1. Subpart J: Welding and Cutting
Doris Kemp
BCT 480

2. Welding
Welding joins two pieces of metal by the use of heat and/or pressure
Brazing or soldering involves a filler metal which has a lower melting point than the metal pieces to be joined
Metal cutting is done by heating the metal with a flame and directing a stream of pure oxygen along the line to be cut

3. Welding Arc Welding Shielded Metal Arc Welding (SMAW)
Metal Inert Gas (MIG)
Tungsten Inert Gas (TIG)
Plaza Arc Welding (PAW)
Submerged Arc Welding (SAW)
And Many More…..more than 80 in all

4. Health Hazards…Gases & Fumes
Generally, gases and fumes come from…
Base material & filler material
Coatings & paints
Shielding gases & chemical reactions
Process & consumables used
Contaminants in the air

5. Health Hazards…Gases & Fumes
Welding “Smoke” is a mixture of very fine particles called fumes and gases
Welding “Smoke” contains fumes and gases including…
Chromium, nickel, arsenic, asbestos, manganese, silica, beryllium, cadmium, nitrogen oxides, phosgene, acrolein, fluorine compounds, carbon monoxide, cobalt, copper, lead, ozone, selenium, and zinc
cancer causing agents include: cadmium, nickel, beryllium, chromium, and arsenic

6. Health Hazards Exposure to welding “smoke” may have…
Short-term effects
Effects happen at or very soon after exposure
Long-term effects
Effects may happen after repeated overexposures or an extended time after the exposure
It is difficult to list all the health effects of welding exposures because the fumes may contain so many different substances that are known to be harmful
The individual components of welding “smoke” can affect just about any part of the body, including the lungs, heart, kidneys, & central nervous system

7. Short-term exposures Welding “smoke” can :
irritate the eyes, nose, chest and respiratory tract
cause coughing, wheezing, shortness of breath, bronchitis, pulmonary edema, and pneumonitis
cause nausea, loss of appetite, vomiting, cramps, and slow digestion

8. Long-term exposures
Studies of have shown that welders have an increased risk of lung cancer and, possibly, cancer of the larynx and urinary tract
Welders may experience a variety of chronic respiratory problems, including:
Bronchitis, asthma, pneumonia, emphysema, pneumoconiosis, decreased lung capacity, silicosis, and siderosis

9. Long-term exposures Other health problems include: Heart disease
skin diseases
hearing loss
chronic gastritis
ulcers of the stomach and small intestine
other reproductive risks

10. Other Health Hazards Heat exposure Noise Heat stress, heat stroke
Skin burns and skin cancer
Noise
Can result in stress, increased blood pressure, may contribute to heart disease, tiredness, nervousness, and irritability

11. Other Health Risks…
Eye damage- More than 5% of all eye injuries in the construction industry are associated with welding, cutting, and brazing
damage to retina
damage to cornea, resulting in cataracts
permanent eye damage
Invisible UV light can cause “arc eye” or “welders’ flash”
May include sandy or gritty eye, blurred vision, intense pain, tearing, burning and headache

12. Engineering Controls and Work Practices
Welding booths should be painted with dull finishes so they don’t reflect UV light
Acoustic shields between the worker and noise sources can reduce exposures
Noisy machinery can be totally enclosed

13. Engineering Controls and Work Practices
Use cadmium-free silver solders
Use asbestos- free electrodes, gloves, and hot pads
Use work area barriers to protect others working in the same general area

14. General Precautions
Construction personnel that is welding should be properly trained and qualified
Inspect work area for fire hazards before welding
Make provisions for ventilation before welding
Compressed gas cylinders should always be secured in an upright position when not in use and handled with extreme care

15. General Precautions
Gas cylinders should be stored at least 20 feet away from flammable materials and heat sources
Oxygen cylinders should be stored at least 20 feet away from gas cylinders and combustible materials.
When not possible, use a 5 ft tall noncombustible barrier with a 30 min. fire-resistance rating or better

16. General Precautions
All combustible materials should be removed from welding area or covered with noncombustible material, prior to welding
If covered, a worker that has experience using a fire extinguisher should be posted near as fire watch
Workers should stand to the rear or side of regulators when opening valves on tanks
Proper PPE should be worn, even by workers not welding

17. Other Precautions Don’t weld on painted surfaces
Use water table to reduce noise
Properly maintain equipment
Proper housekeeping
Use lowest possible amperage
Hold electrode perpendicular and close to work surface
Never weld or cut within 200 feet of degreasing equipment or solvents

