Chapter 2Chapter 2Safety in WeldingSafety in Welding

ObjectivesObjectives

Burn classifications and emergency Burn classifications and emergency treatmenttreatment

Dangers of types of light, and avoiding eye Dangers of types of light, and avoiding eye and ear injuriesand ear injuries

Use a chart to select eye and face Use a chart to select eye and face protectionprotection

Describe various types of respiratory Describe various types of respiratory protectionprotection

Avoid dangerous fumes and gasesAvoid dangerous fumes and gases

Objectives (continued)Objectives (continued)

The purpose of Material Safety Data SheetsThe purpose of Material Safety Data Sheets The benefits of recycling waste materialThe benefits of recycling waste material General work clothing and special General work clothing and special

protective clothingprotective clothing Safely handle, secure, and store cylindersSafely handle, secure, and store cylinders Protect against fire danger when weldingProtect against fire danger when welding

Objectives (continued)Objectives (continued)

The importance of planned maintenanceThe importance of planned maintenance Tools commonly used by weldersTools commonly used by welders Good electrical safety practicesGood electrical safety practices Types of metal cutting machinesTypes of metal cutting machines Safely lift heavy assembliesSafely lift heavy assemblies Ladder safetyLadder safety

IntroductionIntroduction

No substitute for caution and common No substitute for caution and common sensesense

Each person must take personal Each person must take personal responsibilityresponsibility

Welding has a number of potential safety Welding has a number of potential safety hazardshazards

Most large welding companies have Most large welding companies have mandated safety classesmandated safety classes

Burn ClassificationBurn Classification

Burns are one of the most common and Burns are one of the most common and painful injuriespainful injuries

Caused by ultraviolet light rays and contact Caused by ultraviolet light rays and contact with hot welding torcheswith hot welding torches

All burns must receive proper medical All burns must receive proper medical treatmenttreatment

Burns are divided into three classificationsBurns are divided into three classifications

First-Degree BurnsFirst-Degree Burns

The surface of the skin is reddishThe surface of the skin is reddish Tender and painfulTender and painful No broken skinNo broken skin Put the burned area under cold water or Put the burned area under cold water or

apply a cold compressapply a cold compress Cover the area with sterile bandagesCover the area with sterile bandages Never apply butter or greaseNever apply butter or grease

Second-Degree BurnsSecond-Degree Burns

The surface of the skin is severely damagedThe surface of the skin is severely damaged Blisters and possible breaks in the skinBlisters and possible breaks in the skin Put the area under cold water or use cold Put the area under cold water or use cold

water compresseswater compresses Pat the area with a dry lint-free towel and Pat the area with a dry lint-free towel and

cover with a sterile bandagecover with a sterile bandage Seek medical attentionSeek medical attention

Figure 2-2 Second-degree burn

Third-Degree BurnsThird-Degree Burns Surface of the skin appears white, charredSurface of the skin appears white, charred Never remove any clothingNever remove any clothing Never put ice water or ice, ointments, Never put ice water or ice, ointments,

sprays, etc.sprays, etc. If the victim is on fire, smother the fire with If the victim is on fire, smother the fire with

a blanket, rug or jacketa blanket, rug or jacket Cover the burn with a thick sterile dressingCover the burn with a thick sterile dressing Call for an ambulanceCall for an ambulance

Burns Caused by LightBurns Caused by Light

Some types of light can cause burnsSome types of light can cause burns Three types of light include:Three types of light include:

– UltravioletUltraviolet– InfraredInfrared– VisibleVisible

Arc welding produces all three types of lightArc welding produces all three types of light Light from the welding process can be Light from the welding process can be

reflected from walls, ceilings, and floorsreflected from walls, ceilings, and floors

Ultraviolet LightUltraviolet Light

The most dangerousThe most dangerous Causes first and second degree burns to Causes first and second degree burns to

eyes or exposed skineyes or exposed skin The closer the welder is to the arc and the The closer the welder is to the arc and the

higher the current, the quicker a burn may higher the current, the quicker a burn may occuroccur

A welder's eyes can receive a flash burn in A welder's eyes can receive a flash burn in secondsseconds

Figure 2-6 The eye can be burned on the white or retina by ultraviolet light.

