Welding Safety

Welding is controlled by the general duties under the Health and Safety at Work Act 1974, the Provision and Use
of Work Equipment Regulations 1992 (for the equipment), the Workplace (Health, Safety and Welfare)
Regulations 1992 (for the workplace requirements), the Control of Substances Hazardous to Health Regulations
1994 (for the fumes emitted by the welding process), and in detail by a number of Health and Safety Executive
Guidance Notes
HSE Guidance Note EH55 - The Control of Exposure to Fume from Welding, Brazing and Similar Processes
HSE Guidance Note EH54 - Assessment of Exposure to Fume from Welding and Allied Processes
HSE Guidance Note MS 15 - Welding
Hazards
The main hazards likely to be encountered during welding and cutting processes are:
 High temperatures causing the risk of burns and fire
 Directly or indirectly produced fumes, liable to cause injury to health
 Thermal radiation causing burns or ultra violet radiation (especially associated with electric arc welding)
which causes damage to the eyes
 Oxygen deficiency or enrichment within a confined space
 Explosions during the welding of tanks, drums, and vessels which have not been fully purged of their
flammable contents
These hazards to personnel and plant can be minimised by the wearing of suitable protective equipment and by
following laid down procedures. For this reason all potential welders must be given adequate training to cover
both the operation of welding equipment and avoidance of the hazards involved. Departments should keep a
register of their trained welders and restrict welding operations to those on the register.
Confined Spaces
In cases of working in a confined space a Permit to Work system will be appropriate and fume extraction
equipment and facilities should be provided. Where a confined space is a tank which has contained a flammable
liquid or gas it needs to be purged with an inert gas or liquid before the welding commences. In both cases if a
welder is required to enter the space the atmosphere needs to be analysed for safety. This will ensure that it is
breathable and is not flammable or toxic.
Gas Flame Welding
The gases most commonly used are oxygen, acetylene and propane. The storage, transport and use of the
cylinders containing these gases are the subject of the Highly Flammable Liquids and Liquefied Petroleum Gas
Regulations 1972 which stipulate the following:
 Fuel and oxygen supplies should be stored at least 6 metres apart
 Cylinders should be secured either in a trolley or lashed upright in a suitable support
 Cylinders must not be rolled along the ground
 Grease must not be used to lubricate fittings because of the dangers of ignition in the presence of
oxygen
 The proper fittings, hoses, regulators, gauges, etc. must always be used and makeshift arrangements
avoided
Purpose designed protective clothing should also be used when gas welding, e.g. gas workers goggles, leather
aprons, jackets and gauntlets to protect against sparks and molten metal burns. Due to their hazard in case of
fire the correct storage of cylinders is extremely important, and they must not be placed in dead-end corridors
or similar single means of exit in laboratories.

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Gas Cylinders
Cylinders and hoses are colour coded. These and the valve thread details are given below:
 
Acetylene cylinders are filled with a
Gas Cylinder Colour Valve Thread Hose porous substance such as charcoal or
kapok which is soaked with acetone to
Oxygen Black Right Hand Blue take up the acetylene gas. Because of
their design the cylinders should always
Acetylene Maroon Left Hand Red be stored upright and because of the
danger of an acetylene explosion when
the gas is under pressure, the pressure of
Propane Red Left Hand Orange gaseous acetylene should not be allowed
to exceed 0.63 Bar (9 PSI). There are many
other safety features to be observed with
acetylene systems (e.g. copper and copper alloys should not be used ) and hence the Safety, Health and
Environment Unit should be contacted whenever an acetylene system is to be installed.

Electric Arc Welding

HSE Guidance Note PM 64 - Electrical Safety in Arc Welding
The electric supply for welding can be supplied either by a separate generating set or a transformer fed from the
mains. The arc voltage is normally of the order of 50 to 60 Volts DC, but may be up to 100 V AC. The electrical
safety precautions of earthing and insulation apply as to other electrical equipment, but due to the special
nature of welding and its potential for passing high currents under fault conditions, special attention has to be
paid to the prevention of fire. Hence welding cables need to be regularly inspected for cuts or other damage to
the insulation arising out of rough usage and, as well as the normal earthing of the cases of the welding
machinery, the workpiece itself should be capable of carrying the full welding current.
Some protective clothing and gloves should be worn but cannot be regarded as adequate protection against
electric shock. Hence the electrode holder needs to be properly constructed and insulated to prevent accidental
contact with live metal parts.

Ultraviolet, visible and infrared radiation hazards

Radiation is emitted by the welding arc in three principal ranges:-

Wavelength
Type (nanometres) These types of radiation do not cause ionisation of body tissue, but they
can still cause damage to body systems and membranes.
Infrared (heat) >700 Ultraviolet radiation (UV)

Visible light 400-700 UV is generated by all arc processes. Excess exposure to UV causes skin
inflammation, and possibly even skin cancer or permanent eye damage.
However the main risk amongst welders is for inflammation of the
Ultraviolet radiation <400
cornea and conjunctiva, commonly known as 'arc eye' or 'flash'.

