Welding safety, hazards and how to avoid them

Toxic welding fumes and gases

Typically, we breathe 4,000 liters of air during an 8-hour work shift. At the same time, one single welding operator can produce up to 40 grams of airborne fume and particulate per hour. This welding fume is composed of gases and small particles and may contain more than 40 different substances that come from the processed material itself, from the filler metals, or from surfaces such as paints and coatings. The welding fume, all-in-all, is dangerous to human health, and if unprotected, tiny fume particles can pass deep into the lung structure.

Furthermore, exposure to airborne contamination and carcinogens for lengthy periods may result in long-term health issues, including cancer and respiratory illnesses. Occupational lung diseases are preventable by using proper welding respiratory protection.

If proper safety precautions are followed, the exposure to fumes and gases can be controlled:

• Make sure the welding area is properly ventilated to keep fumes and gases from the breathing zone and the general area.
• Welders should always wear an approved welder’s respirator.
  
  

Working in a confined space

There are situations when a welder is required to work in a confined space such as tanks, pipes and pits. Inert gases and some common chemical reactions can reduce or even replace the amount of oxygen in these spaces. Always consider if the job can be done without entering a confined space. Risk assessment must be carried out before working in confined spaces where the Oxygen level of the atmosphere could fall below 17%.

In case you need to enter a confined space:

• Wear an approved welding respirator or welding fume mask.
• Make sure you know the emergency rescue plan.
• Do not use oxygen supplies as it is a very serious fire risk.
• Remember that most welding gases, including all the inert gases, have no smell and can displace the breathing air.
• Make sure that the shielding gas hoses and connectors are tightly sealed.
• Never work alone.

Heat, fire and burns

Having flammable materials in the working area is the most common reason for a fire. Maintaining the working area clean of any flammable material such as wood or fabrics helps to prevent the risk of fire. Remember that heat and sparks can travel a considerable distance.

Always be sure to know the emergency plan and the location of fire extinguishers in case of fire. The fire extinguishers should be in the proximity of the welding area. In case it is not possible to keep the area completely clean, a fire watch should be maintained during and at least 60 minutes after the welding process to keep track of sparks. The welding area may also be separated from the surroundings by a fire-resistant blanket or sheet metal.

Though not serious but very common injuries of welders are burns due to spattering. They are also called “arc tattoo”. If the welder’s neck area is not properly protected, it is subject to UV radiation that causes sunburn called “welder’s neck”. Long term, exposure can cause more permanent damage. Always protect exposed skin areas with appropriate clothing.

Injuries are preventable by using an approved Personal Protective Equipment (PPE) and covering the body completely during welding. Thick gloves and long-armed, flame-retardant clothing are part of the basic equipment for any welder.