Infrared LightInfrared Light

The light wave is felt as heatThe light wave is felt as heat A person will immediately feel this type of A person will immediately feel this type of

lightlight Burns can be easily avoidedBurns can be easily avoided Protective action should be taken to cover Protective action should be taken to cover

yourselfyourself

Visible LightVisible Light

The light that we seeThe light that we see Produced in varying quantities and Produced in varying quantities and colorscolors May cause temporary night blindnessMay cause temporary night blindness Too little visible light may cause eye strain Too little visible light may cause eye strain Visible light is not hazardousVisible light is not hazardous

Face Eye and Ear ProtectionFace Eye and Ear Protection

Eye protection must be worn in the shop at Eye protection must be worn in the shop at all timesall times– Safety glassesSafety glasses with side shields with side shields– GogglesGoggles– Full face shieldFull face shield– Flash glassesFlash glasses

Welding light damage often occurs without Welding light damage often occurs without warningwarning

Welding HelmetsWelding Helmets

Even with quality Even with quality welding helmetswelding helmets, the , the welder must check for potential problemswelder must check for potential problems

Undetectable leaks of ultraviolet light can Undetectable leaks of ultraviolet light can cause a welder's eyes to itch or feel sorecause a welder's eyes to itch or feel sore

Ensure lens gasket is installed correctlyEnsure lens gasket is installed correctly Tape can be used as a temporary repairTape can be used as a temporary repair

Safety GlassesSafety Glasses

Adequate for general useAdequate for general use Not suitable for heavy grinding, chipping, or Not suitable for heavy grinding, chipping, or

overhead workoverhead work Must be worn under an arc welding Must be worn under an arc welding

helmet at all timeshelmet at all times

Ear ProtectionEar Protection

Welding environment can be very noisyWelding environment can be very noisy Hot sparks can drop into an open ear, Hot sparks can drop into an open ear,

causing severe burnscausing severe burns EarmuffsEarmuffs cover the outer ear completely cover the outer ear completely EarplugsEarplugs fit into the ear canal fit into the ear canal Damage caused by high sound levels may Damage caused by high sound levels may

not be detected until later in life – hearing not be detected until later in life – hearing will not improve with timewill not improve with time

Respiratory ProtectionRespiratory Protection

Welding and cutting produce harmful by-productsWelding and cutting produce harmful by-products Respirators protect against welding by-productsRespirators protect against welding by-products Welders are responsible for following the shop's Welders are responsible for following the shop's

written respiratory protection policywritten respiratory protection policy Training should include:Training should include:

– Proper use of respirator Proper use of respirator – Maintenance schedules and respirator selectionMaintenance schedules and respirator selection– Procedures for testing the proper fitting and useProcedures for testing the proper fitting and use– Regular evaluation of the programRegular evaluation of the program

EquipmentEquipment

Some types of respiratory protection Some types of respiratory protection equipment:equipment:– Air-purifying respiratorsAir-purifying respirators– Atmosphere-supplying respiratorsAtmosphere-supplying respirators– Demand respiratorsDemand respirators– Positive pressure respiratorsPositive pressure respirators– Powered air-purifying respiratorsPowered air-purifying respirators– Self-contained breathing apparatusSelf-contained breathing apparatus– Supplied-air respiratorsSupplied-air respirators

Fume SourcesFume Sources

Paints, coating, or plating on metals can Paints, coating, or plating on metals can cause respiratory problemscause respiratory problems

Before welding or cutting any painted Before welding or cutting any painted metal, the surface must be cleanedmetal, the surface must be cleaned

Marine industry still uses lead-based paintsMarine industry still uses lead-based paints Exposure to cadmium fumes can cause Exposure to cadmium fumes can cause

lung and kidney damagelung and kidney damage The best way to avoid problems is to The best way to avoid problems is to

provide adequate provide adequate ventilation.ventilation.

VaporVapor Sources Sources

Ozone gas is produced by ultraviolet Ozone gas is produced by ultraviolet radiationradiation

Ozone irritates mucous membranesOzone irritates mucous membranes The collection of fumes and gases can go The collection of fumes and gases can go

unnoticedunnoticed Concentrated fumes can cause a fire or Concentrated fumes can cause a fire or

explosionexplosion

VentilationVentilation

Welding area should be well ventilatedWelding area should be well ventilated Natural ventilationNatural ventilation is bestis best Forced ventilation may be requiredForced ventilation may be required Large enough areas may not require forced Large enough areas may not require forced

ventilationventilation

Figure 2-15 A room with a ceiling 16 ft. high may not require forced ventilation

Forced VentilationForced Ventilation

Small shops or shops with many welders Small shops or shops with many welders require forced ventilationrequire forced ventilation