Arc eye
Arc eye is caused by UV radiation. This damages the outmost protective layer of cells in the cornea. Gradually
the damaged cells die and fall off the cornea exposing highly sensitive nerves in the underlying cornea to the
comparatively rough inner part of the eyelid. This causes intense pain, usually described as 'sand in the eye'. The
pain becomes even more acute if the eye is then exposed to bright light.
Arc eye develops some hours after exposure, which may not even have been noticed. The 'sand in the eye'
symptom and pain usually lasts for 12 - 24 hours, but can be longer in more severe cases.
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Fortunately, arc eye is almost always a temporary condition. In the unlikely event of prolonged and frequently
repeated exposures, permanent damage can occur. A person would have to be stubborn and/or foolish to allow
himself to be repeatedly exposed to such arc eye risks without taking some precautions.
Treatment of arc eye is simple, rest in a dark room. Various soothing anaesthetic eye drops can be administered
by a qualified person, or hospital Casualty Departments. These can provide almost instantaneous relief.

Ultraviolet effects upon the skin

The UV from arc processes does not produce the browning effect of sunburn; but does cause reddening and
irritation caused by changes in the minute surface blood vessels. In extreme cases, the skin may be severely
burned and blisters may form. The reddened skin may die and flake off in a day or so. Where there has been
intense prolonged or frequent exposure, skin cancers can develop, but there is little evidence of this in welders.
Visible light
Intense visible light particularly approaching UV or 'blue light' wavelengths, passes through the cornea and lens
and can dazzle and, in extreme cases, damage the network of optically sensitive nerves on the retina.
Wavelengths of visible light approaching the infrared have slightly different effects but can produce similar
symptoms. Effects depend on the duration and intensity and to some extent upon the individual's natural reflex
action to close the eye and exclude the incident light. Normally this dazzling does not produce a long-term effect
but in welders it is thought to progressively reduce their ability to adapt to extreme light conditions.
Infrared radiation
Infrared radiation is of longer wavelength than the visible light frequencies, and is perceptible as heat. The main
hazard to the eyes is that prolonged exposure (over a matter of years) causes a gradual but irreversible opacity
of the lens. Fortunately, the infrared radiation emitted by normal welding arcs causes damage only within a
comparatively short distance from the arc. There is an immediate burning sensation in the skin surrounding the
eyes should they be exposed to arc heat. The natural human reaction is to move or cover up to prevent the skin
heating, which also reduces eye exposure.
There is very little evidence that welders can be exposed to the required intensity of radiation long enough for
lens cataracts to be formed by infrared radiation. Oxy-fuel cutting can also emit high levels of infrared radiation
and it is recommended that anti-flash, or impact resistant, eye protection is worn by anyone continuously
engaged in heating or thermal cutting processes.

Avoiding the hazards

Although there are differing effects from UV, visible and infrared radiation, there is one common protection
mechanism that is completely effective; this is to provide a barrier to prevent the radiation reaching sensitive
surfaces. The welder should therefore be equipped with protective equipment as indicated below.It should not
be forgotten that radiation can be reflected off shiny surfaces, and several cases of arc eye attributable to
unwanted reflections have been recorded. The walls, etc, of the work area should have a matt finish.
Eye protection
The welder protects his eyes by means of a filter glass to absorb the radiation in the dangerous wavelengths, and
limit visible light so he can see the progress of the welding process. There are two basic types: permanent filters,
and photosensitive filters which react rapidly to the incident light from the arc and darken.
BS EN169 specifies a range of permanent filter shades of gradually increasing optical density which limit
exposure to radiation emitted by different processes at different currents. It must be stressed that shade
numbers indicated in the standard and the corresponding current ranges are for guidance only.
The operator's own preference and the application should be taken into account when selecting the shade
number for a particular task. Standard filter glasses are now marked with the CE mark showing they have been
independently tested to meet the full requirements of the standard.

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BS EN 379 defines requirements for the photosensitive variable density lenses that are now available. These can
be used with complete confidence, as there are failsafe requirements in the standard such that even if the lens
does not darken when the arc is struck, dazzle may occur but no permanent eye damage will result. The
overriding benefit of such reactive lenses is the welder's ability to see and position the electrode correctly before
striking the arc. This can greatly reduce arc initiation defects.
Although arc-eye and other radiation effects appear to be the most significant hazards for welders, more than
half all eye injuries are caused by flying particles of slag, grinding, chipping etc. It is therefore strongly
recommended that anyone working close to arc welding activities should wear some eye protection even when
arcing has stopped.

