Subpart J Welding and Cutting These handouts and documents with attachments are not final, complete, or definitive instruments. This information is for guidance purposes only. You should independently verify and satisfy yourself as to its accuracy. The AHBSIF does not assume any liability for damages arising from the use of this information or exhibits and attachments thereto and renders no opinion that any of the terms, conditions, and/or cited federal standards in this document and the exhibits and attachments should be explicitly followed by the fund member. Seek specific guidance from the appropriate regulator (OSHA) or professional advisor.

Potentially Hazardous Fumes and Gases  Fumes – Solid particles that originate from the welding media, base metal, or coating  Gas – Generated by the shielding gas or process radiation  Nickel  Zinc  Iron Oxide  Copper  Cadmium  Fluorides  Manganese  Chrome & Gases

Effects of Overexposure  Acute Effects  Irritation of eyes, skin, respiratory system  nausea, headaches, dizziness  Metal Fume Fever  Asphyxiation (confined space)  Chronic Effects  Central nervous system impairment  Respiratory illness  Reproductive disorders  Possible links to Parkinson’s

Radiation  Visible – intense light emitted during welding operations  Infrared - produced by electric arc and other flame cutting equipment  Ultraviolet - generated by all arc processes

Radiation Effects - Influencing Factors  Wavelength  Intensity  Duration of exposure  Exposure may result in skin burns or eye damage

Common Welding Techniques  MIG Welding  TIG Welding  MAPP Gas  Oxy-fuel Welding

MIG Welding  “Metal Inert Gas”  Semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun.  Can use alternating or direct current, DC is most common  Typically used with steel  Fast welding technique

TIG Welding  “Tungsten Inert Gas”  Uses a nonconsumable tungsten electrode and filler metal to produce the weld.  A shielding gas such as argon protects the process from atmospheric contamination  Commonly used with Aluminum, Magnesium, Copper, light gauge Stainless Steel  Slower than other welding techniques  Harder to master than other forms of welding but produces higher quality and stronger welds

MAPP Gas  “Methyl Acetylene Propodiene”  Consists of LPG mixed with MAPP  Does not require dilution or special container fillers during transport which allows a greater volume of gas to be transported at the same given weight  Most commonly used for brazing and soldering  Ideal for aluminum and copper

Oxy-fuel Welding  “Oxyacetylene Welding” aka Gas Welding  Two pieces are heated to a temperature that produces a shared pool of molten metal.  The molten pool is supplied with additional metal called filler.

Safe Work Practices  The surrounding work area should be clean and free of potentially combustible material  A fire extinguisher should be kept on hand at all times  Good ventilation is a must for all welding operations  Personal protective equipment (PPE) should include eye and face protection as well as protective clothing  Less toxic materials should be substituted when possible  Cadmium-free silver solders  Asbestos-free electrodes

Pre-Shift Inspection  Leads – insulation breech, kinks  Torch – tip, valves, tool body  Hoses & Fittings  Bottles & Valves  Cart or other CG Bottle Support  Surrounding Area  Fire Protection  Any defective equipment must be replaced, repaired, or removed from service

Personal Protective Equipment Helmet  Must Comply with ANSI Z87.1  Most equipped with auto-darken features, 1/10,000 of a second  OSHA Tables E-1 and E-2 specify minimum protection levels

Personal Protective Equipment Gloves  ANSI Z49.1  Must be flame resistant  Gloves should be in good shape  Must resist potential electric shock from welding unit

Personal Protective Equipment Apron  ANSI Z49.1  Produced in variety of fire retardant materials  Leather  Nomex  Chemically treated textiles

Compressed Gas Cylinders  Typical Oxygen cylinder pressures are around 2600 lbs/in²  Oxy fittings should be kept clean and free of oil and grease  Hose colors determine use:  Red – fuel gas hose  Green – Oxygen  Black – Inert gas

Compressed Gas Cylinders  Cylinder valves must be protected at all times  Cylinders should be stored in an upright and secure position  The tilt and roll method is accepted practice for movement, never attempt to hoist with chokers  Valve caps must be secure any time the cylinder is not in use  When stored, oxygen cylinders should be separated from other gas cylinders.  The required separation is 20’ or or  A five foot high fire wall with an approved fire-resistance rating

Welding Torch - Cutting Torch Comparison

Cutting Torch Safety  Take appropriate precautions for flooring surface  Work benches made of steel or other fire retardant material is acceptable  Adequate ventilation  Confined Spaces  Toxic Fumes

Cutting Torch Safety  Appropriate personal protective equipment  Control potentially combustible materials around work area  Fire extinguisher handy at all times  Equipment maintenance

Safe Welding Checklist Familiarization with all applicable Material Safety Data Sheets (MSDS) Surrounding area free of potentially combustible materials Leeds should be fully insulated, no kinks or deformation Fire extinguisher readily available, fully charged and functional Torch tip, valves, and tool body in good working order Proper face, hand, and body protection in use Hoses and fittings tight and free of wear, dry rot Surrounding work areas protected by welding curtains Bottles secured and upright whether stored or in use, cap secured Adequate ventilation for all processes at all locations Bottles free of excessive corrosion, no dents, collar threads intact, clean fitting Insure proper grounding of welding machine Valves and gauges secured and operational Any defective equipment replaced or repaired prior to the start of work