10

Technology and Livelihood

Education (TLE-IA)
Shielded Metal Arc Welding
Quarter 3 – Week 1
Unified Learning Activity Sheet (ULAS)
Safety and Health of Welders

Writer:
EPHRAIM E. TAYLAN
Jagupit National High School
Santiago District
Division of Agusan del Norte
Technology and Livelihood Education
(TLE-IA)
Shielded Metal Arc Welding
Junior High School Grade 10
Alternative Delivery Mode
Quarter-3 Week -1 Safety and Health of Welders
First Edition, 2021

Development Team of the ULAS

Writer: Ephraim E. Taylan

Editor: Grace H. Balagot

Reviewers: Grace A. Ando, Annabelle A. Remonte, Flordeliza V. Cabiguing

Glenn Mark V. Dela Sala,

Illustrator: Neil J. Arado

Layout Artist: Junel M. Anino

Management Team: Romeo O. Aprovechar, CESO V

Love Emma B. Sudario
Rayfrocina T. Abao
Grace A. Ando
Bernie R. Pamplona
 Introduction
Welder’s safety and health is extremely important. All workers engaged in
production and constructions are continually exposed to potential hazards. There are
a number of safety and health problems associated with welding. When correct
precautionary measures are followed, welding is a safe occupation. Health officials
state that welding, as an occupation, is no more hazardous or injurious to health than
other metalworking operations. The government has become increasingly active
concerning the safety and health of workers. Laws prescribing safety regulations and
the publication of safety warnings to ensure the safety of workers have been
implemented.

This weekly learning activity sheet will be able to provide a safe environment to
welders which encompass a number of considerations.

This learning activity sheet contains one learning outcome:

Learning Outcome: Ensure safety and health of welders
(TLE-IAAW9-12FC-IIIa-IVj-2)

After going through this learning activity sheet, you are expected to:
1. enumerate the hazards in welding;
2. identify the safety practices in welding; and;
3. appreciate the importance of safety measures in welding.

Pre-Test
Directions: Choose the letter of the correct answer. Write the answer in a
separate sheet of paper.

1. To show concern about safety and health of welders, the government has___________
a. ensured safety and health of workers.
b. published safety regulations and control.
c. guarded the safety and health of welders.
d. enacted laws prescribing safety regulations.
2. These are hazards related to welding, EXCEPT:
a. Arc radiation c. Fire and explosion
b. Electric shock d. Water contamination
3. To prevent arc rays from skin contact, welders should wear clothes without
a. Buttons c. Openings
b. Collar d. Sleeves
4. The following are safety devices that welding workplace must have EXCEPT
a. Electrical tape c. Fire extinguisher
b. First aid kit d. Life saving and support equipment
5. The type of clothing that will not disintegrate from arc radiation or will not catch fire
quickly.
a. Cotton c. Linen
b. Leather d. Woolen
6. It is the most serious hazard posed by welding and can result in serious injuries
and fatalities, either through a direct shock or from a fall from height after a shock.
a. Air contamination c. Electrical shock
b. Arc radiation d. Fire and explosion
7. It will expose you to invisible gaseous fumes, including ozone, nitrogen oxides,
chromium and nickel oxides, and carbon monoxide which can easily penetrate into
your lungs.
a. Air contamination c. Electrical shock
b. Arc radiation d. Fire and explosion
8. Most of them are explosives. It should be used only with adequate ventilation and a
leak detection program.
a. Arc radiation c. Fire and explosion
b. Electrical shock d. Compressed gases
9. The welding arc creates extreme temperatures, and may pose a hazard if safe
practices are not followed. Before beginning to weld, inspect the work area for any
flammable materials and remove them from the area.
a. Air contamination c. Electrical shock
b. Arc radiation d. Fire and explosion
10. Without appropriate PPE or welding curtains, this can result in a painful and
sometimes long-lasting condition called arc-eye.
a. Arc radiation c. Fire and explosion
b. Electrical shock d. Compressed gases

Lesson: Hazards in Welding

Welding operations present several hazards to both those undertaking the
activity and others in the vicinity. Therefore, it’s important that you are aware of the
risks and hazards welding poses, and understand what precautions you can take to
protect yourself. These are the hazards related to welding:

