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Welding hazards

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Welding Safety ==============

Date: 2025-09-07

Duration: \[DURATION] minutes

Presenter: \[PRESENTER NAME]

Location: \[LOCATION]

Objective

To understand the hazards associated with welding operations and implement necessary safety precautions to prevent injuries and illnesses.

Introduction

Welding is a joining process in which metals, or sometimes plastics, are heated, melted and mixed to produce a joint with properties similar to those of the materials being joined. There are over 70 different welding processes. The type of welding process used is related to the specific application. The most common processes are Shielded Metal Arc Welding (SMAW), Gas Tungsten Arc Welding (GTAW), Gas Metal Arc Welding (GMAW), Flux Cored Arc Welding (FCAW). Health and safety hazards are always present. [1] [6]

Key Points

  • Hazard Awareness: Understanding the specific hazards associated with welding, such as fumes, radiation, electric shock, and fire, is crucial for prevention.
  • Ventilation: Adequate ventilation is essential to remove harmful fumes and gases from the welding area. Use local exhaust ventilation or general ventilation systems. [7]
  • Personal Protective Equipment (PPE): Using appropriate PPE, including welding helmets, gloves, and protective clothing, is vital for protecting against burns, radiation, and other hazards. [7]
  • Fire Safety: Maintaining a fire-safe environment by removing flammable materials and having fire extinguishers readily available is essential to prevent fires. [5]
  • Electrical Safety: Ensuring proper grounding and avoiding contact with live electrical parts can prevent electric shock. [1]
  • Confined Spaces: When welding in confined spaces, ensure proper ventilation and follow specific safety procedures to mitigate the risks of toxic fume buildup and oxygen deficiency. [8]
  • Equipment Inspection: Regularly inspect welding equipment for defects and ensure it is properly maintained to prevent malfunctions and accidents. [2]
  • Safe Work Practices: Adhering to safe work practices, such as proper lifting techniques and avoiding awkward positions, can reduce the risk of ergonomic injuries. [7]

Hazard Identification

Welding operations present several hazards that can lead to injuries and illnesses if not properly controlled.

  • Exposure to Welding Fumes and Gases: Respiratory irritation, metal fume fever, lung cancer, and other respiratory illnesses. [1]
  • Ultraviolet (UV) Radiation: Skin and eye damage, including burns and welder's flash (arc eye). [3]
  • Electric Shock: Severe burns, cardiac arrest, and electrocution. [1]
  • Fire and Explosions: Burns, property damage, and serious injuries due to flammable materials igniting. [1]
  • Ergonomic Hazards: Strains, sprains, and musculoskeletal disorders from lifting heavy objects and working in awkward positions. [3]

Control Measures

  • Use Local Exhaust Ventilation: Install and maintain local exhaust ventilation systems to capture fumes and gases at the source. [1]
  • Wear Appropriate PPE: Always wear a welding helmet with the correct shade of lens, gloves, and protective clothing to shield against radiation, burns, and sparks. [7]
  • Ensure Proper Grounding: Ground welding equipment and workpieces to prevent electric shock. [4]
  • Remove Flammable Materials: Clear the welding area of all flammable materials or cover them with fire-resistant materials. [5]
  • Provide Fire Extinguishers: Keep a minimum of one 2A-10BC portable fire extinguisher readily available in the welding area. [5]
  • Implement Safe Lifting Techniques: Use proper lifting techniques and equipment to avoid strains and sprains. [7]

Personal Protective Equipment (PPE) Requirements

  • Welding Helmet: Always wear a welding helmet with the correct shade of lens to protect your eyes and face from UV radiation and sparks. [7]
  • Welding Gloves: Wear fire-resistant gloves to protect your hands from burns and sparks. [9]
  • Protective Clothing: Wear fire-resistant clothing, such as a leather apron and sleeves, to protect your body from burns and sparks. [9]
  • Safety Glasses: Wear safety glasses with side shields under your welding helmet to protect your eyes from flying particles. [3]

Real-World Example or Case Study

A welder was working in a confined space without proper ventilation. He collapsed due to exposure to toxic fumes and had to be rescued by emergency personnel. This incident highlights the importance of ventilation and confined space procedures.