18. Personal Protective Equipment (PPE)
PPE must be used in conjunction with engineering controls and safe work practices
Use of one does not eliminate the need for the other
Eye protection should be used in all welding operations
Wear face shields or helmets and goggles or safety glasses
Use appropriate filters on eye protection

19. Protective Clothing Fire resistant gauntlet gloves Head cap
High top hard toed shoes
Leather apron
Face shield
Flame retardant clothing
Safety Glasses
Safety helmet
Hearing plugs and/or muffs

20. Electrical Hazards
Even though welding generally uses low voltage, there is still a danger of electric shock
Wet work areas, cramped work spaces
Falls, fractures and other accidents can result from electrical exposure
Even small shock can cause brain damage
Death can occur from large shocks

21. Electrical Precautions
Always use dry gloves
Always wear rubber soled shoes
Always use insulating layers
Protect yourself from surfaces that conduct electricity
When working on electrically powered machinery, make sure the frame is grounded
Keep insulation on all welding equipment and components dry and in good condition
Don’t change electrodes with bare hands, wet gloves or while standing on wet or ungrounded surfaces

22. Fire and Explosion Precautions
Never weld or cut on containers that have held a flammable or combustible material unless the container is thoroughly cleaned or filled with an inert gas
A fire inspection should be performed prior to leaving a work area and for at least 30 minutes after the operation is completed
Fire extinguishers should be nearby, of proper size, type and number for the hazards involved

23. Dangerous Machinery
All machines in the area with moving parts must be guarded to prevent worker’s contact
e.g. hair, clothing, fingers
When repairing machinery by brazing and welding, power must be disconnected, locked out, and tagged so the machinery cannot be started up accidentally

24. Trips and Falls
Keep work areas clear of equipment, machines, cables, and hoses
Always properly maintain and use handrails
Always use and maintain safety lines, harnesses and lanyards
Always make sure that scaffolds are properly assembled and used

25. Welding Hazards in Confined Space
A work area with limited access, little or no airflow, not intended for continuous occupation
May also have dangerous atmospheres, hazardous configurations, or other hazards
All employees working in or around confined space must be trained
Adequate ventilation must hold fumes and smoke to levels within the safe breathing range set forth in 29 CFR 1926 subpart D

26. Welding Hazards in Confined Space
No worker should work in an area with less than 19.5% or more than 23.5% oxygen content
Use continuous mechanical ventilation and proper respiratory protection
When adequate ventilation cannot be achieved, workers must be provided with air supplying respirators as described in 29 CFR 1926 Subpart E

27. Welding Hazards in Confined Space
Always leave gas cylinders and welding power sources outside the confined space…
Only take hoses or welding leads into confined space and remove when leaving for breaks, shift or crew changes
All pipes, ducts, and power lines that are not necessary for the work should be disconnected/locked out/tagged out

28. Gas welding Precautions
When transporting and handling, valve cap should be securely in place
Cylinders should never be lifted by valve cap
Cylinder valve should be closed when cylinder is empty, being moved or not in use
Cylinders should be secured to a pallet, cradle, or sling board for hoisting
Cylinders should not be dropped, bumped, struck or receive any other huge impact
Cylinders should be thawed with warm water when frozen in place

29. Gas welding Precautions
Fuel, gas and oxygen hoses must be easily and clearly distinguishable.
Oxygen and gas hoses must not be interchangeable
When oxygen and fuel hoses are taped, no more than 4 inches per foot of hose may be taped
Gas and oxygen hoses must be inspected before every shift and removed if defects are found.
Torches should be inspected before each shift to detect leaks
Tip openings should be kept clean and unclogged
Torches should be lighted by friction lighters

30. Arc welding Precautions
Only use manual electrode holders designed specifically for arc welding
All current-carrying parts should be properly insulated for maximum voltage encountered
Cables must be properly insulated, flexible and able to handle maximum current required
All equipment and cables should be inspected before each shift and should be removed if any defects are found
Operations should be shielded appropriately as to protect other workers in the area

31. Compressed Gas Cylinder Safety
Subject to damage
from other activities in
the vicinity
Electrical cord in
Contact with the
cylinder
Cylinder laying
in a horizontal
position.
Compressed Gas Cylinder Safety

32. Compressed Gas Cylinder Safety
Chain
Cylinders are not protected from falling. Note
that the Chain is not secured across.
Compressed Gas Cylinder Safety

33. Compressed Gas Cylinder Safety
Electrical
Cord
1. Cylinder not secured
2. Cylinder should be stored
3. Subject to damage.
4. Electrical cord draped over.
Compressed Gas Cylinder Safety