• Electrical shock
• Arc radiation
• Air contamination
• Fire and explosion
• Compressed gases
• Other hazards related to specific processes
◊ Accident from falling
◊ Hit by falling objects/debris
◊ Exposure to hot metal

Electric Shock
During the arc welding process, live electrical circuits are used to create a pool of
molten metal. Therefore, when welding, you are at risk of experiencing an electric
shock. Electric shock is the most serious hazard posed by welding and can result in
serious injuries and fatalities, either through a direct shock or from a fall from height
after a shock. You are also at risk of experiencing a secondary electric shock should
you touch part of the welding or electrode circuit at the same time as touching the
metal you are welding.
You are particularly at risk if you work in electrically hazardous conditions. These
include welding:
 In damp conditions.
 While wearing wet clothing.
 On metal flooring or structures.
 In cramped conditions where you are required to lie, kneel or crouch.
Arc Radiation
Looking at the intense bloom of UV light produced when welding, without
appropriate PPE or welding curtains, can result in a painful and sometimes long-
lasting condition called arc-eye. Many factors can affect the severity of a flash burn
injury, such as distance, duration and the angle of penetration. Long-term exposure to
arc flashes could also potentially result in cataracts and lead to a loss of vision.
Other forms of eye damage include:
 Foreign bodies entering the eye, including grit, sparks and dust.
 Particulate fumes and gases which could lead to conjunctivitis.
Air contamination
Undertaking welding activities will expose you to invisible gaseous fumes,
including ozone, nitrogen oxides, chromium and nickel oxides, and carbon monoxide
which can easily penetrate into your lungs. Depending on the gas or fume, the
concentration and duration of your exposure, the resultant damage can be severe.
Fire and Explosion
The welding arc creates extreme temperatures, and may pose a significant fire
and explosions hazard if safe practices are not followed. While the welding arc may
reach very high temperatures, the real danger is not from the arc itself, but rather the
intense near the arc and the heat, sparks and spatter created by the arc. This spatter
can reach up to 35 feet away from the welding space.
To prevent fires, before beginning to weld, inspect the work area for any
flammable materials and remove them from the area. Flammable materials are
comprised of three categories: liquid, such as gasoline, oil and paint; solid, such as
wood, cardboard and paper; gas, including acetylene, propane and hydrogen.
Know where the fire alarms and extinguishers are located, and check the
extinguisher’s gauge to make sure it is full. If an extinguisher is not available, be sure
to have access to fire hoses, sand buckets or other equipment that douses fire. And,
know the location of the nearest fire exit.
If welding within 35 feet of flammable materials, have a fire watcher nearby to
keep track of sparks, and remain in the work area for at least 30 minutes after
finishing welding to be sure there are no smoldering fires. Put a fire resistant material,
such as a piece of sheet metal or fire resistant blanket, over any flammable materials
within the work area, if you can’t remove them.
Hazards of Compressed Gases
Gas welding and flame cutting use a fuel gas and oxygen to produce heat for
welding. For high-pressure gas welding, both the oxygen and the fuel gas (acetylene,
hydrogen, propane, etc.) supplied to the torch are stored in cylinders at high pressure.
The use of compressed-gas cylinders poses some unique hazards to the welder.
Acetylene is very explosive. It should be used only with adequate ventilation and a leak
detection program.
 Oxygen alone will not burn or explode. At high oxygen concentrations, however,
many materials (even those that are difficult to burn in air, such as normal dust,
grease, or oil) will burn or explode easily.
Other hazards
In an elevated location, make sure no flammable materials are beneath you,
and watch out for other workers below you in order to prevent dropping sparks or
spatter on them. Even high concentrations of fine dust particles may cause explosions
or flash fires. If a fire starts, don’t panic – and call the fire department immediately.
To prevent trips and falls, keep welding areas clear of equipment, machines,
cables and hoses, and use safety lines or rails. We should always use and maintain
safety lines, harnesses and lanyards. And always make sure that scaffolds are
properly assembled and used.
Welding Workplace Safety
The welding shop management and its supervisors are responsible for providing
training for workers in the safe conduct of their day to day activities. Employees must
be informed and trained to detect hazards as well as protect themselves. The welders
and other employees have an obligation to learn and observe safe practices by obeying
safety rules and regulations. They are responsible for the use of safe equipment and
materials. It is the responsibility of supervisors to enforce the implementation of safety
rules and regulations. Good housekeeping practices should always be employed inside
the welding shop. Adequate safety devices should be provided, such as fire
extinguishers, life-saving and support equipment, first aid kit plus training of
personnel to utilize the appropriate equipment properly.
Workshop rules in Welding
Do’s
1. Check if the area contains flammable liquids / gases. Ensure that there
are no floor openings, open windows nearby or any su ch ready access
through which sparks can pass and fall on combustible materials.
2. Remove all combustible materials to a safe distance at least 20 feet.
3. Sweep the floor and the area nearby and remove all waste materials.
4. If any of the combustible materials c annot be removed, cover it with non -
combustible coverings like metal sheets or asbestos curtains.
5. If the floor itself is combustible, cover it likewise and wet it before
starting welding work.
6. In case welding or cutting has to be done on a vessel, pipe or other
container which contains or had earlier contained flammable liquids,
ensure that a detailed “permit –to-work” procedure involving isolation,
blanking, purging, inverting methods is followed.
7. Use portable screens, booths or partitions to minimize t he spread of
sparks.
8. Keep an observer ready with a portable extinguisher, water buckets etc.
9. Ensure that gas cylinders, hose pipes, torches and other appliances are
properly selected, installed and used.
10. In case of electric welding check the connections, cables and every thing
in particulars.
 Ensure that the welder uses appropriat e personal protective
equipment like goggles, gloves, boots, spats, fire blanket and if
necessary an approved respirator.
  Inspect the area for sparks or moldering materia ls. If you find any,
remove and extinguish them.
 If any portable extinguisher has been used, replenish it.
 Gas cylinders, blow-torches etc. should be returned to the stores or
kept at authorized place.
 Cordon off lower areas where welding or gas cutting is going.
 Display suitable signage.
Don’ts
1. No combustible material should be present in the vicinity.
2. Don’t allow any unauthorized person in working area.
3. Don’t allow any loose connection.
4. Don’t allow unsafe joints of electric cables.
5. Don’t use damaged hose pipe/welding lead.
6. Don’t allow untrained welder or gas c utter.
7. Don’t use bare electric cable.
8. Do not leave electric circuits on, or blow -torches burning when the
welder has to take a tea break or has to be away for any reason.
9. Don’t leave the gas cylinders valves open during lunch or tea breaks.
10. Don’t allow any parallel work with welding and cutting work.
11. Don’t allow smoking near the work area.
Protective Clothing
Welders should wear appropriate work clothes without openings or gaps to
prevent the arc rays from contacting the skin. If the arc rays contact the skin for a
period of time, it will result to painful “sunburn” or “arc burns”. Wool fabric is much
more satisfactory than cotton since it will not disintegrate from arc radiation.

