1. Chapter 2
Safety in Welding

2. Objectives
Describe the three classifications of burns and the emergency steps that should be taken to treat each of them
Describe the dangers all three types of light pose to welding and how to protect yourself and others from these dangers
Explain how to avoid eye and ear injuries
Use a chart to select the correct eye and face protective devices for working and welding in a shop

3. Objectives (cont'd.)
List the safety points that should be covered in a training program for respiratory protection
Describe the various types of respiratory protection equipment that are available
Tell how to avoid dangerous fumes and gases by providing ventilation to the welding area
Explain the purpose of material safety data sheets (MSDSs) and where they can be found
Discuss the benefits of recycling waste material

4. Objectives (cont'd.)
Describe what type of general work clothing should be worn in a welding shop
Describe special protective clothing worn by welders to protect the hands, arms, body, waist, legs, and feet
Describe the proper way to handle, secure, and store cylinders
Discuss how to protect against the danger of fire when welding

5. Objectives (cont'd.)
Explain why planned maintenance of tools and equipment is important
Describe the most commonly used hand and power tools used by a welder
Explain good electrical safety practices and list rules for extension cords and portable power tools
Discuss the types of metal cutting machines
Describe proper ways to safely lift heavy welded assemblies
List the rules for ladder safety

6. Introduction No substitute for caution and common sense
Each person must take personal responsibility
Their own safety and safety of others on the job
Welding is a very large and diverse industry
This chapter concentrates on light welding fabrication
A number of potential safety hazards
Learning to work safely
As important as learning to be a skilled welding fabrication worker

7. Burn Classification Burns One of the most common and painful injuries
Caused by ultraviolet light rays or contact with hot welding torches
Chance of infection is high
All burns must receive proper medical treatment
Divided into three classifications
First-degree, second-degree, and third-degree

8. First-Degree Burns Characteristics Treatment
Surface of the skin is reddish, tender, and painful
No broken skin
Treatment
Put burned area under cold water or apply a cold compress
Cover the area with sterile bandages
Never apply butter or grease

9. FIGURE 2-1 First-degree burn—only the skin surface (epidermis) is affected.
© Cengage Learning 2012

10. Second-Degree Burns Characteristics Treatment
Surface of the skin is severely damaged
Blisters and possible breaks in the skin
Treatment
Put the area under cold water or use cold water compresses
Pat area with a dry lint-free towel and cover with a sterile bandage
Seek medical attention

11. FIGURE 2-2 Second-degree burn—the epidermal layer is damaged, forming blisters or shallow breaks.
© Cengage Learning 2012

12. Third-Degree Burns Characteristics Treatment
Surface of skin appears white or charred
Treatment
Never remove any clothing
Never use ice water or ice, ointments, sprays, etc.
If victim is on fire: smother fire with a blanket, rug, or jacket
Cover with a thick, nonfluffy, sterile dressing
Call for an ambulance

13. FIGURE 2-3 Third-degree burn—the epidermis, dermis, and the subcutaneous layers of tissue are destroyed.
© Cengage Learning 2012

14. Burns Caused by Light Some types of light can cause burns
Ultraviolet
Infrared
Visible
Arc welding produces all three types of light
Gas welding produces visible and infrared light only
Light from the welding process
Can be reflected from walls, ceilings, floors, etc.

15. Ultraviolet Light Ultraviolet light waves Most dangerous
Causes first- and second-degree burns to eyes or exposed skin
Closer welder is to the arc and higher the current: quicker a burn may occur
Welder's eyes can receive a flash burn in seconds

16. Infrared Light Light wave is felt as heat
A person will immediately feel this type of light
Burns can be easily avoided
Protective action should be taken to cover yourself

17. Visible Light Light that we see
Produced in varying quantities and colors
May cause temporary night blindness
Too little visible light may cause eye strain
Visible light is not hazardous

18. Face, Eye, and Ear Protection
Eye protection
Must be worn in the shop at all times
Safety glasses with side shields
Goggles
Full face shield
Flash glasses
Welding light damage
Often occurs without warning

19. Welding Helmets
Even with quality welding helmets, the welder must check for potential problems
Undetectable leaks of ultraviolet light can cause a welder's eyes to itch or feel sore
Ensure lens gasket is installed correctly
Tape can be used as a temporary repair

20. Safety Glasses Safety glasses with side shields
Adequate for general use
Not suitable for heavy grinding, chipping, or overhead work
Must be worn under an arc welding helmet at all times

