07 Feb Arc Welding Safety

Arc Welding Safety

Arc welding uses an intense electric arc to join, repair, or cut metal. The process exposes workers to several serious hazards, including electric shock, burns, ultraviolet and infrared radiation, flying sparks, molten metal, hazardous fumes, fire, and explosion. Proper equipment, PPE, ventilation, and safe work practices are essential.

Electrical Safety

Arc welding equipment must be properly installed, grounded, maintained, and operated according to the manufacturer’s instructions.

Before beginning work:

• Inspect welding leads, electrode holders, connectors, and insulation for damage.
• Keep cables away from water, hot metal, sharp edges, and areas where they may be damaged.
• Never use damaged or improperly repaired welding equipment.
• Keep yourself, your gloves, and your clothing as dry as possible.
• Use additional precautions when welding in damp, wet, confined, or highly conductive locations.
• Disconnect and control energy before servicing or repairing welding equipment.

Engine-driven welders should be operated where exhaust gases cannot accumulate. Shut the engine off before refueling and keep fuel away from flames, sparks, and hot surfaces.

Protect Against Arc Radiation and Burns

The welding arc produces intense radiation capable of causing serious eye and skin injuries. Sparks, slag, and molten metal can also cause severe burns.

Welders should wear appropriate PPE, including:

• A welding helmet with the proper filter shade for the welding operation.
• Safety glasses with side shields underneath the welding helmet.
• Flame-resistant clothing that fully covers exposed skin.
• Leather welding gloves or gauntlets.
• Appropriate safety footwear.
• Hearing protection when required.

Keep clothing free from oil, grease, and other combustible substances. Avoid cuffs, open pockets, or other areas where sparks or hot metal can collect.

Use welding curtains, screens, or barriers to protect nearby employees and visitors from arc radiation and flying sparks.

Prevent Fires and Explosions

Welding sparks and molten metal can travel considerable distances and ignite combustible materials.

Before welding:

• Remove or protect combustible and flammable materials.
• Check nearby, adjoining, and lower areas for hidden fire hazards.
• Keep appropriate fire-extinguishing equipment readily available.
• Follow applicable hot-work permit procedures.
• Assign a fire watch when required and continue monitoring after welding for the required period.

Never weld on a drum, tank, pipe, container, or other equipment that has contained flammable or hazardous substances until it has been properly cleaned, prepared, and determined safe for hot work.

Control Welding Fumes

Welding fumes and gases vary depending on the welding process, electrode, base metal, coatings, and contaminants on the workpiece. Metals containing or coated with substances such as lead, cadmium, chromium, zinc, mercury, or beryllium may create particularly hazardous exposures.

Use adequate general or local exhaust ventilation to keep fumes and gases away from the breathing zone. Never position your head directly in the welding plume.

Respiratory protection may be required when engineering and ventilation controls cannot adequately control exposure. Respirators must be properly selected for the specific hazard and used under an appropriate respiratory protection program.

Extra precautions are necessary when welding in confined or enclosed spaces because hazardous gases can accumulate and oxygen levels can become unsafe.

Protect Nearby Workers

Welding hazards are not limited to the welder. Nearby employees can also be exposed to arc radiation, sparks, fumes, and hot materials.

Clearly identify or isolate the welding area, use appropriate screens or curtains, and prevent unauthorized personnel from entering the hot-work area without suitable protection.

Remember

Arc welding combines electricity, extreme heat, intense radiation, hazardous fumes, and significant fire hazards. Inspect equipment before use, wear the proper PPE, provide adequate ventilation, control combustibles, protect nearby workers, and follow established hot-work procedures.