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INTRODUCTION
Arc welding is a safe occupation when sufficient measures are
taken to protect the welder from potential hazards. When these
measures are overlooked or ignored, however, welders can
encounter such dangers as electric shock, overexposure to
fumes and gases, arc radiation, and fire and explosion; which
may result in serious, or even fatal injuries.
This bulletin is written with the arc welding operator in mind,
containing both mandatory safety practices and those based on
shop experience. Be sure to read ANSI Z49.1, and refer to the
other publications listed at the end of the bulletin for more
detailed information on specific topics of arc welding safety, as
well as the manufacturers instructions and material safety data
sheets (MSDSs).
Safety Practices in Welding
PERSONAL PROTECTIVE EQUIPMENT
Protective Clothing
Welders, like firemen, must wear clothing to protect them from
being burned. Of all injuries to welders, burns are the most
common due to sparks landing on bare skin. Welding arcs are
very intense and can cause burns to skin and eyes with just a
few minutes of exposure.
The actual gear varies with the job being performed, but
generally protective clothing must allow freedom of movement
while providing adequate coverage against burns from sparks,
weld spatter, and arc radiation. Many types of clothing will
protect you from ultra-violet radiation exposure, which appears
as a skin burn (much like sunburn). Under the worst conditions,
however, severe burns and skin cancer may result from excessive
radiation.
Because of its durability and resistance to fire, wool clothing is
suggested over synthetics (which should never be worn because
it melts when exposed to extreme heat) or cotton, unless it is
specially treated for fire protection. If possible, keep your clothes
clean of grease and oil, as these substances may ignite and burn
uncontrollably in the presence of oxygen.
Avoid rolling up your sleeves and pant-cuffs, because sparks or
hot metal could deposit in the folds; also, wear your trousers
outside your work boots, not tucked in, to keep particles from
falling into your boots. While were on the subject, we suggest
leather high-tops with steel toes (especially when doing heavy
work).
Other protective wear for heavy work or especially hazardous
situations includes: flame-resistant suits, aprons, leggings,
leather sleeves/shoulder capes, and caps worn under your
helmet.
Heavy, flame-resistant gloves, such as leather, should always be
worn to protect your hands from burns, cuts, and scratches. In
addition, as long as they are dry and in good condition, they will
offer some insulation against electric shock.
As to preventing electric shock, the key word is dry! Well have
more on the subject later, but for now keep in mind that moisture
can increase the potential for and severity of electric shock.
When working in wet conditions, or when perspiring heavily, you
must be even more careful to insulate your body from electrically
live parts and work on grounded metal.
ARC RAYS can burn.
Wear eye, ear and body protection.
WARNING
Note To Arc Welding Educators and Trainers:
This Arc Welding Safety brochure may be freely copied for educational purposes if
distributed to welders and welding students at no additional charge.
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SAFETY PRACTICES IN WELDING
ARC RAYS
It is essential that your eyes are protected from radiation
exposure. Infrared radiation has been known to cause retinal
burning and cataracts. And even a brief exposure to ultraviolet
(UV) radiation can cause an eye burn known as welders
flash. While this condition is not always apparent until several
hours after exposure, it causes extreme discomfort, and can
result in swelling, fluid excretion, and temporary blindness.
Normally, welders flash is temporary, but repeated or
prolonged exposure can lead to permanent injury of the eyes.
Other than simply not looking at an arc, the primary preventive
measure you can take is to use the proper shade lens in your
helmet. Refer to the lens shade selector chart in Supplement 1
for the recommended shade numbers for various arc welding
processes. The general rule is to choose a filter too dark to
see the arc, then move to lighter shades without dropping
below the minimum rating. The filters are marked as to the
manufacturer and shade number, the impact-resistant variety
are marked with an H.
Helmets and hand-held face shields (see Figure A) offer the most
complete shading against arc radiation. The shade slips into a window
at the front of the shield so that it can be removed and replaced easily.