21. Ear Protection Welding environment can be very noisy
Hot sparks can drop into an open ear and cause severe burns
Several forms of protection
Earmuffs cover the outer ear completely
Earplugs fit into the ear canal

22. Respiratory Protection
Welding and cutting produce harmful by-products
Respirators protect against welding by-products
Welders are responsible for following the shop's written respiratory protection policy
Training should include:
Proper respirator use
Maintenance schedules and respirator selection
Procedures for testing the proper fitting and use
Regular program evaluation

23. Equipment Respiratory protection equipment Air-purifying respirators
Atmosphere-supplying respirators
Demand respirators
Positive pressure respirators
Powered air-purifying respirators
Self-contained breathing apparatuses
Supplied-air respirators

24. Fume Sources Materials can cause respiratory problems Marine industry
Paints, coating, or plating on metals
Before welding or cutting any painted metal: surface must be cleaned
Marine industry
Still uses lead-based paints
Exposure to cadmium fumes
Can cause lung and kidney damage
Best way to avoid problems
Adequate ventilation

25. Vapor Sources Potentially dangerous gases Ozone gas
Also can be present in a welding shop
Proper ventilation or respirators are necessary when welding in confined spaces
Ozone gas
Produced by ultraviolet radiation
Irritates mucous membranes
Collection of fumes and gases can go unnoticed
Concentrated fumes can cause a fire or explosion

26. Ventilation Welding area should be well ventilated
Natural ventilation is best
Forced ventilation may be required
Large enough areas may not require forced ventilation

27. FIGURE 2-15 A room with a ceiling 16 ft (4
FIGURE 2-15 A room with a ceiling 16 ft (4.9 m) high may not require forced ventilation for one welder.
© Cengage Learning 2012

28. Forced Ventilation
Small shops or shops with many welders require forced ventilation
Can be general or localized
Fixed or flexible exhaust pickups
Required when welding on metals that give off dangerous fumes

29. Material Safety Data Sheets (MSDSs)
Provide details of possible hazards
Must be provided to anyone using the product or working in the area where products are in use
Often posted on a bulletin board or put in a convenient place where products are used
If injured while using a product: take material's MSDS when you seek treatment

30. General Work Clothing Guidelines Some clothes have pockets
Shirts must be long-sleeved
Pants must be long enough to cover the tops of the boots and must be without cuffs
Boots must have high tops
Caps should be thick
Clothing must be free of frayed edges or holes
Some clothes have pockets
Not safe to carry a butane lighter or matches while welding

31. Special Protective Clothing
Extra protection is needed for each person who is in direct contact with hot materials
Hand protection
Body protection
Waist and lap protection
Arm protection
Leg and foot protection

32. Handling and Storing Cylinders
Considerations
Store oxygen and fuel gas cylinders separately
Store inert gas cylinders separately or with oxygen cylinders
Secure gas cylinders
Cylinder storage areas must be located away from halls, stairwells, and exits
Cylinders with a valve protection cap must have the cap in place

33. General Precautions Any cylinders with a defect must be identified
Leak cannot be stopped
Move cylinder to a vacant lot
Slowly release pressure
Post a warning sign
Acetylene cylinders
Must be upright for four hours before use
Otherwise may draw acetone from the cylinder

34. FIGURE 2-25 Move a leaking fuel gas cylinder out of the building or any work area. The pressure should be slowly released after a warning is posted of the danger.
© Cengage Learning 2012

35. Fire Protection Fire is a constant danger
Highly combustible materials should by 35 feet away from any welding
Fire watch can be provided by any person who knows how to sound an alarm
Fire extinguisher must be the type required to put out a fire for the type of combustible material

36. Fire Extinguishers Four types Location Type A: combustible solids
Type B: combustible liquids
Type C: electrical fires
Type D: combustible metals
Location
Appropriate type should be located near types of combustible materials it is used for

37. Fire Extinguishers (cont’d.)
Use
Extinguishers cool the fire and remove oxygen
Use foam, carbon dioxide, a pump tank, or dry chemicals
CO2 extinguisher: direct discharge as close to the fire as possible
Dry chemical extinguisher: direct toward the base of the flames

38. Equipment Maintenance
Planned maintenance (PM)
Detects problems
Hoses must be used for the gas or liquids for which they were designed
Green hoses are used only for oxygen
Red hoses are used only for fuel gases
Never use oil grease, or other pipe-fitting compounds on joints
Any leaking or bad joints must be repaired

