills or hammers; - (ii) Working on or around high speed emery or other grinding wheels unprotected by guards; - (iii) Cutting or chipping terra cotta ducts, tile, etc.; - (iv) Working under motor vehicles requiring hammering; - (v) Cleaning operations using compressed air, steam, or sand blast; - (vi) Acetylene welding or similar operations where sparks are thrown off; - (vii) Using powder actuated stud drivers; - (viii) Tree pruning or cutting underbrush; - (ix) Handling battery cells and solutions, such as taking battery readings with a hydrometer and thermometer; - (x) Removing or rearranging strand or open wire; and - (xi) Performing lead sleeve wiping and while soldering. - (3) Tent heaters. Flame-type heaters may not be used within ground tents or on platforms within aerial tents unless: - (i) The tent covers are constructed of fire resistant materials, and - (ii) Adequate ventilation is provided to maintain safe oxygen levels and avoid harmful buildup of combustion products and combustible gases.

[7] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1565

Open source document

Source excerpt

<!-- image --> Oregon Occupational Safety and Health Division Oregon Administrative Rules 2BDivision 2 - (5) Switches. It shall be determined that proper switching equipment for shutting down the machines is provided. - (6) Manufacturers' instructions. Printed rules and instructions covering operation of equipment supplied by the manufacturers shall be strictly followed. - (7) Electrode holders. Electrode holders when not in use shall be so placed that they cannot make electrical contact with persons, conducting objects, fuel or compressed gas tanks. - (8) Electric shock. Cables with splices within 10 feet (3 m) of the holder shall not be used. The welder should not coil or loop welding electrode cable around parts of his body. - (9) Maintenance. - (i) The operator should report any equipment defect or safety hazard to his supervisor and the use of the equipment shall be discontinued until its safety has been assured. Repairs shall be made only by qualified personnel. - (ii) Machines which have become wet shall be thoroughly dried and tested before being used. - (iii) Cables with damaged insulation or exposed bare conductors shall be replaced. Joining lengths of work and electrode cables shall be done by the use of connecting means specifically intended for the purpose. The connecting means shall have insulation adequate for the service conditions. [55 FR [redacted postal code], Apr. 11, 1990, as amended at 61 FR 9241, Mar. 7, 1996; 70 FR [redacted postal code], Sept. 13, 2005] Stat. Auth.: ORS 654.025(2) and ORS 656.726(4). Stats. Implemented: ORS 654.001 through 654.295. Hist: OR-OSHA Admin. Order 23-1990, f. 9/28/90, ef. 12/1/90. OR-OSHA Admin. Order 4-1997, f. 4/2/97, ef. 4/2/97. OR-OSHA Admin. Order 4-2005, f. 12/14/05, ef. 12/14/05. ## 1910.255 Resistance Welding - (a) General.

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