Forced ventilationForced ventilation – Can be general or localized Can be general or localized – Fixed or flexible Fixed or flexible exhaust pickupsexhaust pickups

Forced ventilation is required when welding Forced ventilation is required when welding on metals that contain dangerous fumeson metals that contain dangerous fumes

Material Safety Data SheetsMaterial Safety Data Sheets

Material safety data sheets (MSDS)Material safety data sheets (MSDS) provide provide details of possible hazardsdetails of possible hazards

Often posted on a bulletin board or put in a Often posted on a bulletin board or put in a convenient place where products are usedconvenient place where products are used

If injured while using a product, take the If injured while using a product, take the material's MSDS when you seek treatmentmaterial's MSDS when you seek treatment

Waste Material DisposalWaste Material Disposal

Welding shops generate a lot of waste Welding shops generate a lot of waste materialsmaterials

All scrap metal can be recycledAll scrap metal can be recycled Hazardous waste materials include:Hazardous waste materials include:

– Burned fluxBurned flux– Cleaning solventsCleaning solvents– Dust collected in the filtration systemDust collected in the filtration system

Throwing hazardous material away is illegalThrowing hazardous material away is illegal

General Work ClothingGeneral Work Clothing

Guidelines for work clothing:Guidelines for work clothing:– Shirts must be long-sleevedShirts must be long-sleeved– Pants must be long enough to cover the tops Pants must be long enough to cover the tops

of the boots and must be without cuffsof the boots and must be without cuffs– Boots must have high topsBoots must have high tops– Caps should be thickCaps should be thick– Clothing must be free of frayed edges or Clothing must be free of frayed edges or

holesholes There is no safe place to carry a butane There is no safe place to carry a butane

lighter or matches while weldinglighter or matches while welding

Special Protective ClothingSpecial Protective Clothing

Extra protection is needed for each person Extra protection is needed for each person who is in direct contact with hot materialswho is in direct contact with hot materials– Hand protectionHand protection– Body ProtectionBody Protection– Waist and Lap ProtectionWaist and Lap Protection– Arm ProtectionArm Protection– Leg and Foot ProtectionLeg and Foot Protection

Leather is often the best material to useLeather is often the best material to use

Handling and Storing CylindersHandling and Storing Cylinders

Store oxygen and fuel gas cylinders Store oxygen and fuel gas cylinders separatelyseparately

Store inert gas cylinders separately or with Store inert gas cylinders separately or with the same type of fuel cylindersthe same type of fuel cylinders

Store all cylinders verticallyStore all cylinders vertically Securely fasten the protective capSecurely fasten the protective cap

Securing and Storing Gas CylindersSecuring and Storing Gas Cylinders

Secure cylinders Secure cylinders with a chain or other with a chain or other devicedevice

Chain cylinders attached to a manifold or Chain cylinders attached to a manifold or stored in a special roomstored in a special room

Cylinder storage area must be away from Cylinder storage area must be away from halls, stairwells, and exitshalls, stairwells, and exits

Storage areas should be away from heating Storage areas should be away from heating units and welding sparksunits and welding sparks

Secure storage areas from unauthorized Secure storage areas from unauthorized peoplepeople

Cylinders with Valve Protection Cylinders with Valve Protection CapsCaps

Must have the cap in place unless the Must have the cap in place unless the cylinder is in usecylinder is in use

The cap prevents the valve from being The cap prevents the valve from being broken offbroken off

Never lift the cylinder by the safety valveNever lift the cylinder by the safety valve When moving cylinders, the valve When moving cylinders, the valve

protection cap must be onprotection cap must be on All cylinders must be handled with careAll cylinders must be handled with care

General PrecautionsGeneral Precautions

Any cylinders with a defect must be Any cylinders with a defect must be identifiedidentified

If a leak cannot be stoppedIf a leak cannot be stopped– Move cylinder to a vacant lotMove cylinder to a vacant lot– Slowly release pressureSlowly release pressure– Post a warning signPost a warning sign

AcetyleneAcetylene cylinders cylinders – Must be upright for four hours before useMust be upright for four hours before use– Otherwise may draw Otherwise may draw acetoneacetone from the from the

cylindercylinder

Figure 2-25 Move a leaking fuel gas cylinder out of any work area

Fire ProtectionFire Protection

Fire is a constant dangerFire is a constant danger Highly combustible materials should by 35 Highly combustible materials should by 35

feet away from any welding sitefeet away from any welding site A A fire watchfire watch can be provided by any person can be provided by any person

who knows how to sound an alarmwho knows how to sound an alarm The The fire extinguisherfire extinguisher must be the type must be the type

required to put out a fire for the type of required to put out a fire for the type of combustible materialcombustible material

