WELDING

Fire prevention.

Accident prevention and reporting.

Risk assessment.

Manual handling eg materials.

Checking conditions.

Personal protective equipment (PPE).

Ventilation and extraction.

Closing down.

Emergency procedures eg within the learning environment and the workplace.

Hazards associated with welding.

Welding Health and Safety Engineering health and safety is very important Every year people
working in engineering need to have time off, lose a finger, a leg and die due to not following
health and safety guidelines.
The Health & Safety at Work act is law in the UK The employers and employees responsibilities
regarding H&S are defined within the act. Everyone has their responsibilities in health and safety.
Welding Health and Safety Your responsibilities (the employee) : –Don’t do anything that might
endanger you –Don’t do anything that might endanger someone else. –Always use any safety
equipment given to you –Co-operate with your employer or tutor To protect others when
welding you can: work behind fixed barriers or curtains erect temporary barriers or curtains
display signs that warn people as they enter the welding area Verbal – most welders shout
“eyes” just before they start welding.
Welding Health and Safety Employers’ responsibilities: –Provide a safe place of work –Provide
safe equipment –Provide welfare facilities –Provide personal protective equipment
Personal Protective Equipment Personal protective equipment is shortened to PPE Before
entering the workshop the correct PPE must be worn Each item has a important role in
protecting the operator.
Arc Eye Arc eye is painful and repeated exposure to UV radiation can cause permanent damage.
Welding head shields should always be worn when welding or working close to another welder
You do not need to look directly at the arc to get arc eye, it can be reflected off shiny surfaces
into your eyes. Wearing safety glasses that have UV protection will help reduce the risk of arc
eye. Good practice is to wear a pair of safety glasses under your welding helmet
Other Protection Welders often work in areas where there is a risk of falling objects. Helmets
should be worn at all times. Engineering can be noisy, protect your hearing at all times. When
welding make sure your throat is protected, button overalls all the way up.
Other Protection Skull caps are used to protect the welder from falling sparks especially when
working overhead. Lighter, thinner leather gloves are needed for TIG welding
PPE Problems All PPE must be kept in good condition. In certain circumstances PPE may become
unsafe or not protect the user completely. Overalls –The flame retardant chemical in the overalls
washes out over a period of time –Ripped overalls will catch fire easily –Oily or greasy overalls
can catch fire.
10 PPE Problems Welding helmet –If dropped, the shell of the helmet can be cracked letting
fumes or stray radiation to enter –Fitting the incorrect filter lens can strain the eye Hand
protection –Gauntlets should be used when MIG welding –Ripped or burnt gloves should not be
used. General –All PPE, including safety footwear should be good fitting. –Any damaged PPE
should be returned for replacement
11 Welding Fumes Welding fumes are influenced by: –type of process –welding consumable –
presence of any material coatings –welding parameters –shielding gas composition.
12 Welding Fumes The fume given off by welding is a mixture of gases and very fine particles
which can cause illness. Gases that can be present in welding are: nitrous oxide (NO), carbon
dioxide (CO2), carbon monoxide (CO) shielding gas (eg Argon, helium) and ozone (O3) The visible
fume includes particles of metal, metal oxide and flux (if used) The level of risk from the fume
will depend on: How toxic the fume is How concentrated the fume is How long you are breathing
the fume
13 Illnesses Occupational asthma –Stainless steel fume contain chemicals that can cause
asthma. Cancer –Welding fume is internationally recognised as carcinogenic. Metal fume fever –
Metal fume fever has flu like symptoms linked to the welding of galvanised metals. Irritation of
throat and lungs –Welding fume can cause dryness to the throat, coughing or a tight chest.
Ozone can cause of this.
14 Fume Removal Depending on the amount of welding taking place various forms of fume
attraction are available. For low levels a simple extractor fan in the wall will provide a level of
background ventilation. Natural ventilation can be achieved by opening windows and doors or
when working out doors. Local exhaust ventilation (LEV) LEV ducted system
15 Fume Removal PPE can be used to protect the welder from inhaling fumes. Air fed mask
Respirator under mask
16 Electrical Hazards Electric shocks occur when the current flows through you. It’s the current
(amps) not voltage that causes injury. To protect against shock it is important that electric
circuits: are insulated are earthed contain fuses and circuit breakers
17 Electrical Hazards Besides shocks there are other hazards associated with electricity. Faulty
connections can generate sparks which can cause fires. Loos connections can heat up causing
burns to the welder of melting of the insulating cover.
18 Risk Assessment Risk assessment Prior to starting welding you should: Check all connections
are connected correctly are tight Check all cables –no damage to insulation –return lead is
correct size for the amperages being used –earth is connected (fixed sets)
19 Hot Metal Hot metal is a common hazard in the welding workshop. To protect yourself and
others make sure: –All hot metal is marked as “HOT”, with date and time included. –Only carry
metal using tongs. –Quench (dip in water) to cool down unless the weld is going to be tested. –
Good practice is to treat every piece of metal as hot, don’t pick it up unless you are sure its cool!
20 Good Housekeeping At the end of the shift or lesson it is important to leave the work area in
a safe state. This includes: –isolating the welding set –turning the shielding gas off –returning all
tools to storage area –dispose of any scrap material –generally tidy up the area.