The major health hazards in
welding and cutting are:
► fumes
► gases
► radiation
► noise
► various safety factors
► manual handling problems
The variables that influence
exposure to these hazards include:
► variables in the welding process
► effect of the work area
►
effect of the operator
Fumes are fine, solid particles, formed by the following general process:
1. Metal and flux
undergo rapid melting accompanied by limited vapourisation
2. Vapours are oxidised
3. Reaction takes place with flux
constituents and other materials present
4. Vapours condense and agglomerate to produce fine particles of fume of complex
composition.
Gases may be produced in certain welding processes in the following ways:
1. Decomposition
of flux or electrode coatings and base metal coatings such as paints and solvents.
2. Reaction products of the shielding
gases.
3. Oxidation of elements present in the arc or flame.
4. Photochemical reaction of atmospheric gases due to
ultraviolet radiation from the arc or flame.
The electrode coating is a
complex mixture of various components such as:
1. Moulding Agents (aluminium and magnesium silicate)
2 Extruding
Agents (alginates, starch, glucose and methyl cellulose)
3. Binders (potassium and sodium silicates)
4.
Strengthening Agents (mostly mica which has replaced asbestos)
5. Slag Formers (carbonates, silicates, oxides-rutile
(TiO2) and fluorides)
6. Metal Powders (e.g., iron) to act as alloying additions, to increase deposition
rate or act as deoxidants
7. Shielding Gas Formers (cellulose, calcium carbonate)
8. Fluxing Agents
(fluorspar, calcium carbonate and sodium silicate)
Routes of entry into the body
► inhalation
► ingestion
► skin
FUMES |
Substance |
How Formed |
Some Potential Health
Consequences |
Cadmium |
welding or cutting of metal coated with cadmium |
acute irritation of the respiratory passages, delayed pulmonary
oedema; lung and kidney damage |
Chromium |
use of chrome-plated, or stainless steels or of hard-facing and
chrome alloy electrodes |
some forms of chromium have been found to be carcinogenic; other
forms are biologically inert |
Cobalt |
welding or cutting of certain alloys |
shortness of breath, pneumonitis |
Fluorides |
certain fluxes contain fluoride and can give rise to dust, fume
and vapour |
fluoride fumes may cause irritation of eyes, throat, respiratory
tract and skin; long-term exposure can lead to bone hardening |
Iron |
welding or cutting of ferrous materials |
siderosis (temporary) |
Lead |
welding or cutting of metal coated with lead or lead-based paints
|
central nervous system & gastro-intestinal |
Manganese |
use of manganese-containing electrode cores, coatings or wire;
welding of manganese steel |
metal fume fever, nervous system |
Molybdenum |
welding or cutting of molybdenum-containing alloys |
bronchial irritation, liver and kidney changes |
Nickel |
welding and cutting of nickel-plated and stainless steels |
irritation of respiratory tract; potentially carcinogenic |
Silica(and silicates) |
certain fluxes or dirt contamination could cause silica fume emissions
|
silica fume from welding operations is amorphous and not regarded
as harmful |
Vanadium |
use of certain filler wires and special alloy steels |
eye and respiratory tract irritation; chemical pneumonia |
Zinc |
welding or cutting of galvanised steel |
metal fume fever (transient) |
Other Metals |
welding may produce fumes of other metals such as aluminium, copper,
magnesium, tin, titanium and tungsten |
no known serious health disorders are known to be due exposure
to these fumes |
GASES |
Substance |
How Formed |
Some Potential Health
Consequences |
Oxides Of Nitrogen |
formed by the direct combination of oxygen and nitrogen in the
air surrounding the arc or flame |
not a problem in outdoor or open shop welding; in confined spaces
can build up to levels that can cause respiratory irritation or delayed pulmonary oedema |
Ozone |
formed by certain welding operations, particularly when high amperages
are involved, by the action of ultraviolet radiation on oxygen in the air |
very irritant to the upper respiratory tract and lungs (effect
may be delayed) |
Carbon Monoxide |
reduction of carbon dioxide shielding gas and to some extent in
all welding operations due to reduction of consumables or incomplete combustion of acetylene |
can cause drowsiness, headaches and nausea; unconsciousness and
death can result in extreme cases |
Carbon Dioxide |
shielding gas or combustion product |
