Every year, thousands of people begin welding, whether for a living or for pleasure, and not all of them receive enough training, putting their lives at risk. Despite the fact that welding is a far safer profession in 2020 than it was a few decades ago, thanks to significant technological advances in personal protective equipment (PPE) and more dependable tools, precise safety requirements are essential in every workplace.
This page, similar to Welding Safety 101, is meant to serve as a welding safety reference, including topics such as common injuries, safety hazards, and critical welding safety advice.
Welding Safety: 4 Sever Hazards
As previously stated, advances in welding technology (such as pulsed-laser welding) have made many welding dangers obsolete. On the other hand, arc welding continues to create certain safety concerns.
Four of the most important welding safety issues are as follows:
1. Burns (inadequate protective gear)
Even if you don’t come into direct contact with the welding arc, it can burn your skin. These types of burns, known as flash burns, are caused by UV radiation and strong flashes. Sparks or the arc might create far more long-term devastation (to the internal tissue). UV rays, a form of radiation, are emitted by the welding arc and can cause wounds to get infected (if not treated properly in time).
UV light’s strong flashes have the potential to cause eye burns. Workers may come into contact with molten or extremely hot metal, which can easily burn even fully clothed skin, providing a serious safety risk. Use welding helmet to eye and face protection
2. Fumes
When metal is exposed to a welding arc, it starts to burn, and the top layer, which is usually a chemical coating, evaporates, generating a variety of poisonous chemicals that workers can inhale. Despite the fact that individual dangerous particles cannot be seen with the naked eye, welding fumes are characterized by a cloud of fine dust (almost fog-like) rising from the hot metal.
Welders are exposed to metal fumes, which can cause symptoms such as fume fever (a flu-like risk), disorientation, and unconsciousness, as well as long-term lung and brain damage. In severe cases, fumes can cause lung cancer and even death. The best welding respirators on the market should be your first line of defense against these hazardous welding gases.
3. Electrocution
Workers working with arc welders are exposed to voltages of 20 to 100 volts, with up to 575 volts inside the welding machine’s enclosure, placing them at risk of electric shock. Electrocution at this level can cause skin burns, spasms, muscular injury (including paralysis), and death.
Low-voltage shocks can catch a person off guard during welding, causing them to collapse or hurt themselves.
4. Fire
Although the tremendous heat of the welding arc can cause burns, it is the flying sparks that cause clothing, furniture, paper, and other flammable things to catch fire or explode.
Most Common Injuries Associated with Welding
Metal shards flying into the eyes or skin, breathing toxic metal vapors, or cutting themselves on sharp or rough metal edges have all been known to hurt welders. Welders and contractors are at risk of heat exhaustion, heat strokes, overexertion, muscle cramps, back difficulties, and repetitive strain injuries (RSI) such as carpal tunnel and tarsal tunnel syndrome.
Welding Safety Tips and Precautions
1. Protect Eye Protection.
According to the Occupational Safety and Health Administration, eye injuries are the most common type of welding mishap (OSHA). This illustration illustrates two points: first, welders seek to safeguard their eyes because they are the most vulnerable part of the arc welding process, and second, regular eye protection is insufficient.
With so many different types of lenses available for welding helmets and visors, choose the correct welding helmet for the job is critical. A 12 filter is recommended for arc welding, for example. When the wrong lens is used, it can cause both short- and long-term retinal damage.
Auto-darkening helmets are also recommended since they can automatically adjust the shade level, keeping your eyes secure while retaining excellent vision.
2. Always Wear High-Quality Gloves
Another important element of personal protective equipment is gloves. When working with a welding arc, regular gloves will not protect you, so invest in a good pair of welding gloves laced with Kevlar to give your hands an extra layer of protection.
Additionally, make sure your gloves are completely dry before touching any equipment, since even a small quantity of water can short an electric current and increase the risk of electrocution.
3. Look After Your Clothes
Sparks can burn your skin and clothes quickly, and while you must be fully clothed from head to toe, your usual clothing will not suffice since it can catch fire. We propose investing in a high-quality leather apron to wear over your clothes to protect yourself from sparks. Wearing a synthetic apron, which can catch fire just as easily as cotton or woollen clothes, is not recommended (if not faster).
Welding is a hot process that causes you to sweat, but you don’t want to operate high-voltage equipment while you’re sweating. Leather boots are also essential, and they, like the rest of your costume, must be complete.
4. Prepare The Metal By Stripping It
Because the gases produced by burning metal can be exceedingly harmful, it is critical to strip and prepare the metal in advance. Stripping is the removal of a metal’s top layer, which is usually a chemical coating that gives the metal its distinct properties (like strength, color, and durability).
In other circumstances, though, removing the metal’s top layer isn’t possible, therefore welders should wear masks and use a fume or smoke extractor instead. These small gadgets (which look like a portable vacuum cleaners) help to remove hazardous gases from the welder while also enhancing ventilation.
5. Make Sure Ventilation
As a result of the headgear and the heat, body temperatures can rise dramatically, increasing the risk of overexertion, heat exhaustion, and even heat strokes. By providing sufficient ventilation and airflow, improved airflow would help maintain acceptable workplace temperatures, ease breathing, and boost staff morale.
6. Beware of Your Surroundings
Before you start welding, evaluate the area to make sure it meets OSHA’s welding safe working environment requirements.
- In the immediate vicinity, there are no combustible items.
- The floor isn’t even made of wood.
- Tanks transporting flammable or explosive materials, as well as related items, have been meticulously cleaned.
- The floor is completely dry.
- On the desk, there are no scattered items (welder could be seriously injured in case of a fall).
- In the workplace, there are no claustrophobic or confined locations.
7. Read the Manual and Do Not Experiment
Whether you’re a novice welder or an expert in your profession, reading instructions is usually a good first step, especially when working with new equipment. Instead of experimenting with torches or regulators in typical working environments, follow the recommendations (without additional safety precautions).
8. Be on the lookout for Emergencies
Emergencies do not knock on your door. Prepare for any potential tragedy ahead of time. Welders should be taught how to utilize proper approaches in a variety of settings, as well as how to deal with fundamental disasters (fire, electrocution, explosion, etc.) Fire extinguishers should, at the absolute least, be kept close to the workplace and within easy reach of personnel.
FAQs
Final Verdict
Welding safety is a major concern, and there are several dos and don’ts.
Therefore, we’ve compiled a list of the most important topics and rules to ensure welding safety.
With 8 years of experience a senior welding instructor and safety equipment researcher and writes articles, reviews and guidelines on helmets and other welding and safety gears at Welder Choice, and other written works have been published in various publications.