Emergency Procedures

  1. In case of fire, use the nearest fire extinguisher to put out the fire.
  2. In case of electric shock, immediately turn off the power source and provide first aid.
  3. In case of exposure to fumes, move to fresh air and seek medical attention if symptoms persist.

Questions and Answers

Here are some common questions related to welding safety:

  • Q: What should I do if I feel sick from welding fumes?

A: Move to an area with fresh air immediately and seek medical attention if symptoms persist.

  • Q: How often should I inspect my welding equipment?

A: Inspect your welding equipment before each use to ensure it is in good working condition.

  • Q: What type of fire extinguisher should be used for welding fires?

A: A 2A-10BC portable fire extinguisher should be readily available in the welding area. [5]

Summary

Recap of main points:

  • Always be aware of the hazards associated with welding.
  • Use appropriate PPE to protect yourself from injuries and illnesses.
  • Ensure proper ventilation to avoid exposure to harmful fumes and gases.
  • Follow safe work practices and regularly inspect equipment to prevent accidents.

Report all hazards, near-misses, and incidents to your supervisor immediately.

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9 source record(s)

Sources used for this answer

[1] Safety Standards for General Safety and Health Standards (Chapter 296-24 WAC)

Page 328

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Source excerpt

# WAC 296-24-685 Application, installation, and operation of arc welding and cutting equipment. (cont.) ## WAC 296-24-[redacted postal code] Operation and maintenance. (cont.) Chapter 296-24 WAC General Safety and Health Standards Part I Welding, Cutting, and Brazing (8) Electric shock. You must not use cables with splices within 10 feet of the holder. The welder should not coil or loop welding electrode cable around parts of the body. (9) Maintenance. (a) The operator should report any equipment defect or safety hazard to the supervisor and you must discontinue the use of the equipment until its safety has been assured. Repairs must be made only by qualified personnel. (b) You must thoroughly dry and test machines which have become wet before being used. (c) Work and electrode lead cables should be frequently inspected for wear and damage. You must replace cables with damaged insulation or exposed bare conductors. Joining lengths of work and electrode cables must be done by the use of connecting means specifically intended for the purpose. The connecting means must have insulation adequate for the service conditions. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), $ 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Statutory Authority: Chapter 49.17 RCW. 94-15-096 (Order 94-07), 296-24-[redacted postal code], filed 7/20/94, effective 9/20/94; Order 73-5, 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-690 Installation and operation of resistance welding equipment. [Order 73-5, 296-24-690, filed 5/9/73 and Order 73-4, 296-24-690, filed 5/7/73.] <table><tr><th>You must meet the requirements</th><th>in this section</th></tr><tr><td>General</td><td>WAC 296-24-[redacted postal code]</td></tr><tr><td>Spot and seam welding machines (nonportable)</td><td>WAC 296-24-[redacted postal code]</td></tr><tr><td>Portable welding machines</…

[2] Safety Standards for General Safety and Health Standards (Chapter 296-24 WAC)

Page 338

Open source document

Source excerpt

# WAC 296-24-685 Application, installation, and operation of arc welding and cutting equipment. (cont.) ## WAC 296-24-[redacted postal code] Eye protection. (cont.) Chapter 296-24 WAC General Safety and Health Standards Part I Welding, Cutting, and Brazing Note: In gas welding or oxygen cutting where the torch produces a high yellow light, is not desirable to use a filter or lens that absorbs the yellow or sodium line in the visible light of the operation. (j) All filter lenses and plates must meet the test for transmission of radiant energy prescribed in ANSI Z 87.1-1968--American National Standard Practice for Occupational and Educational Eye and Face Protection. (3) Protection from arc welding rays. Where the work permits, the welder should be enclosed in an individual booth painted with a finish of low-reflectivity such as zinc oxide (an important factor for absorbing ultraviolet radiations) and lamp black, or must be enclosed with noncombustible screens similarly painted. Booths and screens must permit circulation of air at floor level. You must protect workers or other persons adjacent to the welding areas from the rays by noncombustible or flameproof screens or shields or they must be required to wear appropriate goggles. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), $ 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Statutory Authority: RCW 49.17.010, .040, .050. 01-11-038 (Order 99-36), $ 296-24-[redacted postal code], filed 05/09/01, effective 09/01/01. Statutory Authority: Order 73-5, 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-[redacted postal code] Protective clothing. (1) General requirements. You must protect employees exposed to the hazards created by welding, cutting, or brazing operations by personal protective equipment in accordance with the requirements of chapter 296-24 WAC, Part I, and WAC [redacted i…