Fire ExtinguishersFire Extinguishers

There are four types of fire extinguishersThere are four types of fire extinguishers– Type AType A: combustible solids: combustible solids– Type BType B: combustible liquids: combustible liquids– Type CType C: electrical fires: electrical fires– Type DType D: fires involving combustible metals: fires involving combustible metals

Some fire extinguishers can be used on Some fire extinguishers can be used on more than one typemore than one type

Using the wrong type of extinguisher can Using the wrong type of extinguisher can be dangerousbe dangerous

TYPE A FIRETYPE A FIRE

TYPE B FIRETYPE B FIRE

TYPE C FIRETYPE C FIRE

TYPE D FIRETYPE D FIRE

Location of Fire ExtinguishersLocation of Fire Extinguishers

Fire extinguishers should be easily removedFire extinguishers should be easily removed Should be easily liftedShould be easily lifted Location marked with red paint and signsLocation marked with red paint and signs Should be marked near the floorShould be marked near the floor

LOCATIONLOCATION

UseUse

Extinguishers cool the fire and remove Extinguishers cool the fire and remove oxygenoxygen

Use foam, carbon dioxide, a pump tank, or Use foam, carbon dioxide, a pump tank, or dry chemicalsdry chemicals

COCO22 extinguisher – direct the discharge as extinguisher – direct the discharge as close to the fire as possibleclose to the fire as possible

Dry chemical extinguisher – direct toward Dry chemical extinguisher – direct toward the base of the flamesthe base of the flames

Figure 2-34 Point the extinguisher at the material burning, not the flames

Equipment MaintenanceEquipment Maintenance

Planned maintenance (PM) detects Planned maintenance (PM) detects problemsproblems

HosesHoses must be used for the gas or liquids must be used for the gas or liquids for which they were designedfor which they were designed– Green hoses are used only for oxygenGreen hoses are used only for oxygen– Red hoses are used only for fuel gasesRed hoses are used only for fuel gases

Never use oil grease, or other pipe-fitting Never use oil grease, or other pipe-fitting compounds on jointscompounds on joints

Any leaking joints must be repairedAny leaking joints must be repaired

Work AreaWork Area

Should be picked up and swept cleanShould be picked up and swept clean Arc welding area painted with a flat dark Arc welding area painted with a flat dark

colorcolor Portable screens used if welding outside the Portable screens used if welding outside the

welding boothwelding booth If a piece of hot material is left unattended, If a piece of hot material is left unattended,

write hot on it before leavingwrite hot on it before leaving

Hand ToolsHand Tools

Used for assembly and disassembly of partsUsed for assembly and disassembly of parts The adjustable wrench is the most popular The adjustable wrench is the most popular

tooltool Fewer points = strongerFewer points = stronger Mushroomed heads of chisels, punches, Mushroomed heads of chisels, punches,

and the faces of hammers should be and the faces of hammers should be ground offground off

Always use the correct tool for the jobAlways use the correct tool for the job

Electrical SafetyElectrical Safety

Injuries and death can be caused by Injuries and death can be caused by electrical shockelectrical shock

ResistanceResistance is lowered in the presence of is lowered in the presence of water or moisturewater or moisture

Electrically powered machines must be Electrically powered machines must be groundedgrounded

Welding circuits must be turned off when Welding circuits must be turned off when the work station is left unattendedthe work station is left unattended

Electrical Safety SystemsElectrical Safety Systems

Two safe systems for electrical power Two safe systems for electrical power tools:tools:

External grounding External grounding – A wire runs from the housing to a third prongA wire runs from the housing to a third prong– Third prong plug fits into grounded receptacleThird prong plug fits into grounded receptacle

Double insulationDouble insulation– Extra layer of insulation Extra layer of insulation – Eliminates need for grounded outletEliminates need for grounded outlet

Voltage WarningsVoltage Warnings

Voltage is the same as specified on the toolVoltage is the same as specified on the tool A voltage greater than the tool can lead to A voltage greater than the tool can lead to

injuryinjury A voltage lower than the tool can damage A voltage lower than the tool can damage

the motorthe motor Amperes (Amps) measures electrical Amperes (Amps) measures electrical

currentcurrent

Extension CordsExtension Cords

Use only three-wire, grounded extension Use only three-wire, grounded extension cordscords

