 Welding joins two pieces of metal by the use of heat and/or pressure
 Brazing or soldering involves a filler metal which has a lower melting point than the metal pieces to be joined
 Metal cutting is done by heating the metal with a flame and directing a stream of pure oxygen along the line to be cut

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Arc Welding
Shielded Metal Arc Welding (SMAW)
Metal Inert Gas (MIG)
Tungsten Inert Gas (TIG)
Plaza Arc Welding (PAW)
Submerged Arc Welding (SAW)
And Many More…..more than 80 in all

 Generally, gases and fumes come from…
 Base material & filler material
 Coatings & paints
 Shielding gases & chemical reactions
 Process & consumables used
 Contaminants in the air

 Welding “Smoke” is a mixture of very fine particles called fumes and gases
 Welding “Smoke” contains fumes and gases including…
 Chromium, nickel, arsenic, asbestos, manganese, silica, beryllium, cadmium, nitrogen oxides, phosgene, acrolein, fluorine compounds, carbon monoxide, cobalt, copper, lead, ozone, selenium, and zinc
 cancer causing agents include: cadmium, nickel, beryllium, chromium, and arsenic

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Exposure to welding “smoke” may have…
Short-term effects
 Effects happen at or very soon after exposure
Long-term effects
 Effects may happen after repeated overexposures or an extended time after the exposure

 Welding “smoke” can :
 irritate the eyes, nose, chest and respiratory tract
 cause coughing, wheezing, shortness of breath, bronchitis, pulmonary edema, and pneumonitis
 cause nausea, loss of appetite, vomiting, cramps, and slow digestion

 Studies of have shown that welders have an increased risk of lung cancer and, possibly, cancer of the larynx and urinary tract
 Welders may experience a variety of chronic respiratory problems, including:
 Bronchitis, asthma, pneumonia, emphysema, pneumoconiosis, decreased lung capacity, silicosis, and siderosis

 Other health problems include:
 Heart disease
 skin diseases
 hearing loss
 chronic gastritis
 ulcers of the stomach and small intestine
 other reproductive risks

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Heat exposure
 Heat stress,
 heat stroke
 Skin burns and skin cancer
Noise
 Can result in stress, increased blood pressure, may contribute to heart disease, tiredness, nervousness, and irritability

 Eye damage- More than 5% of all eye injuries in the construction industry are associated with welding, cutting, and brazing
 damage to retina
 damage to cornea, resulting in cataracts
 permanent eye damage
 Invisible UV light can cause “arc eye” or “welders’ flash”
 May include sandy or gritty eye, blurred vision, intense pain, tearing, burning and headache

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Welding booths should be painted with dull finishes so they don’t reflect UV light
 Acoustic shields between the worker and noise sources can reduce exposures
Noisy machinery can be totally enclosed

 Use cadmium-free silver solders
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Use asbestos- free electrodes, gloves, and hot pads
Use work area barriers to protect others working in the same general area

 Construction personnel that is welding should be properly trained and qualified
 Inspect work area for fire hazards before welding
 Make provisions for ventilation before welding
 Compressed gas cylinders should always be secured in an upright position when not in use and handled with extreme care

 Gas cylinders should be stored at least 20 feet away from flammable materials and heat sources
 Oxygen cylinders should be stored at least 20 feet away from gas cylinders and combustible materials.
 When not possible, use a 5 ft tall noncombustible barrier with a
30 min. fire-resistance rating or better

 All combustible materials should be removed from welding area or covered with noncombustible material, prior to welding
 If covered, a worker that has experience using a fire extinguisher should be posted near as fire watch
 Workers should stand to the rear or side of regulators when opening valves on tanks
 Proper PPE should be worn, even by workers not welding

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Don’t weld on painted surfaces
Use water table to reduce noise
Properly maintain equipment
Proper housekeeping
Use lowest possible amperage
Hold electrode perpendicular and close to work surface
Never weld or cut within 200 feet of degreasing equipment or solvents

 PPE must be used in conjunction with engineering controls and safe work practices
 Use of one does not eliminate the need for the other
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Eye protection should be used in all welding operations
 Wear face shields or helmets and goggles or safety glasses
Use appropriate filters on eye protection

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Fire resistant gauntlet gloves
Head cap
High top hard toed shoes
Leather apron
Face shield
Flame retardant clothing
Safety Glasses
Safety helmet
Hearing plugs and/or muffs

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Even though welding generally uses low voltage, there is still a danger of electric shock
Wet work areas, cramped work spaces
Falls, fractures and other accidents can result from electrical exposure
Even small shock can cause brain damage
Death can occur from large shocks

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Always use dry gloves
Always wear rubber soled shoes
Always use insulating layers
Protect yourself from surfaces that conduct electricity
When working on electrically powered machinery, make sure the frame is grounded
Keep insulation on all welding equipment and components dry and in good condition
Don’t change electrodes with bare hands, wet gloves or while standing on wet or ungrounded surfaces

 Never weld or cut on containers that have held a flammable or combustible material unless the container is thoroughly cleaned or filled with an inert gas
 A fire inspection should be performed prior to leaving a work area and for at least 30 minutes after the operation is completed
 Fire extinguishers should be nearby, of proper size, type and number for the hazards involved

 All machines in the area with moving parts must be guarded to prevent worker’s contact e.g. hair, clothing, fingers
 When repairing machinery by brazing and welding, power must be disconnected, locked out, and tagged so the machinery cannot be started up accidentally

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Keep work areas clear of equipment, machines, cables, and hoses
Always properly maintain and use handrails
Always use and maintain safety lines, harnesses and lanyards
Always make sure that scaffolds are properly assembled and used

