Electric Arc Welding (Revision 1 – 22nd January 2010) Toolbox Talk

HAZARDS AND RISKS ASSOCIATED WITH ELECTRIC ARC WELDING Electric shock, arising from: I.Contact with bare live parts (e.g. electrode holders with damaged insulation). II.Stray currents resulting from not placing the welding return lead as close as possible to the point where welding is being carried out (particularly on pipework installations) OR poor insulation on the welding return lead. III.Using arc welding equipment in damp or wet surroundings. Welding radiation which can cause damage to the eyes and skin. Accidentally igniting combustible material in the vicinity of the works. Burns from the arc, sparks or hot spatter. Inhalation of harmful welding fumes. Asphyxiation if welding is carried out in an area with poor ventilation.

PERSONAL PROTECTIVE EQUIPMENT Face shield with eye protection filter (worn by welder and any other persons in the immediate vicinity of the works). The filter strength should be appropriate for the task (range from 11 – 14). Welders gauntlets Protective apron (optional) Boilersuit – flameproof/flame retardant material Steel toe capped safety boots (Riggers boots should not be worn)

In addition to the above PPE: Operatives should remove personal jewellery, in particular rings, bracelets and metallic watch straps before starting work. Plastic disposable cigarette lighters must not be kept in pockets whilst carrying out arc welding. Do not leave bare skin exposed to the rays of the welding arc. Gauntlets should be kept dry.  

EQUIPMENT REQUIRED Screen Portable fan and ducting (except welding bay in workshop) AFFF fire extinguisher

PRE-USE CHECKS OF WELDING EQUIPMENT The following items should be checked for any signs of wear or damage (Note: It is particularly important that the integrity of insulation on these items is checked). Electrode holder Welding and return leads Clamps Cables and plugs

AREA WHERE ELECTRIC ARC WELDING IS TO BE CARRIED OUT Ensure that there is a good ventilation in the area, refer to the Estates Section Confined Spaces procedures for work in underground ducts or other potential confined spaces. Locate fume extract as close to the work area as possible, portable extract ductwork must terminate to an external area away from any ventilation intake points. Screen the area off to protect the eyes of others not working on the job.

AREA WHERE ELECTRIC ARC WELDING IS TO BE CARRIED OUT (continued) Remove any flammable material adjacent to the job in hand. Ensure that any pipework being worked on has been isolated and drained. Never weld anything that may have held inflammable materials. (see the following article on a fatal accident which occurred locally) Use an insulating mat when standing on steelwork or plate. Do not stand on damp or wet areas whilst welding. 

ARC WELDING OPERATIONS If using a portable machine, ensure that it has been PAT Tested within the last 3 months. If the welding is not being carried out in the workshop welding bay a Hot Works Permit MUST be issued for the work. Care must be taken to avoid allowing the uninsulated part of the electrode holder coming in contact with the earthed job or the earthing clamp whilst the current is switched on as the resulting flash is extremely hazardous to the eyes. Never allow the “live parts” of the electrode holder to touch bare skin.

ARC WELDING OPERATIONS (continued) The electrode holder must always be isolated (i.e. machine unplugged) when changing the electrode. When welding is complete switch off the power supply and remove the electrode from the holder. When welding on pipework installations, the welding return lead should be placed as close as possible to the point of welding and preferably no further away than 3 metres. Avoid welding stainless steels, aluminium or using thiorated thoriated tungsten electrodes wherever possible as the fumes and dusts emitted by these processes is potentially more harmful.

FURTHER INFORMATION further information on electric arc welding refer to the following publications: HSE publication HS(G)204 Health and Safety in Arc Welding 2000 HS(G)118 Electrical safety in arc welding