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REDUCE WORKPLACE ACCIDENTS: Use safe welding practices on the job |
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Written by Carl Peters
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 Arc welding is safe when sufficient measures are taken to protect the welder from potential hazards. Before starting your next project, be sure to understand and follow safe practices to protect yourself from such hazards as electric shock, fires and explosions, fumes and gases and arc rays.
Personal protective equipment
Like fireman, welders need appropriate clothing to protect them from being burned. Of all welding injuries, burns are the most common — primarily from sparks landing on bare skin. Welding arcs are very intense and can also cause burns to the skin and eyes.
In general, protective clothing must allow freedom of movement, while still providing adequate coverage against burns from sparks, weld spatter and radiation. Because of its durability and fire resistance, wool is recommended over synthetics, which can melt from extreme heat. Cotton is preferred over synthetics particularly if treated for fire resistance.
Always wear long sleeves and pants. Avoid rolling up sleeves and pant-cuffs because sparks or hot metal can find its way into folds. Wear pants outside your work boots to keep sparks from falling into the boots. Leather high-top work boots with steel toes are recommended, especially during heavy work.
Heavy, flame-resistant gloves, such as leather, should always be worn to protect your hands from burns, cuts, radiation and scratches.
Arc rays
Wear proper eye protection at all times. Looking directly at the arc without protection can cause temporary or even permanent damage. The primary preventative measure to protect your eyes from arc rays is to wear a welding helmet with the proper shade lens. To find the proper shade, choose a filter too dark to see the arc then move to lighter shades without dropping below the minimum rating. Shade numbers are marked on the filter plates. Also, wear safety glasses with side shields or goggles to protect from flying particles.
Electric shock
Electric shock is one of the most serious and immediate risks in welding. Welding shock hazards may be divided into two categories:
• Primary (input to the welder) voltage shock (i.e. 230, 460 volts); and
• Secondary (welding output) voltage shock (i.e. 20-100 volts).
Only a qualified electrician should connect input power. Also, only a qualified technician should repair your welder. Remember, turning the welder power switch "off" does not turn the power off inside the welder.
When you are welding, insulate yourself to protect against shock. Wear dry, hole-free gloves. Moisture increases the potential for and severity of electrical shock. When working in wet conditions or perspiring heavily, carefully insulate your body from "live" electrical parts, including the electrode and metal parts of the electrode holder. Also, keep dry insulation between your body and the metal being welded. Never touch an electrode or metal parts of the electrode holder with skin or wet clothing. Also, keep your welding cable and electrode holder insulation in good condition.
Fumes and gases
Keeping your head out of the fume plume and using adequate ventilation is key to controlling exposure to hazardous materials in the welding fumes and gases. See the material safety data sheet for the electrode for information about how to protect yourself.
When welding mild steel, natural ventilation is usually considered sufficient provided that the room or welding area is at least 10,000 cubic feet for each welder. That's an area about 25'x 25' with a ceiling height of 16'. Be sure that partitions or other structures do not block cross ventilation.
When you are welding in situations that don't meet these requirements use mechanical ventilation and exhaust equipment. It may be necessary to wear an approved respirator if adequate ventilation can't be provided. Read the product label and material safety data sheet (MSDS) that comes with the filler metals for specific recommendations.
Welding sparks
A welding arc can reach 10,000 degrees Fahrenheit or more, but the heat of the arc alone is generally not a fire hazard. The danger results from the intense heat and sparks and molten metals, which can spray up to 35 feet from the work. Keep your work area free of flammable materials or cover them with a fire-resistant shield. Always keep fire extinguishers nearby.
For more details on welding safety, you can download Lincoln Electric's free "Arc Welding Safety" guide (Bulletin E205) at www.lincolnelectric.com, or the American Welding Society's "Safety in Welding, Cutting & Allied Processes" (ANSI z49.1) at www.aws.org.
This is an edited article provided by Cleveland, OH-based Lincoln Electric Company. Carl Peters is director of technical training, The Lincoln Electric Company. His welding career spans 35 years, and he serves as director of technical training for The Lincoln Electric Company. You can contact him by email at:
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