Head and face protection

Filter glasses are relatively small and are mounted in a dark, opaque shield, either hand-held or pivoted on a
head-band so it can be raised or lowered by a movement of the head. The shield has to be designed to screen
the entire face, ears and portions of the neck from the direct radiation from the arc. BS EN 175 lays down
requirements for the basic types.
Gloves/gauntlets
Hands are usually the closest part of the body to the arc and the work piece. It is therefore important that
welder's gloves provide thermal insulation as well as blocking out UV and visible light frequencies. The gloves
should be designed to cover hand and wrist and overlap the sleeves.
With manual metal arc and MIG/MAG processes, spatter can also be a problem, and therefore gloves need to be
able to resist penetration by droplets of molten metal. The combined effects of UV and ozone can rapidly
degrade many glove materials. The durability of the material has to be taken into account in relation to the
process control requirements. For example, tightly woven cotton or supple leather gloves may be ideal for low
current TIG welding where a delicate control of the torch is required, but where little heat, and no spatter is
generated. For most other arc welding processes, which emit high levels of radiation and spatter, much heavier
or more substantial gloves are required.
Clothing
Almost any heavy-duty, dark coloured, opaque fabric will block UV and infrared radiation. However, as with
gloves, damage by spatter and the combined effects of UV/ozone may be significant, depending upon the
application. The welder's clothing must cover all parts of the body, arms, neck and chest that could otherwise be
exposed to direct arc radiation.
Heavy-duty cotton overalls are usually the minimum required for protection. Man-made fibres and plastics are
not suitable as they may be melted by spatter or even infrared heat. British Standard BS EN 470-1 specifies the
design features and the spatter resistance for clothing suitable for welders.
It is important to prevent the welder from becoming too hot. He will be close to a source of intense heat and a
complete suit of heavy protective clothing might significantly increase his discomfort. Local protection in the
form of chrome leather aprons, hoods, capes, spats, half jackets or knee-pads is effective. In this way the right
degree of protection can be provided where required and the rest of the welder's body can be protected
adequately and comparatively inexpensively, for example, by overalls.
Footwear, not normally subjected to radiation, is also important. It must be able to resist molten spatter falling
on it from above, or being trodden on thus melting the sole. Ankle boots with anti-crush toecaps are
recommended for all processes except TIG welding, where shoes (with protective toecaps) may be adequate.
Protection for welder's helpers
Anyone working regularly within 2m of a welding arc needs to be protected against skin and eye exposure in the
same way as the welder. He should at least have overalls, gloves and a hand-held or head shield if required to

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look at the arc. Additionally, he should have anti-flash glasses with side pieces to protect from inadvertent arc
eye hazards. The same recommendation applies to one welder working in comparatively close proximity of
another. Welders frequently suffer arc eye from inadvertent exposure not to their own arc, but to that of
another welder working one or two metres away from them.
Tinted anti-flash glasses may be selected from BS EN 169, scale number 1.2 - 4 for example. If the assistant is to
work at a similar distance from the arc as the welder, then the same filter number should be selected for the
assistant as for the welder.
BS EN 175 contains details of the specifications for robustness and impact resistance for the various types of
eye/face protection available.
Contact lenses
Reports that radiation from arc processes can fuse contact lenses to the eye are entirely without foundation. The
UK Employment Medical Advisory Service and others have investigated the subject and issued statements saying
that there is no risk that contact lenses can stick to the cornea due to incident radiation from welding.
However contact lens wearers can still suffer arc eye, and must remove the lens immediately they feel any
discomfort, which could be some hours after the actual exposure. Welding also exposes the eyes to heat and
dust so that it may be necessary to remove and wash the lenses more frequently than normal.
Eye protection for others
Where practicable screens, walls or partitions should be provided to stop any arc radiation reaching the eyes of
others working or passing through the area. Partitions or walls should be painted with matt colours to
minimise reflections and glare.
Screens or curtains can be either fixed permanently or on portable frames where welding can take place at
various locations in a shop. Flexible translucent plastic material is available from welding distributors, which will
positively filter out UV glare and the other harmful blue-white radiation.
Obviously opaque textile or plastic materials will also stop radiation and provide complete protection, but they
also restrict visibility.
Most rigid polycarbonate or even ordinary glass windows will also reflect or absorb enough harmful radiation to
prevent eye injury to someone observing an arc through the material. However obviously the glare will be
transmitted and can cause dazzle if the observers and the windows are too close (i.e. closer than 3m to the arc).
If such materials are to be used for prolonged observation of an arc, the supplier should be asked to confirm that
the material is suitable.
If no screens or windows are possible, then safety must be provided by arranging that unprotected observers
should not be allowed to approach closer than 10m to an arc. At this distance even a wilful observer who insists
at staring at the arc for up to say 10 minutes would only be dazzled.
References
1. Personal Eye Protection - Filters for welding and related techniques - Transmittance requirements and
recommended use
2. Personal Eye Protection - Automatic welding fillers
3. BS EN 470-1 Protective clothing for use in welding and allied processes
4. BS EN 175 Personal protection - Equipment for eye and face protection during welding and allied
processes
5. BS EN 166 Personal eye-protection - specifications
6. IIS/IIW-1161-92 Eye damage from radiation in arc welding
7. IIS/IIW-1082-90 Welder's eye injuries

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