Ergonomics in Welding

What You Will Learn: How to identify Work-Related Musculoskeletal Disorders (WMSD’s) in welding jobs Propose solutions for hazardous exposures Find further information about ergonomics in welding operations

Common Hazards Common hazards found in welding are: Inhaling metals fumes Eye exposure to welding arc light Foreign objects in eyes Burns Noise

WMSD Hazards Welding also includes musculoskeletal disorder (WMSD) hazards such as: Awkward body postures Lifting heavy equipment or materials Static postures for prolonged periods Awkward postures of the wrist

WA State-funded compensable claims 1994-2004 Welders, Cutters, Solderers By Nature of Injury Sprains account for more than 1/3 of the compensable claims among welders in the State of Washington. Some of those could be caused by hazardous WMSD exposures.

WA State-funded compensable claims 1994-2004 Welders, Cutters, Solderers By Body Part The back, neck and shoulder together with the arm and hand regions make up more than one half of the injuries among welders in Washington State. Preventive efforts should therefore focus on those body parts among welders at your workplace. Welding is a strenuous occupation involving work in awkward postures and handling heavy equipment, usually with a high degree of sustained stress to arm and shoulders.

Consequences of a poor working environment Absences due to injury or illness and the transfer of welders to other tasks Overtime for replacement workers. Welders are skilled employees High employee turnover Increased training and supervisory time Reduced productivity and quality

WMDS hazards most common in welding OFTEN, MORE THAN 1 RISK FACTOR IS PRESENT Rigorous manual precision requirements High degree of uniformity Awkward and static postures Difficult work position Heavy lifting, difficult material handling Heavy objects, heavy welding equipment Repetition High work intensity

Hazard Elements Duration (how long?) Frequency (how often?) Intensity (how hard?)

Common postures adopted in welding Working in front Working at ground level Working above the shoulders Working at ground level, precision work Working at ground level, confined space Working above shoulders, confined space

Awkward postures in welding Severe torso flexion Awkward postures in welding Torso twisting Kneeling, squatting Bent wrists Neck flexion/extension Shoulder flexion/abduction (separation)

The goal of a healthy work environment To simplify the welding tasks for the welder and reduce the physical load during the work Automate physically demanding or repetitive jobs Expand the work content of welders (provide flexibility between jobs) (Multi-skilled workers who are able to perform different tasks within a group)

The Real World Often cost, ease of maintenance, space considerations drive the design of the workplace When hazards can’t be engineered out, using best practices is a good alternative Examples of good design: providing opportunities for work station adjustments, providing different types of tools, using good planning to eliminate unnecessary work

Ergonomic Solutions for Welding

Heavy Lifting Use: Manipulators Lighter weight welding equipment Lighter weight cables with low stiffness Cable supporting balancers Overhead hoists Lifting and turning tables

Awkward Postures Position work between waist and shoulder when possible Provide lifting tables Use motorized positioning devices Use welding guns with swivels and designed for use in both hands Try work stools

Team Lifting BEFORE AFTER Team lifting helps reduce heavy, awkward lifting of equipment and materials. Hazard: Manual wire welding is a primary element in ship construction and repair.  The use of standard straight welding "whips" forces the worker to flex the wrist towards the little finger side.  Carpal Tunnel Syndrome may also be associated with the use of straight welding whips. Solution: A bent-tip wire-welding handle (see photo) allows the worker to maintain a more natural or neutral wrist posture than straight "whips."  In this manner, the tool, not the wrist is bent. From: SIMA San Diego Ergonomics Program

Tables BEFORE AFTER This picture shows the worker with considerable bending over at the waist Because the work is on a table, the worker doesn’t have to bend over as far From: Shipyard Ergonomics, 2003

Pre-Assembly Pre-assembly and material handling equipment helps reduce unnecessary lifting or any other kind of manual material handling

Ergonomic improvements This rotational clamp for pipe helps reduce awkward postures for the neck, shoulders and arms.

Ergonomic improvements Use wheeled tables for welding work and to transport stock and jobs. This reduces lifting and carrying of heavy materials.

Ergonomic improvements Welding leads on pulleys help reduce heavy and awkward lifting, and minimize static postures.

Ergonomic improvements Robotic automation is a feasible solution to highly repetitive motion with the arms and hands. May also reduce the exposure to fumes.

Possible Consequences Not implementing some or all these ergonomics guidelines may result in the following…

Work-related musculoskeletal disorders They are cumulative (occur over time and not a result of a single incident): Occur when the physical demands of work cause wear and tear on the body. Involve soft tissues such as muscles, tendons, ligaments, joints, nerves, blood vessels. Most think of workplace injuries as those that are immediate and have a visible, physical effect (e.g. broken bone, cut) and the causes are tangible, concrete (e.g. slip, hit by object) But injuries can develop over time and not be a result of a single incident. The effects are less visible (tingling, numbness, swelling) which can become more disruptive (pain, loss of function, loss of range of motion).

Work-related musculoskeletal disorders They are not acute injuries such as: Broken bones Cuts Slips Falls Trips Motor vehicle accidents Being struck by or caught with objects Most think of workplace injuries as those that are immediate and have a visible, physical effect (e.g. broken bone, cut) and the causes are tangible, concrete (e.g. slip, hit by object) But injuries can develop over time and not be a result of a single incident. The effects are less visible (tingling, numbness, swelling) which can become more disruptive (pain, loss of function, loss of range of motion).

Common disorders among welders Back injuries Shoulder pain/loss of range of motion Tendinitis/Bursitis Reduced muscle strength Carpal tunnel syndrome White finger Knee joint diseases

The Ergonomics Cycle The ergonomics cycle shows an organized way to start your ergonomics effort.

Credits The technical contents of this slideshow are based upon the presentation developed by Ninica Howard, MS, CPE, research ergonomist with the SHARP program at the Washington state Dept. of Labor and Industries.

More resources NIOSH’s Ergonomic Interventions in the Building, Repair, and Dismantling of Ships SHARP Program Easy Ergonomics. A practical approach for improving the workplace OR OSHA & CAL OSHA Services. www.cbs.state.or.us/osha/pdf/pubs/3347.pdf On WMSD hazardous exposures visit the DOSH webpage at: www.lni.wa.gov/Safety/Topics/Ergonomics Example Template of an accident prevention program : www.lni.wa.gov/Safety/Basics/Programs/Accident Ideas to reduce hazardous exposures can be found at the Ergonomics Ideas Bank You may also write us at: ergonomics@LNI.WA.GOV

Thank you

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