Chapter 2
Welding Safety
© 2012 Delmar, Cengage Learning
Objectives
• After completing this chapter, you will
be able to:
– Explain how to work safely
– Identify each degree of burn and describe
how to provide first aid
– List the types of protective clothing a
welder should wear
– Explain the importance of proper
ventilation and respiratory protection
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Objectives (cont’d.)
– Describe how to safely lift, climb, and
handle materials
– Demonstrate electrical safety
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Introduction
• Welding fabrication
– Very large and diverse industry
• Light welding fabrication
– Has a number of potential safety hazards
– Safety is your own responsibility
• Accident consequences
– Injury
– Local, state, or national investigations
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Burns
• Classifications
– First-degree burns
• Skin surface is reddish, tender, and painful
• Do not involve broken skin
• Immediate treatment: cold water or compress
– Second-degree burns
• Skin is severely damaged
• Result in blisters and possibly breaks
• Immediate treatment: cold water or compress
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FIGURE 2-1 First-degree burn—only the FIGURE 2-2 Second-degree burn—the
skin surface (epidermis) is affected.
epidermal layer is damaged, forming
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blisters or shallow breaks.
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Burns (cont’d.)
– Third-degree burns
• Skin surface appears white or charred
• Immediate treatment: cold cloth or cool water
on burns of the face, hands, or feet and cover
– Burns caused by light
• Types of light: ultraviolet, infrared, and visible
• Ultraviolet light waves: most dangerous
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FIGURE 2-3 Third-degree burn—the
epidermis, dermis, and the subcutaneous
layers of tissue are destroyed.
FIGURE 2-4 Portable welding
curtains.
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Frommelt Safety Products
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Eye and Ear Protection
• Face and eye protection
– Safety glasses with side shields or goggles
– Face shield
– Flash glasses
– Welding helmets
• Ear protection
– Earmuffs
– Earplugs
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Respiratory Protection
• Equipment should be certified by NIOSH
– Air-purifying respirators
– Atmosphere-supplying respirators
– Demand respirators
– Positive pressure respirators
– Powered air-purifying respirators
– Self-contained breathing apparatuses
– Supplied-air respirators
– Filtering facepiece
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FIGURE 2-14 Typical respirator for contaminated environments.
The filters can be selected for specific types of contaminant.
MSA
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Ventilation
• Actual welding area
– Should be outside or well-ventilated
• Natural ventilation is the best
• Forced ventilation may be required
• Forced ventilation
– Required in small shops or shops with a
large number of welders
– May be general or localized
• Using fixed or flexible exhaust pickups
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Material Specification Data
Sheet (MSDS)
• Give detailed information about hazards
resulting from product use
– Provided to anyone using the products or
working in the area where they are in use
– Often posted on a bulletin board
• Right-to-know laws
– Require specific training of employees who
handle or work in areas with hazardous
materials
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Waste Material Disposal
• Welding shops generate waste
materials
– Mostly scrap metal
– All scrap metal can be easily recycled
• Good for the environment
• Source of revenue
– Hazardous waste disposal
• Consult local, state, and federal regulations
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Ladder Safety
• Falls: major cause of injury and death
– Improper ladder use is often a factor
• Types of ladders
– Stepladders, straight ladders, and
extension-type ladders
• Ladder inspection
– Inspect for wear and damage with each
use
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Ladder Safety (cont’d.)
• Rules for ladder use
– Follow all recommended practices
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•
•
•
•
•
•
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Do not exceed maximum weight limit
Surface should be level and solid
Never use in a wet or muddy area
Tie ladder securely in place
Climb and descend cautiously
Don’t carry tools
Never use a ladder around electrical wires
Never use a ladder too short for the job
Wear well-fitted shoes
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Electrical Safety
• Electric shock
– Can cause injuries and even death
• Proper precautions must be taken
• Electrical safety systems
– Standard portable tool safety systems
• External grounding or double insulation
FIGURE 2-21
Typical portable
power tool
nameplate.
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Voltage Warnings
• Voltage supplied
– Should be same as specified on tool
nameplate
• Extension cords
– Conductors must be large enough to prevent
an excessive drop in voltage
• Safety rules for portable electric tools
– Observe safety precautions
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General Work Clothing
• Should minimize burn chances
– Wool is the best choice
– All-cotton is a good second choice
• Guidelines
– Shirts: long-sleeved, collared, long enough
to tuck in, and flapped pockets
– Pants: cover top of boots and without cuffs
– Boots: high tops and steel toes
– Caps: thick
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Special Protective Clothing
• Includes:
– Hand protection: all-leather, gauntlet-type
gloves
– Body protection: full leather jackets and
capes
– Waist and lap protection: bib or full aprons
– Arm protection: full- or half-sleeves
– Leg and foot protection: leather pants or
leather aprons with leggings
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Handling and Storing Cylinders
• Cylinders with flammable materials:
stored separately
– Securing gas cylinders
• Chain or other device must be used
– Storage areas
• Considerations: location and temperature
– Cylinders with valve protection caps
• Cap is in place unless the cylinder is in use
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Handling and Storing Cylinders
(cont’d.)
• General precautions
FIGURE 2-31 Move a leaking fuel gas cylinder out of the building or any work area.
The pressure should slowly be released after a warning of the danger is posted.
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Fire Protection
• Fire: constant danger to the welder
• Fire watch
– Provided by anyone who knows how to
sound the alarm and use a fire extinguisher
• Fire extinguishers
– Type A, B, C, and D
– Should be located near materials
– Work by breaking the fire triangle of heat,
fuel, and oxygen
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Equipment Maintenance
• Routine schedule of maintenance
– Aids in detecting potential problems
• Examples: leaking coolant, loose wires, poor
grounds, frayed insulation, or split hoses
• Hoses
– Must be used only for the gas or liquid for
which they were designed
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Work Area
• Should be kept picked up and swept
clean
FIGURE 2-42 An easy-to-build electrode caddy
can be used to hold both electrodes and stubs.
Larry Jeffus
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Hand Tools
• Uses
– Assembly and disassembly of parts
– Routine equipment maintenance
• Types
– Adjustable wrench, hammer, chisels, etc.
• Hand tool safety
– Treat properly and do not abuse
• Hammer safety
– Follow precautions
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Power Tools
• Must be properly grounded
– Prevents accidental electrical shock
• Types
– Grinders and grinding stones
– Drills
FIGURE 2-48 Always check to be sure
that the grinding stone and the grinder
are compatible before installing a stone.
Larry Jeffus
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Metal Cutting Machines
• Many types
– Examples:
shears, punches,
cut-off machines,
and band saws
• Shears and
punches
– Frequently used
in fabrication of
metal for welding
FIGURE 2-52 Power shear.
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Material Handling
• Proper lifting, moving, and handling of
large, heavy-welded assemblies
– Important to worker and weldment safety
• Follow specific precautions for:
– Lifting
– Hoists or cranes
– Hauling
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Summary
• Safety in welding fabrication
– Utmost importance
• When done correctly, welding and
fabrication are safe
– Read and follow all manufacturer literature
– Perform maintenance and servicing
– Perform safety checks
– Keep equipment in good working order
© 2012 Delmar, Cengage Learning