can be an asphyxiant (excludes oxygen) |
Phosgene |
formed by the oxidation of chlorinated hydrocarbons (trichloroethylene,
etc.) in the atmosphere or on the weldments |
irritation tot he respiratory tract (and lung damage) after a latent
period of several hours |
Phosphine |
formed when welding steel coated with rust proofing compound |
irritating to the eyes, nose and skin; may also cause serious effects
on lungs and other organs |
Lack Of Oxygen |
inert gases (argon, helium, etc.) exclude oxygen from confined
spaces (as can carbon dioxide) |
can cause asphyxiation |
Pyrolysis Products |
formed by the thermal decomposition of the resins in primers and
paints - could include phenol, formaldehyde, acrolein, isocyanates and hydrogen cyanide |
can cause a wide variety of health effects |
Worksafe Australia Exposure Standards |
Compound |
TWA (8 hour average) |
Short Term Exposure
Limit (15 min) |
Carbon Dioxide (CO2) |
5,000 ppm |
30,000 ppm |
Carbon Monoxide (CO) |
30 ppm |
- |
Chromium (Cr) |
0.5 mg/m3 |
none specified |
Copper (Cu) |
0.2 mg/m3 |
none specified |
Fluorides |
2.5 ppm |
none specified |
Nickel (Ni) |
1.0 mg/m3 |
none specified |
Nitrogen Dioxide |
3 ppm |
5 ppm |
Ozone |
0.1 ppm |
peak limitation |
Total Welding Fume |
5 mg/m3 |
none specified |
Notes: Short term exposure
limit (STEL) means a 15 minute time weighted exposure which should not be exceeded at any time during a working day even if
the 8 hour average is within the exposure standard. Exposures at the STEL should not be longer than 15 minutes and should
not be repeated more than 4 times per day. There should be at least 60 minutes between successive exposures at the STEL. A
peak limitation should not be exceeded at any time. If required the STEL for carbon monoxide may be derived from the National
Commission Documentation.
CONTROL OPTIONS
elimination, substitution and process modification
engineering controls
administrative controls use of personal protective equipment
ARE YOU RISKING ELECTRIC SHOCK WHEN YOU WELD?
Although manual metal arc welding can be performed perfectly safely, there is a substantial risk
of electric shock. It is obvious that poorly maintained or badly connected equipment may be extremely hazardous. What is not
so well known is that an electric shock from the output terminals of the welding machine can cause death or serious injury.
Manual
metal arc welding and arc-air gouging are particularly risky because the electrode is changed frequently while the electrode
holder is electrically live. There is a high risk that the welder can receive a shock by simultaneously touching the electrode
and work piece. Fuses or earth leakage contact breakers do not protect the welder
from such a hazard. Many welders have suffered such shocks and have only experienced an unpleasant tingle, but muscle
spasms from even a mild shock may lead to a fall from a height or injury by striking. Death by electrocution has occurred
in such extreme circumstances.
Factors
which affect the severity of the shock are: The no-load or open circuitry voltage (OCV) of the welding machine; Whether the
machine supplies alternating or direct current (a.c. is 2 to 3 times more dangerous than d.c.) The pressure of moisture from
rain, perspiration or other source; How well the victim is insulated from the electrode and the work piece; Which parts of
the body are in contact with the work and the electrode. Current flow between the left hand and the torso is the most dangerous;
the susceptibility of the victim to shock, which is dependent on health and other factors. Processes such as GMAW (MIG) do
not require frequent electrode changes and are activated by a contact switch at the torch. They therefore carry less risk.
To avoid electric shock: Avoid bare skin contact with the electrode; and either prevent contact with the work piece, or use
a welding machine which is safe for electrically hazardous environments as defined by AS 3195, or which has a voltage limiting
device fitted.
An
environment is considered electrically hazardous whenever the welder has to work in physical contact with the work piece,
particularly in a cramped (kneeling, sitting or lying) position. The environment is not electrically hazardous if the welder
is electrically insulated from the work piece, but in many cases this may be impossible or uneconomical. Examples include
shipbuilding work, inside vessels, pipes and structural components. The electrically
hazardous environment does not need to be a confined space.