34. Compressed Gas Cylinder Safety
1. Small cylinder not tied off
2. Combustibles stored with cylinders
3. Bad housekeeping
4. Acetylene and Oxygen stored
too close together and no chain.
Compressed Gas Cylinder Safety

35. Compressed Gas Cylinder Safety
1. Cylinder with no valve or cap installed
2. Laying horizontal on the ground
3. Subject to damage
Compressed Gas Cylinder Safety

36. Compressed Gas Cylinder Safety
Electrical arc
damage
Cylinder is damaged. Should be taken out of service immediately!
Compressed Gas Cylinder Safety

37. Compressed Gas Cylinder Safety
Cylinder should be in storage protected from damage and not
laying on the ground regardless if it is full or empty
Compressed Gas Cylinder Safety

38. Compressed Gas Cylinder Safety
Old, corroded cylinder that should have been disposed
of a long time ago.
Compressed Gas Cylinder Safety

39. Compressed Gas Cylinder Safety
Forklift
1. Cylinders laying on the ground and improperly stored
2. Subject to damage from forklift operation in vicinity
Compressed Gas Cylinder Safety

40. Compressed Gas Cylinder Safety
1. Feed line exposed to damage/leak that could cause a fire/explosion
2. Tripping Hazard
Compressed Gas Cylinder Safety

41. Compressed Gas Cylinder Safety
1. Inadequate housekeeping
2. Valve caps should be installed.
Compressed Gas Cylinder Safety

42. Compressed Gas Cylinder Safety
Acetylene
Cylinder
Unsecured acetylene cylinder 2. Exposed to damage
Compressed Gas Cylinder Safety

43. Compressed Gas Cylinder Safety
Unsecured cylinders
Compressed Gas Cylinder Safety

44. Compressed Gas Cylinder Safety
Regulator left pressurized after use
Compressed Gas Cylinder Safety

45. Compressed Gas Cylinder Safety
Improper Storage
Compressed Gas Cylinder Safety

46. Compressed Gas Cylinder Safety
Tie Off?
Compressed Gas Cylinder Safety

47. Compressed Gas Cylinder Safety
Improper storage of cylinders- acetylene and oxygen stored next to each other
Compressed Gas Cylinder Safety

48. Compressed Gas Cylinder Safety
Evidence of smoking next to acetylene cylinders
Compressed Gas Cylinder Safety

49. Compressed Gas Cylinder Safety
This cylinder should be taken to storage and
housekeeping should be improved.
Compressed Gas Cylinder Safety

50. Compressed Gas Cylinder Safety
Unsecured
cylinder
Compressed Gas Cylinder Safety

51. Compressed Gas Cylinder Safety
Unsecured Cylinder
Compressed Gas Cylinder Safety

52. Compressed Gas Cylinder Safety
Cooking equipment
within 20 ft
of containers
Compressed Gas Cylinder Safety

53. Compressed Gas Cylinder Safety
Tied
Not Tied
Compressed Gas Cylinder Safety

54. Compressed Gas Cylinder Safety
oxy-acetylene torch connected
To bottles without the torch connected.
Compressed Gas Cylinder Safety

55. Compressed Gas Cylinder Safety
Not in use.
Should be
Stored.
No cap installed
Housekeeping
Compressed Gas Cylinder Safety

56. Compressed Gas Cylinder Safety
Cylinder not in use
with regulators still
On the cylinder
Free standing
cylinder
Compressed Gas Cylinder Safety

57. Compressed Gas Cylinder Safety
Free standing
cylinder
Compressed Gas Cylinder Safety

58. Compressed Gas Cylinder Safety
Free standing cylinders
Chain
Compressed Gas Cylinder Safety

59. Compressed Gas Cylinder Safety
tied only
With a bungee
cord
Compressed Gas Cylinder Safety

60. Compressed Gas Cylinder Safety
Cylinders not
Secured properly
Compressed Gas Cylinder Safety

61. Compressed Gas Cylinder Safety
Free standing
cylinders
Exposed to damage
From construction
Activities in area
Compressed Gas Cylinder Safety

62. Compressed Gas Cylinder Safety
Free standing
cylinders
Compressed Gas Cylinder Safety

63. Compressed Gas Cylinder Safety
Cylinder laying on its side
Compressed Gas Cylinder Safety

64. References
Coll, R. (2002, October 17). Compressed Gas Cylinder Training Slides. Retrieved September 10, 2009 from , Web site: Goetsch, D. (2010). Construction safety and the OSHA standards. Boston: Pearson. Saverio (2003). Welding Safety. Retrieved September 10, 2009 from , Web site: Welding-Safety-2003-Health-Hazards-HazardsGases-Fumes-Short- term-Entertainment-ppt-powerpoint/