15

Safe Practices in Welding

This chapter is intended only as a brief overview of selected important topics associated
with welding safety, and is not intended to be all‐encompassing, or to be used for the
development of safe practices and procedures. For comprehensive details and training
guidance regarding safe practices during welding, the most common standard in the United
States is ANSI/ASC Z49.1, “Safety in Welding, Cutting, and Allied Processes”. This stan-
dard is listed in most AWS codes, and is typically invoked when a welding code is mandated
by the contract or law.

15.1  Electrical Shock

Most arc welding power supplies operate at open circuit voltages of 60–80 V. Although
these voltages are relatively safe, the risk of serious injury or death exists if proper electrical
safety practices are not followed. Common electrical safety practices include avoiding
working in wet or damp conditions, use of rubber soles, proper maintenance and grounding
of equipment, and special precautions when two or more welders are working on the same
structure. Some equipment (such as Electron Beam Welding) operates at much higher volt-
ages than arc welding equipment, increasing the danger if proper electrical safety is not
practiced.

15.2 Radiation
Welding arcs produce both ultraviolet and infrared radiation. Damage to the eyes can occur if
the arc is viewed without the use of proper lenses. Welders should also be careful to protect
exposed skin to prevent painful burns similar to sunburn. Electron Beams and Lasers produce

Welding Engineering: An Introduction, First Edition. David H. Phillips.

© 2016 John Wiley & Sons, Ltd. Published 2016 by John Wiley & Sons, Ltd.
Safe Practices in Welding 271

radiation as well. All equipment producing radiation should use appropriate screens or booths
to provide additional protection to personnel in the vicinity of the welding operation. Thoriated
tungsten electrodes used for Gas Tungsten Arc Welding are radioactive, and therefore, proper
ventilation and protection is required during grinding.

15.3 Burns
Obviously, the risk of getting burned always exists when working around any welding opera-
tion. In addition to radiation burns, a welder or welding operator may be easily burned by
touching hot metal or getting hit by spatter or sparks. While arc welding, proper protective
equipment including a welding helmet, and fireproof protection for the rest of the body must
always be worn. Anyone working in and around a welding operation should always assume
that a welded part is hot and avoid touching it without the use of proper gloves. In addition to
fireproof clothing, arc welders should avoid the use of pants with cuffs and open pockets, both
of which can easily catch molten spatter.

15.4  Smoke and Fumes

Welding processes produce a wide variety of potentially hazardous fumes. Sources include
molten metal vaporization, oils, paint, coatings such as zinc, and fumes and gases from
decomposing fluxes. Proper ventilation must always be used. Other important considerations
include the size of the welding space, the type of welding process, the amount of welding
being ­conducted, and the location of the welder’s head relative to the flow of the fumes. Both
general and local ventilation techniques are typically practiced. General ventilation refers to
methods for ventilating the entire space such as opening doors to allow natural ventilation,
while local ventilation refers to methods to protect personal at a work station such as with a
movable hood.

15.5  Welding in Confined Space

Special precautions must be taken when welding in confined spaces such as tanks. Confined
spaces produce extremely poor ventilation, and therefore, special proactive approaches to
­ventilating such as providing oxygen to the welder and monitoring air quality in the space are
typically mandated. The Z49.1 document provides specific guidance for safe practices when
welding in confined spaces.

15.6  Fire and Explosion Danger

Most welding processes produce significant sources of heat such as sparks and spatter for fire
­ignition, which are capable of travelling up to 35 ft. Therefore, combustible material or fuel
should be kept at least 35 ft away from the welding area. Combustible material on the other
side of any wall adjacent to the work station should be removed as well.
272 Welding Engineering

15.7  Compressed Gasses

Pressurized gas cylinders used for many of the arc welding processes must be handled
­properly to avoid explosions or leaks. Safe handling of compressed gasses is also covered in
ANSI Z49.1 and includes labeling, storage, gas withdrawal, valves and pressure relief
devices, ­prevention of fuel gas fires, and concern for air displacement. The concern for air
displacement refers to the use of gasses that are capable of ­displacing oxygen because they
are either heavier than air (argon) or lighter than air (helium). For example, when welding
with argon, if proper ventilation is not ensured, the argon will begin to pool at the floor and
rise in depth much like filling a room with water. Eventually, asphyxiation is possible if the
depth reaches the level of the welder’s head. The same danger exists with helium, but in this
case, the pooling begins at the ceiling and grows downward. This can be a dangerous situation
especially when welding overhead.

15.8  Hazardous Materials

When dealing with hazardous materials, the use of Material Safety Data Sheets (MSDSs)
becomes paramount. Typical hazardous materials around a welding operation may include
fluorine, zinc, cleaning compounds, chlorinated hydrocarbons, and chromium and nickel in
stainless steels. When welding involves hazardous materials, special ventilation techniques
are typically required and the collection of air samples may be mandated. OSHA and other
organizations have established allowable limits of airborne contaminants referred to as
threshold limit values (TLV) and permissible exposure limits (PEL).

Recommended Reading for Further Information

AWS Welding Handbook, Ninth Edition, Volume 1—“Welding Science and Technology”, American Welding
Society, 2001.
Safety in Welding, Cutting, and Allied Processes, American Welding Society, 2012.