Environment |
Maximum OCV direct current |
Maximum OCV alternating current |
Non electrically hazardous |
113 volts |
113 volts peak or 80 volts rms |
Electrically hazardous (dry) |
113 volts |
68 volts peak or 48 volts rms |
Electrically hazardous (wet) |
35 volts |
35 volts peaks or 25 volts rms |
An
electrically hazardous environment is compounded in wet, damp or hot locations where moisture or perspiration considerably
reduces the electrical resistance of the human body and the insulating properties of accessories. The precautions described
below can often be taken to the limit risk. If there is difficulty in keeping dry, a voltage limiting device should be used
to limit the OCV to a maximum of 25 volts, or the power should be controlled by a contactor switch. Such damp environments
include: underwater, in the splash zone, while standing in water, in rain, welding in a hot or humid area when it is impossible
to avoid accumulation of perspiration or condensation, and in mines.
All
persons who work near or assist in welding operations should be familiar with rescue procedures. The following precautions
are required to protect from electric shock:
1.
When a workplace hazard assessment is conducted, ensure the risk of such electric shock is considered and appropriate measures
are taken to minimise the risk (see below).
2.
The use of dry, hole free welding gloves on both hands while welding, particularly when changing electrodes should be compulsory
and be a written safety policy.
3.
Remove stub ends immediately after welding; do not leave an electrode holder with a stub end in it.
4.
Turn off the power at end of each shift or when taking a break. Do not drag live leads to the work.
5.
If possible make the environment electrically safe by using dry, fire resisting insulation. Wooden duckboards, leather covered
cushions, leather aprons, leather jackets, heat resisting blankets should be used to cover those parts of the work piece which
the welder may contact. It it is not possible to provide such insulation, or to keep it dry, the environment must be considered
electrically hazardous, and equipment should be safe for such environments.
6.
In hot conditions the risk of electrocution is increased because of clothing and equipment being soaked in perspiration. The
risk is far worse in closed environments, such as tanks or vessels, particularly when these are exposed to the sun's heat.
Take frequent rest periods, during which time dry off equipment and clothing. Frequently change or alternate gloves and protective
clothing to avoid perspiration accumulating. Ventilate or if possible air-condition the work air. Ventilation will help dry
perspiration and cool the body. Cool the face with an air mask. If clothing (including gloves) becomes soaked with perspiration,
it must be changed.
7.
If it is not possible to keep it dry, the environment must be considered extremely dangerous. Either a voltage limited welding
power source should be used, or the power should be controlled by a contractor switch on the torch.
Welding Safety on the Site
• Wear proper protective gear for
welding.
• Thoroughly clean any container
that contained a combustible substance before welding or cutting it.
• Maintain a fire extinguisher
at the welding site.
• Ventilate the welding area.
• Keep tanks, valves and welding
equipment in good condition.
• Keep flames, heat and sparks
away from combustible materials.
• Avoid electric welders with defective
jaws or poor insulation on the cables.
Personal
Protective Equipment for Welding
The
employer must provide the proper personal protective equipment needed for welding jobs on the farm. Fire-resistant gauntlet
gloves, aprons, coveralls, leggings and boots are the basics needed. Welding helmets, respirators, ultraviolet radiation filter
plates for arc welding, and goggles with filter lenses are a must.
Maintain,
store, inspect, clean and evaluate respirators routinely. Make sure everyone using them has been fit-tested. Workers doing
overhead welding should be provided with fire-resistant shoulder covers, head covers and ear covers. When welding highly toxic
materials, provide work uniforms, coveralls or full body coverings. There should be lockers or separate areas to store or
change into street clothing. Collect all welding clothing, and launder it properly.
All
protective clothing should be routinely inspected and maintained. Keep clothes free of grease and oil. Retreat fire-resistant
clothing after laundering. Prohibit upturned sleeves and collars, because sparks or other materials may get caught in them.
Button sleeves and collars.
Before
Welding
Properly
train all people welding. Do not allow anyone to use the equipment until they know the exact instructions on how to operate
it. Do routine maintenance to keep equipment in working order. Ventilate the work area well. There must be sufficient movement
of air to prevent toxic fumes from building up or oxygen from becoming deficient.
Cutting
Containers
Never
weld or cut used drums, barrels, tanks or other containers unless they have been thoroughly cleaned of all substances that
may produce flammable vapors or gases. Never use oxygen to ventilate a container, as it may start a fire or cause an explosion.
