1. Chapter 2 Safety in Welding

2. Objectives Burn classifications and emergency treatment
Dangers of types of light, and avoiding eye and ear injuries
Use a chart to select eye and face protection
Describe various types of respiratory protection
Avoid dangerous fumes and gases

3. Objectives (continued)
The purpose of Material Safety Data Sheets
The benefits of recycling waste material
General work clothing and special protective clothing
Safely handle, secure, and store cylinders
Protect against fire danger when welding

4. Objectives (continued)
The importance of planned maintenance
Tools commonly used by welders
Good electrical safety practices
Types of metal cutting machines
Safely lift heavy assemblies
Ladder safety

5. Introduction No substitute for caution and common sense
Each person must take personal responsibility
Welding has a number of potential safety hazards
Most large welding companies have mandated safety classes

6. Burn Classification
Burns are one of the most common and painful injuries
Caused by ultraviolet light rays and contact with hot welding torches
All burns must receive proper medical treatment
Burns are divided into three classifications

7. First-Degree Burns The surface of the skin is reddish
Tender and painful
No broken skin
Put the burned area under cold water or apply a cold compress
Cover the area with sterile bandages
Never apply butter or grease

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

9. Figure 2-2 Second-degree burn

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

11. Burns Caused by Light Some types of light can cause burns
Three types of light include:
Ultraviolet
Infrared
Visible
Arc welding produces all three types of light
Light from the welding process can be reflected from walls, ceilings, and floors

12. Ultraviolet Light The most dangerous
Causes first and second degree burns to eyes or exposed skin
The closer the welder is to the arc and the higher the current, the quicker a burn may occur
A welder's eyes can receive a flash burn in seconds

13. Figure 2-6 The eye can be burned on the white or retina by ultraviolet light.

14. Infrared Light The 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

15. Visible Light The 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

16. 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

17. 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

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

19. Ear Protection Welding environment can be very noisy
Hot sparks can drop into an open ear, causing severe burns
Earmuffs cover the outer ear completely
Earplugs fit into the ear canal
Damage caused by high sound levels may not be detected until later in life – hearing will not improve with time

20. 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 use of respirator
Maintenance schedules and respirator selection
Procedures for testing the proper fitting and use
Regular evaluation of the program

21. Equipment Some types of respiratory protection equipment:
Air-purifying respirators
Atmosphere-supplying respirators
Demand respirators
Positive pressure respirators
Powered air-purifying respirators
Self-contained breathing apparatus
Supplied-air respirators

22. Fume Sources
Paints, coating, or plating on metals can cause respiratory problems
Before welding or cutting any painted metal, the surface must be cleaned
Marine industry still uses lead-based paints
Exposure to cadmium fumes can cause lung and kidney damage
The best way to avoid problems is to provide adequate ventilation.

23. Vapor Sources Ozone gas is produced by ultraviolet radiation
Ozone irritates mucous membranes
The collection of fumes and gases can go unnoticed
Concentrated fumes can cause a fire or explosion

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

25. Figure 2-15 A room with a ceiling 16 ft
Figure 2-15 A room with a ceiling 16 ft. high may not require forced ventilation

26. Forced Ventilation
Small shops or shops with many welders require forced ventilation
Forced ventilation
Can be general or localized
Fixed or flexible exhaust pickups
Forced ventilation is required when welding on metals that contain dangerous fumes

27. Material Safety Data Sheets
Material safety data sheets (MSDS) provide details of possible hazards
Often posted on a bulletin board or put in a convenient place where products are used
If injured while using a product, take the material's MSDS when you seek treatment

28. Waste Material Disposal
Welding shops generate a lot of waste materials
All scrap metal can be recycled
Hazardous waste materials include:
Burned flux
Cleaning solvents
Dust collected in the filtration system
Throwing hazardous material away is illegal

29. General Work Clothing Guidelines for work clothing:
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
There is no safe place to carry a butane lighter or matches while welding

30. 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
Leather is often the best material to use

31. Handling and Storing Cylinders
Store oxygen and fuel gas cylinders separately
Store inert gas cylinders separately or with the same type of fuel cylinders
Store all cylinders vertically
Securely fasten the protective cap