The shields are made from a hard plastic or fiberglass to protect your
head, face, ears, and neck from electric shock, heat, sparks, and
flames. You should also use safety glasses with side shields or goggles
to protect your eyes from flying particles.
Visible light can also be harmful, but it is easy to tell if the light is
dangerous: if it hurts to look at, then its too bright. The same is true for
infrared radiation: it can usually be felt as heat. However, theres no real
way for you to tell if youre being over exposed to UV radiation, so just
dont take chances: always wear eye protection (see Supplement 1 for
recommended lens shade numbers).
Figure A. A helmet (a) required for protecting the
welders eyes and face and (b) a hand-held face
shield that is convenient for the use of foremen,
inspectors, and other spectators.
NOISE
There are two good reasons to wear ear muffs or plugs:
a)
to keep flying sparks or metal out of your ears; and
b)
to prevent hearing loss as a result of working around noisy arc welding equipment, power sources, and
processes (like air carbon arc cutting or plasma arc cutting).
As with radiation exposure to the eyes, the length and number of times that you are exposed to high levels of
noise determine the extent of the damage to your hearing, so be sure to avoid repeated exposure to noise. If it
is not possible to reduce the level of noise at the source (by moving either yourself or the equipment, utilizing
sound shields, etc.), then you should wear adequate ear protection.
If the noise in your work area becomes uncomfortable, causing a headache or discomfort of the ears, you
could be damaging your hearing and should immediately put on ear muffs or plugs.
In fact, the use of ear protection at all times is a good idea, as hearing loss is both gradual and adds up over
time. Damage to your hearing may not be noticed until you have a complete hearing test, and then it could be
too late.
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SAFETY PRACTICES IN WELDING Is the work stable and easy to reach from where youre
standing? Is the Work Lead connected securely? Is there enough dry insulation between your body and the
work piece? Is there adequate ventilation in your work area?
Take some personal responsibility for your own safety. Notify
your supervisor if equipment is in need of repair or not working
properly or any unsafe condition. You have the most to lose if
you get hurt. Dont allow yourself to work in a hazardous
situation without taking appropriate safety precautions.
If the hazard is serious and cannot be corrected readily, the
machine should be shut down until the needed repairs are
made. If the problem is limited to the outside of the welder, such
as a loose connection or a damaged cable that needs to be
replaced, disconnect power to the welder and correct the
problem per the manufacturers instructions in the
operating/service manual. If the hazard requires repairs to the
inside of the welder or to the electrical input supply lines, call a
service technician or an electrician. Never attempt to make
these repairs if you are untrained.
INSPECTION AND MAINTENANCE OF EQUIPMENT
AND WORK
Before starting any arc welding operation, you should make a
complete inspection of your equipment. All it takes on your part
is 5-10 minutes before you turn on your welder; is that too much
to spend in preventing injury to yourself or your co-workers?
To begin with: Have you read the instruction manual and do you
understand the instructions? The instruction manual for your
welder is available upon request to your welding distributor
or the manufacturer. Manuals for Lincoln Electric welders
may be downloaded from lincolnelectric.com at no charge. Have you read the warnings and instructions on the
equipment nameplates and decals as well as the
consumables labels and material safety data sheets? (For
older equipment see Supplement 5 to request a FREE
Warning Label.)
For the welder: Are all the connections tight, including the earth ground? OSHA regulations require output terminals to be insulated.
Rubber boots are available for that purpose. Are the electrode holder and welding cable well insulated
and in good condition? Are the settings correct for the job youre about to begin?
For an engine-driven welder: Is it running OK? Are all the hoses on tight? Is the fuel cap on tight? Is the engine leaking fuel or oil? Some jobsites look for this
and may refuse entry if your engine is leaking. Is the original enclosure and fan guarding in place? Check
with your welding equipment distributor if you are unsure.
(See Supplement 6.)
For the work in general: (See also Supplements 4 and 7) Are the work area conditions such that normal safety
precautions can be observed or must special equipment