As a final precaution after cleaning, a container should be vented and filled with water before welding or cutting begins.
The container should be arranged so water can be kept filled to within a few inches of the point where the welding or cutting
is to take place. Be sure there is a vent or opening to provide for release of air pressure or steam.
Safety
in Cutting
Whenever
cutting, always keep a fire extinguisher nearby. Never use a cutting torch where sparks will be a hazard, such as near rooms
containing flammable materials (especially dipping or spraying rooms). Take extra precaution in greasy, dirty or gassy areas.
If the cutting is to be over a wooden floor, sweep the floor clean and wet it down before starting the cutting. Provide a
bucket containing water or sand to catch the dripping slag. Move combustible materials at least 40 feet away from any cutting
or welding. If cutting is to be done near flammable materials and the flammable materials cannot be moved, use suitable fire-resistant
guards, partitions or screens.
Safety
in Gas Welding
Under
no circumstances should acetylene gas come in contact with unalloyed copper, except in a torch. Any contact of acetylene with
high-alloyed copper piping will generate copper acetylide, which is very reactive and may result in a violent explosion. After
assembling, all piping must be blown out with air or nitrogen to remove foreign materials.
Safety
in Arc Welding
Arc
welding includes shielded metal-arc, gas shielded and resistance welding. Only general safety measures can be shown for these
areas because arc welding equipment varies considerably in size and type. Specific manufacturers’ recommendations should
be followed in each area.
Equip
welding machines with power disconnect switches. Locate them at or near the machines so the power can be shut off quickly.
Do not make repairs to welding equipment unless the power to the machine is disconnected. The high voltage used for arc welding
machines can inflict severe and fatal injuries. Do not use welding machines without proper grounding. Stray current may develop,
which can cause severe shock when ungrounded parts are touched. Do not ground to pipelines carrying gases or flammable liquids.
Whenever
cutting, always keep a fire extinguisher nearby. Never use a cutting torch where sparks will be a hazard, such as near rooms
containing flammable materials.
Do
not use electrode holders with loose cable connections. Always keep connections tight. Avoid using electrode holders with
defective jaws or poor insulation. Do not change the polarity switch when the machine is under a load. Wait until the machine
idles and the circuit is open. Otherwise, the contact switch may be burned and the person throwing the switch may receive
a severe burn from the arcing.
Do
not operate the range switch under load. The range switch, which provides the current setting, should be operated only while
the machine is idling and the current is open. Switching the current while the machine is under a load will cause the arc
to form between the contact surfaces. Do not overload welding cables or operate a machine with poor connections. Operating
with currents beyond the rated cable capacity causes overheating. Poor connections may cause the cable to arc when it touches
metal grounded in the welding circuit.
Do
not strike an arc if someone without proper eye protection is nearby. Arc rays are harmful to the eyes and skin. If other
persons must work nearby, the welding area should be partitioned off with a fire-retardant canvas curtain to protect them
from the arc welding flash. Never pick up pieces of recently welded or heated metal. Always wear protective eye goggles when
chipping or grinding. A small particle of slag or metal may cause a severe eye injury.
Steps
to Prevent Electrical Shock
Electrical
shock can be deadly. There are steps that can be taken to prevent electrical shock. Use well insulated electrode holders and
cables. Keep clothing and gloves dry. Never change electrodes with bare hands, wet gloves or when standing on wet floors.
If the ground is wet, use a dry board or rubber mat to stand on. Ground frames of welding units. Keep welding cables dry and
free of grease and oil. Protect welding cables and leads. Keep welding cables away from power cables. Never loop the welding
cable around the body.
Air
Contaminants
Welding
generates fumes and gases. The amount and type of fumes and gases involved depends on the welding process, base material and
filler material. The toxicity of the contaminates depends primarily upon concentrations. Provide adequate ventilation. Use
exhaust hoods, air moving systems, and roof and wall exhaust fans. Also use natural ventilation.
Five
Basic Rules for Safe Handling of Oxy-Acetylene Equipment
1. Keep oxy-acetylene equipment clean, free
of oil, and in good condition.
2. Avoid oxygen and acetylene leaks.
3. Open cylinder valves slowly.
4. Purge oxygen and acetylene lines before lighting
torch.
5. Keep heat, flame and sparks away from combustibles.