[3] Welding - Overview of Types and Hazards

Page 2

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Source excerpt

# Welding - Overview of Types and Hazards (cont.) ## Is there more than one type of welding process? There are over 70 different welding processes. The type of welding process used is related to the specific application. The most common processes are: - Shielded Metal Arc Welding (SMAW), also known as Manual Metal Arc Welding, MMAW. - Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas (TIG) Welding. - Flux Cored Arc Welding (FCAW). - Gas Metal Arc Welding (GMAW), also known as Metal Inert Gas (MIG) Welding or hard wire welding. - Plasma Arc Welding (PAW), Plasma Arc Cutting (PAC) and Gouging - Submerged Arc Welding (SAW) - Resistance Spot Welding (RSW) or spot welding. - Air Carbon Arc Cutting (CAC-A) and Air Carbon Arc Gouging (CAG) - Oxyfuel Gas Welding (OFG), Cutting and Heating (oxygen-acetylene [oxyacetylene] (OAW) or oxygen-propane [oxy-propane] mixtures are the most common fuel mixtures used). ## What, in general, are the hazards associated with welding? Health hazards associated with welding, cutting, and brazing operations will depend on the composition and exposure level to welding fumes and gases, and to ultraviolet (UV) radiation. Health risks include respiratory irritation, metal fume fever, lung cancer, skin cancer, damage to the nervous system, asphyxiation, and other health risks. Safety hazards associated with these processes include burns, eye damage, electrical shock, cuts, injury to toes and fingers. Fires and explosions may also occur. Many of these hazards can be controlled with elimination and substitution controls (e.g., eliminate need for welding or using a using lower fume-generating welding process), engineering controls (e.g., local exhaust ventilation), work practices (e.g., remove coatings before welding, and worker training), and personal protective equipment (PPE)(e.g., respiratory protection). Risk assessments and occupational hygiene air sampling can be performed to determine health and safety risks and worker exp…

[4] Safety Standards for General Safety and Health Standards (Chapter 296-24 WAC)

Page 339

Open source document

Source excerpt

# WAC 296-24-685 Application, installation, and operation of arc welding and cutting equipment. (cont.) ## WAC 296-24-[redacted postal code] Protective clothing. (cont.) Chapter 296-24 WAC General Safety and Health Standards Part I Welding, Cutting, and Brazing during overhead welding or cutting operations. Leather skull caps may be worn under helmets to prevent head burns. (g) For overhead welding and cutting, or welding and cutting in extremely confined spaces, ear protection is sometimes desirable. (h) Where there is exposure to sharp or heavy falling objects, or a hazard of bumping in confined spaces, hard hats or head protectors must be used. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), $ 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Statutory Authority: RCW 49.17.010, .040, .050. 01-11-038 (Order 99-36), $ 296-24-[redacted postal code], filed 05/09/01, effective 09/01/01. Statutory Authority: Chapter 49.17 RCW. 94-20-057 (Order 94-16), 296-24-[redacted postal code], filed 9/30/94, effective 11/20/94; Order 73-5, 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-[redacted postal code] Work in confined spaces. (1) General. As used herein confined space is intended to mean a relatively small or restricted space such as a tank, boiler, pressure vessel, or small compartment of a ship. (2) Ventilation. Ventilation is a prerequisite to work in confined spaces. For ventilation requirements see WAC 296-24-[redacted postal code] through 296-24-[redacted postal code]. (3) Securing cylinders and machinery. When welding or cutting is being performed in any confined spaces you must leave the gas cylinders and welding machines on the outside. Before operations are started, you must securely block heavy portable equipment mounted on wheels to prevent accidental movement. (4) Lifelines. Where a welder must enter a confined space thro…