Personal Protective Equipment (PPE)

The chart below summarizes the types of personal protective equipment that
can be used when welding

Welding - Personal Protective Equipment (PPE)

Body Part Equipment Illustration Reason
Protects from:
• radiation
• hot slag, sparks
• intense light
Welding helmet, • irritation and
Eyes and face hand shield, and chemical burns
goggles
Wear fire resistant
head coverings under
the helmet where
appropriate
 Protects against:
Lungs (breathing) Respirators
• fumes and oxides

Protects against:
• heat, fires
• burns
Exposed skin (other
Fire/Flame resistant
than feet, hands, Notes: pants should
clothing and aprons
and head) not have cuffs, shirts
should have flaps
over pockets or be
taped closed
Protects against:
• noise

Ears - hearing Ear muffs, ear plugs Use fire resistant ear
plugs where sparks
or splatter may enter
the ear.
Protects against:

• electric shock
Feet and hands Boots, gloves • heat
• burns
• fires

To receive full protection from your PPE, you must NOT:

 Roll up sleeves or trousers. Rolling up your clothes will leave you susceptible
to molten metal or sparks getting caught in the folds, which could potentially
lead to severe burns. You should also never tuck your trousers into your work
boots.
 Remove your helmet while welding. You must always wear your helmet when
welding and when in the vicinity of another welder. While the intensity of the
radiation produced decreases the further you are from a welding arc, those less
than 10 meters away are still susceptible to arc-eye. Therefore, it’s important
that you remain behind the welding curtains or wear the correct PPE, even if
you aren’t the worker carrying out the welding operation.
 Learning Activities
Activity 1. Where do I belong?
Directions: Arrange the given workshop rules in welding. Identify if it belongs to
“do’s” or “don’ts”. Put your answer on the designated column. Write the
answer in a separate sheet of paper.