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A work area with limited access, little or no airflow, not intended for continuous occupation
 May also have dangerous atmospheres, hazardous configurations, or other hazards
All employees working in or around confined space must be trained
Adequate ventilation must hold fumes and smoke to levels within the safe breathing range set forth in 29 CFR 1926 subpart D

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No worker should work in an area with less than
19.5% or more than 23.5% oxygen content
Use continuous mechanical ventilation and proper respiratory protection
When adequate ventilation cannot be achieved, workers must be provided with air supplying respirators as described in 29 CFR 1926 Subpart E

 Always leave gas cylinders and welding power sources outside the confined space…
 Only take hoses or welding leads into confined space and remove when leaving for breaks, shift or crew changes
 All pipes, ducts, and power lines that are not necessary for the work should be disconnected/locked out/tagged out

 When transporting and handling, valve cap should be securely in place
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Cylinders should never be lifted by valve cap
Cylinder valve should be closed when cylinder is empty, being moved or not in use
 Cylinders should be secured to a pallet, cradle, or sling board for hoisting
 Cylinders should not be dropped, bumped, struck or receive any other huge impact
 Cylinders should be thawed with warm water when frozen in place

 Fuel, gas and oxygen hoses must be easily and clearly distinguishable.
 Oxygen and gas hoses must not be interchangeable
 When oxygen and fuel hoses are taped, no more than 4 inches per foot of hose may be taped
 Gas and oxygen hoses must be inspected before every shift and removed if defects are found.
 Torches should be inspected before each shift to detect leaks
 Tip openings should be kept clean and unclogged
 Torches should be lighted by friction lighters

 Only use manual electrode holders designed specifically for arc welding
 All current-carrying parts should be properly insulated for maximum voltage encountered
 Cables must be properly insulated, flexible and able to handle maximum current required
 All equipment and cables should be inspected before each shift and should be removed if any defects are found
 Operations should be shielded appropriately as to protect other workers in the area

Subject to damage from other activities in the vicinity
Cylinder laying in a horizontal position.
Electrical cord in
Contact with the cylinder
Compressed Gas Cylinder Safety

Chain
Cylinders are not protected from falling. Note that the Chain is not secured across.
Compressed Gas Cylinder Safety

Electrical
Cord
1. Cylinder not secured
3. Subject to damage.
2. Cylinder should be stored
4. Electrical cord draped over.
Compressed Gas Cylinder Safety

1. Small cylinder not tied off
2. Combustibles stored with cylinders
3. Bad housekeeping
4. Acetylene and Oxygen stored too close together and no chain.
Compressed Gas Cylinder Safety

1. Cylinder with no valve or cap installed
3. Subject to damage
2. Laying horizontal on the ground
Compressed Gas Cylinder Safety

Electrical arc damage
Cylinder is damaged. Should be taken out of service immediately!
Compressed Gas Cylinder Safety

Cylinder should be in storage protected from damage and not laying on the ground regardless if it is full or empty
Compressed Gas Cylinder Safety

Old, corroded cylinder that should have been disposed of a long time ago.
Compressed Gas Cylinder Safety

Forklift
1. Cylinders laying on the ground and improperly stored
2. Subject to damage from forklift operation in vicinity
Compressed Gas Cylinder Safety

1. Feed line exposed to damage/leak that could cause a fire/explosion
2. Tripping Hazard
Compressed Gas Cylinder Safety

1. Inadequate housekeeping
2. Valve caps should be installed.
Compressed Gas Cylinder Safety

1.
Unsecured acetylene cylinder 2. Exposed to damage
Compressed Gas Cylinder Safety

Unsecured cylinders
Compressed Gas Cylinder Safety

Regulator left pressurized after use
Compressed Gas Cylinder Safety

Improper Storage
Compressed Gas Cylinder Safety

Compressed Gas Cylinder Safety
Tie Off?

Improper storage of cylinders- acetylene and oxygen stored next to each other
Compressed Gas Cylinder Safety

Evidence of smoking next to acetylene cylinders
Compressed Gas Cylinder Safety

This cylinder should be taken to storage and housekeeping should be improved.
Compressed Gas Cylinder Safety

Compressed Gas Cylinder Safety
Unsecured cylinder

Unsecured Cylinder
Compressed Gas Cylinder Safety

Cooking equipment within 20 ft of containers
Compressed Gas Cylinder Safety

Not Tied
Tied
Compressed Gas Cylinder Safety

oxy-acetylene torch connected
To bottles without the torch connected.
Compressed Gas Cylinder Safety

No cap installed
Housekeeping
Not in use.
Should be
Stored.
Compressed Gas Cylinder Safety

Cylinder not in use with regulators still
On the cylinder
Compressed Gas Cylinder Safety
Free standing cylinder

Free standing cylinder
Compressed Gas Cylinder Safety

Free standing cylinders
Chain
Compressed Gas Cylinder Safety

Cylinder tied only
With a bungee cord
Compressed Gas Cylinder Safety

Cylinders not
Secured properly
Compressed Gas Cylinder Safety

Exposed to damage
From construction
Activities in area
Free standing cylinders
Compressed Gas Cylinder Safety

Free standing cylinders
Compressed Gas Cylinder Safety

Cylinder laying on its side
Compressed Gas Cylinder Safety

Coll, R. (2002, October 17). Compressed Gas Cylinder Training Slides.
Retrieved September 10, 2009 from , Web site: http://siri.uvm.edu/ppt/cgcsafety/sld001.htm
Goetsch, D. (2010). Construction safety and the OSHA standards.
Boston: Pearson.
Saverio (2003). Welding Safety. Retrieved September 10, 2009 from , Web site: http://www.authorstream.com/Presentation/Saverio-42953-
Welding-Safety-2003-Health-Hazards-HazardsGases-Fumes-Shortterm-Entertainment-ppt-powerpoint/