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

Page 331

Open source document

Source excerpt

# WAC 296-24-685 Application, installation, and operation of arc welding and cutting equipment. (cont.) ## WAC 296-24-[redacted postal code] Hazards and precautions. (cont.) Chapter 296-24 WAC General Safety and Health Standards Part I Welding, Cutting, and Brazing 01/05/2016. Order 73-5, 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-[redacted postal code] Maintenance. Periodic inspection must be made by qualified maintenance personnel, and records of the same maintained. You must instruct the operator to report any equipment defects to the supervisor and you must discontinue the use of the equipment until safety repairs have been completed. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), $ 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Statutory Authority: Chapter 49.17 RCW. 94-15-096 (Order 94-07), 296-24-[redacted postal code], filed 7/20/94, effective 9/20/94; Order 73-5, 96-24-[redacted postal code], filed 5/9/73 and Order 73-4, 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-695 Fire prevention and protection. [Order 73-5, 296-24-695, filed 5/9/73 and Order 73-4, 296-24-695, filed 5/7/73.] <table><tr><th>You must meet the requirements</th><th>in this section</th></tr><tr><td>Basic precautions</td><td>WAC 296-24-[redacted postal code]</td></tr><tr><td>Special precautions</td><td>WAC 296-24-[redacted postal code]</td></tr><tr><td>Welding of cutting containers</td><td>WAC 296-24-[redacted postal code]</td></tr><tr><td>Confined spaces</td><td>WAC 296-24-[redacted postal code]</td></tr></table> ## WAC 296-24-[redacted postal code] Basic precautions. For elaboration of these basic precautions and of the special precautions of WAC 296-24-[redacted postal code] as well as a delineation of the fire protection and prevention responsibilities of welders and cutters, their supervisors (including outside contractors) …

[6] Welding - Overview of Types and Hazards

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CCOHS CCHST Welding Canadian Centre for Occupational Health and Safety Centre canadien d'hygiène et de sécurité au travail # Welding - Overview of Types and Hazards On this page What is welding? Is there more than one type of welding process? What, in general, are the hazards associated with welding? ## What is welding? Welding is a joining process in which metals, or sometimes plastics, are heated, melted and mixed to produce a joint with properties similar to those of the materials being joined. There are three main components needed to create a weld. These are: - A heat source such as an electric arc, a flame, pressure, or friction. The most common heat source is an electric arc. An arc is the physical gap between the end of the electrode and the base metal. The physical gap causes heat due to resistance of current flow and arc rays. The arc melts the metals to create the joint. - Shielding, which is the use of gas, or another substance to protect the weld from air as the weld is being formed. Oxygen from the air makes welds brittle and porous. - Filler material, which is the material used to join to the two pieces together. Other processes that join metals together include: - Brazing is the joining of metals with a filler metal having a melting point above 450°C (842°F), but below the melting point of base metals. The joined metals can be different metals. The joint is not as strong as a welded joint. - Soldering is the joining of metals using a filler metal with a melting point below 450°C (842°F). The joined metals can be different metals. The "filler" metals commonly used are lead-tin alloys. The joint is not as strong as a welded joint or a brazed joint. Metals can also be cut or separated by a flame or an electric arc, or removed by "gouging" with an electric arc. Welding - Overview of Types and Hazards CCOHS