39. Work Area Considerations
Work area: should be picked up and swept clean
Arc welding areas: painted with a flat dark color
Portable screens: used if welding outside the welding booth
Piece of hot material is left unattended: write hot on it before leaving

40. Hand Tools Used for assembly and disassembly of parts
Adjustable wrench is the most popular
Fewer points a box end wrench or socket has: the stronger it is
Mushroomed heads of chisels, punches, and the faces of hammers should be ground off
Always use the correct tool for the job

41. Hand Tool Safety Considerations
Hand tools should be treated properly and not abused
Keep hand tools clean
Make sure that hand tools are sharp
Protect cutting edges when carrying
Keep hammer handles secure and safe
When swinging a hammer, be absolutely certain that no one is within range

42. Electrical Safety Injuries and death can be caused by electrical shock
Resistance is lowered in the presence of water or moisture
Electrically powered machines must be grounded
Electrical connections must be tight
Do not allow metal parts of electrodes or electrode holders to touch skin or wet coverings on bodies
Welding circuits must be turned off when the work station is left unattended

43. Electrical Safety Systems
Two safe systems for electrical power tools
External grounding
A wire runs from the housing to a third prong
Third prong plug fits into grounded outlet
Double-insulation
Extra layer of insulation
Eliminates need for three-pronged grounded outlet

44. Voltage Warnings Voltage Voltage greater than the tool
Same as specified on the tool
Voltage greater than the tool
Can lead to injury and tool damage
Voltage lower than the tool
Can damage the motor
Amperes (Amps)
Measures electrical current

45. Extension Cords Use only three-wire, grounded extension cords
Safety tips
Connect cord of tool into extension cord first
Unplug extension cord from receptacle first
Extension cords should be long enough
Cord should not come in contact with sharp objects and must be positioned appropriately
Check for loose or exposed wires and unusual heating
Use a knot to prevent accidental separation
Clean before storing

46. Safety Rules for Portable Electric Tools
Safety precautions
Know the tool and ground when needed
Do not expose to water
Keep the area well lighted
Do not use near propane or flammable vapors
Do not force a cutting tool to cut faster
Use the right tool for the job
Wear eye and face protection
Secure your work with clamps
Maintain power tools

47. Safety Rules for Portable Electric Tools (cont’d.)
Disconnect from power source when not in use
Check to see keys or wrenches are removed
Avoid accidental starting
Be sure accessories and bits are attached securely
Do not use tools with cracked or damaged housings
Give your full and undivided attention
Never use a power tool with its safeties or guards removed or inoperable

48. Grinders
Grinding using a pedestal or portable grinder is required to do many welding jobs
Before a grinding stone is put on a machine, it should be tested for cracks
Each grinding stone is made for grinding specific types of metal
Stone should not be used when worn down
Gloves should never be worn when grinding

49. Drills Considerations Secure workpiece before drilling
Center-punch workpiece before drilling
Hold drill perpendicular to the face of the work
Except when drilling a hole at an angle
Use just steady, even pressure
Drill becomes jammed in the hole
Release trigger immediately
Remove drill bit
Determine cause

50. Metal Cutting Machines
Many types
Shears and punches
Used in fabrication of metal for welding
Cut-off machines
Use abrasive wheels or special saw blades
Band saws
Vertical or horizontal
Some can be used in either position

51. Material Handling Improper work habits Lifting Hoists or cranes
Can cause serious personal injury and damage to equipment and materials
Lifting
Weight of the object should be evenly distributed between both hands
Hoists or cranes
Capacity should be checked before lifting a heavy load

52. Ladder Safety Improper use of ladders is often a factor in falls
All ladder use poses potential hazards
Keep the area around the ladder clear
Step ladders and straight ladders
Used extensively in welding shops

53. Ladder Safety (cont’d.)
Ladders can become damaged over time
Look for loose or damaged parts
Check that all hardware is tight
Check wooden ladders for cracks
Never use a defective ladder
Ladder cannot be repaired: replace it
Read the entire ladder manufacturer's list of safety rules for ladder use

54. Summary Safety is of the utmost importance
Safety officer ensures welders comply with safety rules
Wear proper clothing, shoes, and protection
Have established procedures in case of accidents
Check equipment periodically
Further information is available in Safety for Welders, by Larry E. Jeffus