Welding, cutting and brazing are hazardous activities that pose a combination of both safety and health risks to millions of workers in a wide variety of industries. According to OSHA the risk of fatal injuries is more than 4 deaths per 1000 workers over a working lifetime. In order to protect workers during these operations depends upon understanding the hazards involved and methods of control.
Welding joins pieces of metal by use of heat, pressure or both. The most common types of welding includes arc welding, MIG, TIG, plasma arc and submerged arc welding. Other welding processes may use oxy-acetylene gas, electrical current, lasers, electron beams, friction and chemical reactions.
Brazing involved joining piece s of metal together by use of a metal or alloy which has a lower melting point than the metal pieces being joined. The filler materials may contain lead or cadmium.
Cutting involves heating the metal with a frame and directing a stream of oxygen along the line to be cut.
There are a number of health hazards associated with welding. Welding smoke is a mixture of very fine particles termed fumes and gasses. Many of the substances that make up welding smoke are extremely toxic. This includes chromium, nickel, arsenic, manganese, beryllium, cadmium, silica, nitrogen oxides, cobalt, copper, lead, ozone, selenium and zinc. The welding fumes and gasses come from a variety of sources including:
The health effects of welding, brazing and cutting exposures are difficult to list. The fumes may contain a varied number of substances known to be harmful. The individual components of the fumes can affect almost and pat of the body. Health effects may be short or long term. Short term acute effects include:
Long term or chronic health effects include:
The heat associated with welding, brazing and cutting can present a significant hazard. Burns can result from high, heat, hot slag, metal chips, sparks and hot electrodes.
Metal workers have a high incidence rate of musculoskeletal problems including back injuries, shoulder pain, tendonitis, carpal tunnel, white finger and knee joint issues. Work postures and heavy lifting contribute significant to these problems. These issues could be prevented by following a new work practice techniques.
There are a number of safety hazards associated with welding, brazing and cutting. These are generally related to electrical hazards, fire and explosions, dangerous machinery and falls.
Even though welding general uses low voltage there is a possibility of electrical shock. The likihood of a shock may be increased by conditions such as wet or cramped spaces. Accidents can result from even a small shock. Dry gloves should be used to protect against electrical shock. The worker should wear rubber solid shoes and use an insulated layer for protection on surfaces that conduct electricity. The work piece being used and all electrically powered machines must be grounded. Electrodes should not be changed with bare hands, wet gloves, while standing on wet floors or grounded surfaces.
The Intense heat and sparks which are produced can cause fires if combustibles or flammable materials are in the area. Welding, brazing or cutting should only be performed in areas that are free of combustible materials including trash, wood, paper, textiles, plastics, chemicals and flammable materials. Containers that have held a flammable or combustible material should never be welded, brazed or cut unless it has been thoroughly cleaned or filled with an inert gas. Explosions, fires or sudden release of toxic vapors may result. Containers with unknown contents are assumed to be flammable. Fire extinguishers should be located nearby when welding, brazing or cutting.
A confined space is an area with limited access which normally as little or not ventilation. Dangerous concentrations of toxic fumes and gasses can build up very quickly. Suffocation can occur because welding, brazing and cutting can use up or displace oxygen in the air. Workers who enter or work in a confined space should follow the Confined Space Guidelines which are available from EHS or on the EHS web site.
The first step prior to a welding, brazing or cutting job is to identify the hazards associated with a partial task. The hazards will depend on the type of work, the materials used and the environmental conditions. Once the hazard is identified the appropriate control methods are implemented.
Engineering controls and work practices are the preferred method of controlling employee exposure and melting hazards. Among the engineering controls which should be examined are:
Work practices can be modified to eliminate or mitigate hazards. Among the work practice changed to be considered are:
Personal protective equipment (PPE) may be used along with but never in place of engineering controls and work practices. Among the PPE required for welding, brazing and cutting operations are eye protection and protective clothing.
Eye protection must be worn to protect from bright lights, heat, UV light and flying sparks. Helmets, goggles and other eye protection must have lenses for exposure to welding, cutting or brazing.
Protective clothing should be worn by workers welding, cutting or brazing. The clothing should include:
Protective clothing should be made of treated cotton fabric and approved for use in these applications. Sleeves and collars should be kept buttoned. Pants and shirts should not be cuffed.
Hearing protection may be needed, as well as respirators in certain situations.
Welding emissions can be very hazardous. Because of this NISOH recommends that workers involved in welding, cutting and brazing on a routine basis should receive annual medical exams. An eye exam should be part of the annual physical.
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