[7] Welder

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Source excerpt

# Occupations and Workplaces (cont.) ## Are there any long-term health effects of being a welder? (cont.) Chronic poisoning occurs when certain materials are present in welding fumes, such as zinc or cadmium, polychlorinated biphenyls (from the decomposition of anti-corrosion oils), or decomposition products from paints. (Sources: Welder. IARC Monographs Volume 118: Welding, Molybdenum Trioxide, and Indium Tin Oxide; International Hazard Datasheets on Occupations, International Labour Office; and Hansen, et al (2017). "Carcinogenicity of welding, molybdenum trioxide, and indium tin oxide" the Lancet, Vol.18) ## What are some preventative measures that can be taken? - Install effective ventilation wherever possible. - Always wear the correct personal protective equipment (PPE). Protective clothing should be selected to provide protection from radiation, ignition, or electric shock. Clothing should not be able to trap sparks that may ignite the material. Welders should wear eyewear that has UV protection. They also should use ear protection. Fire-resistant earplugs will help protect the ears where sparks or spatter can enter the ear. If local exhaust ventilation is not adequate or practical, respiratory equipment should be used. Aprons and fire-resistant heavy leather gloves will help protect the hands and clothing. Capes, leather sleeves, or shoulder protection may be necessary during some welding operations. - Be sure that flammable products are stored far away from the work areas. - Inspect ladders or scaffolding before using. Know how to use fall protection equipment, and use where appropriate. - Learn safe lifting techniques. - If a job requires work in an awkward position (e.g., with hands above shoulder level) be sure to take frequent breaks. - Make sure that an appropriate fire extinguisher or fire watch personnel is close by in case of a fire. - Know how to use and store the welding equipment, including compressed gas cylinders. What are som…

[8] Welder

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Source excerpt

# Occupations and Workplaces (cont.) ## Ergonomic (cont.) Many injuries to welders are the result of strains, sprains and work-related musculoskeletal disorders (WMSDs). Welders often have to: - Lift or move heavy objects - Work in awkward positions for long periods of time - Handle and hold heavy welding guns - Perform repetitive motions See OSH Answers document on Welding - Ergonomics for more information. ## Physical Welders can be exposed to: - Excessive noise levels - Excessive heat or cold - Electromagnetic fields - Laser light - Radiation Welding arcs and flames can emit intense visible (VIS), ultraviolet (UV) and infrared (IR) radiation. Gamma- or X-rays can be emitted by inspection equipment or welding machines. Skin and eye damage such as "welder's eye" or cataracts can result in certain types of radiation. ## Safety Welders often have to work: - At heights - In confined spaces - Could experience electrical shock or electrocution Other safety hazards include: - Flying particles which can enter the eye or skin. - Cuts and stabs from sharp metal edges. - Injury from other equipment (e.g., using power tools such as grinders, chippers, drills, etc.). Welder CCOHS

[9] Construction Safety and Health Standards (MIOSHA)

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# GENERAL FIRE RULES ## R 408.[redacted postal code]. Fire precautions. - Rule 761. (1) Welding operations shall not be performed within 50 feet of explosives, stored cylinders, or stored fuel. Combustible and flammable materials located within 35 feet of a welding operation shall either be removed or covered with fire-resistant material. (2) Cracks or openings through which sparks could pass in the floor or wall that are within 35 feet of a welding operation shall be covered with a fire- resistant material. (3) A wood floor within 10 feet of a welding operation shall be protected by either wetting down, covering with sand, or covering with a fire-resistant material. (4) A minimum of 1 2A-10BC portable fire extinguisher shall be immediately available to the work area during welding operations. (5) An employer shall designate a person as responsible for fire safety during a welding operation where a fire could start or where 1 of the following conditions exists: (a) Appreciable combustible and flammable materials are more than 35 feet from a welding operation but are easily ignited. (b) Combustible and flammable material is adjacent to the opposite side of a metal partition, wall, ceiling, or roof that is likely to ignite by conduction or radiation. (c) If there is a possibility that a smoldering fire may have started, the person shall remain at the scene of the work for not less than 30 minutes after the welding operation has stopped. Personnel shall be instructed as to the specific anticipated fire hazards and how the firefighting equipment provided is to be used. (6) The connection, by welding, of branches to a pipeline carrying a flammable substance shall be performed in accordance with the regulations of the Department of Transportation, 49 C.F.R. Part 192, "Minimum Federal Safety Standards for Gas Pipelines," which are adopted by reference in R 408.[redacted postal code]. (7) Before welding, cutting, or heating is commenced on any surface covered b…

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