32. Securing and Storing Gas Cylinders
Secure cylinders with a chain or other device
Chain cylinders attached to a manifold or stored in a special room
Cylinder storage area must be away from halls, stairwells, and exits
Storage areas should be away from heating units and welding sparks
Secure storage areas from unauthorized people

33. Cylinders with Valve Protection Caps
Must have the cap in place unless the cylinder is in use
The cap prevents the valve from being broken off
Never lift the cylinder by the safety valve
When moving cylinders, the valve protection cap must be on
All cylinders must be handled with care

34. General Precautions Any cylinders with a defect must be identified
If a 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

35. Figure 2-25 Move a leaking fuel gas cylinder out of any work area

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

37. Fire Extinguishers There are four types of fire extinguishers
Type A: combustible solids
Type B: combustible liquids
Type C: electrical fires
Type D: fires involving combustible metals
Some fire extinguishers can be used on more than one type
Using the wrong type of extinguisher can be dangerous

38. TYPE A FIRE

39. TYPE B FIRE

40. TYPE C FIRE

41. TYPE D FIRE

42. Location of Fire Extinguishers
Fire extinguishers should be easily removed
Should be easily lifted
Location marked with red paint and signs
Should be marked near the floor

43. LOCATION

44. Use Extinguishers cool the fire and remove oxygen
Use foam, carbon dioxide, a pump tank, or dry chemicals
CO2 extinguisher – direct the discharge as close to the fire as possible
Dry chemical extinguisher – direct toward the base of the flames

45. Figure 2-34 Point the extinguisher at the material burning, not the flames

46. 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 joints must be repaired

47. Work Area Should be picked up and swept clean
Arc welding area painted with a flat dark color
Portable screens used if welding outside the welding booth
If a piece of hot material is left unattended, write hot on it before leaving

48. Hand Tools Used for assembly and disassembly of parts
The adjustable wrench is the most popular tool
Fewer points = stronger
Mushroomed heads of chisels, punches, and the faces of hammers should be ground off
Always use the correct tool for the job

49. 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
Welding circuits must be turned off when the work station is left unattended

50. 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 receptacle
Double insulation
Extra layer of insulation
Eliminates need for grounded outlet

51. Voltage Warnings Voltage is the same as specified on the tool
A voltage greater than the tool can lead to injury
A voltage lower than the tool can damage the motor
Amperes (Amps) measures electrical current

52. Extension Cords Use only three-wire, grounded extension cords
When using extension cords:
Connect the cord of tool into the extension first
Extension cords should be long enough
The cord does not come in contact with sharp objects
Check for loose or exposed wires
Clean before storing

53. Figure 2-41 Two types of grounding plugs

54. Safety Rules for Portable Electric Tools
Some general rules:
Know the tool and ground the tool when needed
Do not expose to water
Keep the area well lighted
Do not use near propane, or flammable vapors
Wear eye protection
Secure your work with clamps
Maintain power tools

55. 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 are worn down
Gloves should never be worn when grinding

56. Drills Center punch holes before drilling
If the bit gets caught, stop the motor
Securely clamp all metal before drilling
Sharp metal shavings should be avoided

57. Metal Cutting Machines
Before operating any power tool for the first time, read the manufacturer's instructions
Welders use shears and punches in the fabrication of metal for welding
Cut off machines use abrasive wheels or special saw blades
Band saws are vertical or horizontal
Some can be used in either position

58. Material Handling
Improper work habits can cause serious personal injury
Improper handling can cause damage to tools and materials
When lifting, the weight of the object should be evenly distributed between both hands
The capacity of hoists or cranes should be checked before lifting a heavy load

59. Ladder Safety Improper use of ladders is often a factor in falls
All ladder use poses a danger
In case of a fall, keep the area around the ladder clear
Step ladders and straight ladders are used extensively in welding shops

60. Figure 2-52 Make sure the ladder is leaning at the proper angle.

61. Ladder Inspection and Safety
Over time, ladders can become damaged
Look for loose or damaged parts
Check that all hardware is tight
Check wooden ladders for cracks
Never use a defective ladder
If a ladder cannot be repaired, replace it
Read the entire ladder manufacturer's list of safety rules for ladder use
Never use a ladder that is too short for the job
Climb and descend cautiously

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