When using extension cords:When using extension cords:– Connect the cord of tool into the extension Connect the cord of tool into the extension

firstfirst– Extension cords should be long enoughExtension cords should be long enough– The cord does not come in contact with The cord does not come in contact with

sharp objectssharp objects– Check for loose or exposed wiresCheck for loose or exposed wires– Clean before storingClean before storing

Figure 2-41 Two types of grounding plugs

Safety Rules for Portable Electric Safety Rules for Portable Electric ToolsTools

Some general rules:Some general rules: – Know the tool and ground the tool when neededKnow the tool and ground the tool when needed– Do not expose to waterDo not expose to water– Keep the area well lightedKeep the area well lighted– Do not use near propane, or flammable Do not use near propane, or flammable vaporsvapors– Wear eye protection Wear eye protection – Secure your work with clampsSecure your work with clamps– Maintain power toolsMaintain power tools

GrindersGrinders

Grinding using a pedestal or portable Grinding using a pedestal or portable grinder is required to do many welding jobsgrinder is required to do many welding jobs

Before a Before a grinding stonegrinding stone is put on a is put on a machine, it should be tested for cracksmachine, it should be tested for cracks

Each grinding stone is made for grinding Each grinding stone is made for grinding specific types of metalspecific types of metal

Stone should not be used when are worn Stone should not be used when are worn downdown

Gloves should never be worn when grindingGloves should never be worn when grinding

DrillsDrills

Center punch holes before drillingCenter punch holes before drilling If the bit gets caught, stop the motorIf the bit gets caught, stop the motor Securely clamp all metal before drillingSecurely clamp all metal before drilling Sharp metal shavings should be avoided Sharp metal shavings should be avoided

Metal Cutting MachinesMetal Cutting Machines

Before operating any power tool for the first Before operating any power tool for the first time, read the manufacturer's instructionstime, read the manufacturer's instructions

Welders use Welders use shears and punches shears and punches in the in the fabrication of metal for weldingfabrication of metal for welding

Cut off machinesCut off machines use abrasive wheels or use abrasive wheels or special saw bladesspecial saw blades

Band sawsBand saws are v are vertical or horizontalertical or horizontal– Some can be used in either positionSome can be used in either position

Material HandlingMaterial Handling

Improper work habits can cause serious Improper work habits can cause serious personal injurypersonal injury

Improper handling can cause damage to Improper handling can cause damage to tools and materialstools and materials

When When liftinglifting, the weight of the object , the weight of the object should be evenly distributed between both should be evenly distributed between both handshands

The capacity of The capacity of hoists or craneshoists or cranes should be should be checked before lifting a heavy loadchecked before lifting a heavy load

Ladder SafetyLadder Safety

Improper use of ladders is often a factor in Improper use of ladders is often a factor in fallsfalls

All ladder use poses a danger All ladder use poses a danger In case of a fall, keep the area around the In case of a fall, keep the area around the

ladder clear ladder clear Step ladders and straight ladders are used Step ladders and straight ladders are used

extensively in welding shopsextensively in welding shops

Figure 2-52 Make sure the ladder is leaning at the proper angle.

Ladder Inspection and SafetyLadder Inspection and Safety

Over time, ladders can become damagedOver time, ladders can become damaged– Look for loose or damaged parts Look for loose or damaged parts – Check that all hardware is tightCheck that all hardware is tight– Check wooden ladders for cracksCheck wooden ladders for cracks– Never use a defective ladderNever use a defective ladder– If a ladder cannot be repaired, replace itIf a ladder cannot be repaired, replace it– Read the entire ladder manufacturer's list of Read the entire ladder manufacturer's list of

safetysafety rules for ladder userules for ladder use– Never use a ladder that is too short for the jobNever use a ladder that is too short for the job– Climb and descend cautiouslyClimb and descend cautiously

SummarySummary

Safety is of the utmost importanceSafety is of the utmost importance The safety officer ensures welders comply The safety officer ensures welders comply

with safety ruleswith safety rules Wear proper clothing, shoes, and protectionWear proper clothing, shoes, and protection Have established plans in case of accidentsHave established plans in case of accidents Check equipment periodicallyCheck equipment periodically Further information is available in Further information is available in Safety for Safety for

Welders by Larry E. JeffusWelders by Larry E. Jeffus