 Remove all combustible materials to a safe distance at least

20 feet.
 Allow any loose connection.
 Ensure that gas cylinders, hose pipes, torches and other
appliances are properly selected, installed and used.
 Sweep the floor and the area nearby and remove all waste
materials.
 Leave the gas cylinders valves open during lunch or tea
breaks.
 Keep an observer ready with a portable extinguisher, water
buckets etc.
 Use bare electric cable.
 Allow untrained Welder or Gas Cutter.
 Allow any unauthorized person in working area.
 Use portable screens, booths or partitions to minimize the
spread of sparks.

DO’s DON’Ts
Activity 2. Meant to be!

Directions: Match the drawing in column A to its corresponding protection

(against/from) in column B. Write the letter of your answer on a separate sheet of
paper.
Column A Column B
1.

a. noise

2.

b. fumes and oxides

3.

c. heat, fires, burns

4.

d. electric shock, heat, burns, fires

5.

e. radiation, hot slag, sparks, intense light,

irritation and chemical burns

Reflection

Directions: Discuss the following briefly. Write the answers in a separate sheet of
paper.

1. Give specific situation on how you can apply safety practices in your workplace.
____________________________________________________________________________________
____________________________________________________________________________________

2. How can we avoid welding related injuries?

_____________________________________________________________________________________
_____________________________________________________________________________________

RUBRIC
AREAS OF
4 3 2 1
ASSESSMENT
Presents ideas in a
Ideas are vague and
concise and specific Ideas are too general No ideas presented
Ideas unclear
manner
 Vivid and logical 1-2 sentences are not 3-4 sentences are not All ideas are not
Organization arrangement of ideas properly organized properly organized organized

Post-Test
Directions: Choose the letter of the correct answer. Write the answer in a separate
sheet of paper.

1. The type of clothing that will not disintegrate from arc radiation or will not catch fire
quickly.
a. Cotton c. Linen
b. Leather d. Woolen

2. To show concern about safety and health of welders, the government has
a. Ensured safety and health of workers.
b. Published safety regulations and control.
c. Guarded the safety and health of welders.
d. Enacted laws prescribing safety regulations.

3. These are hazards related to welding, EXCEPT:

a. Arc radiation c. Fire and explosion
b. Electric shock d. Water contamination

4. To prevent arc rays from skin contact, welders should wear clothes without
a. Buttons c. Openings
b. Collar d. Sleeves

5. The following are safety devices that welding workplace must have EXCEPT:
a. Electrical tape c. Fire extinguisher
b. First aid kit d. Life saving and support equipment

6. Without appropriate PPE or welding curtains, this can result in a painful and
sometimes long-lasting condition called arc-eye.
a. Arc radiation c. Fire and explosion
b. Electrical shock d. Compressed gases

7. It is the most serious hazard posed by welding and can result in serious injuries
and fatalities, either through a direct shock or from a fall from height after a shock.
a. Air contamination c. Electrical shock
b. Arc radiation d. Fire and explosion

8. Most of them are explosives. It should be used only with adequate ventilation and a
leak detection program.
a. Arc radiation c. Fire and explosion
b. Electrical shock d. Compressed gases
9. It will expose you to invisible gaseous fumes, including ozone, nitrogen oxides,
chromium and nickel oxides, and carbon monoxide which can easily penetrate into
your lungs.
a. Air contamination c. Electrical shock
b. Arc radiation d. Fire and explosion

10. The welding arc creates extreme temperatures, and may pose a hazard if safe
practices are not followed. Before beginning to weld, inspect the work area for any
flammable materials and remove them from the area.
a. Air contamination c. Electrical shock
b. Arc radiation d. Fire and explosion
 Answer Key
s pr e ad of sp ark s.
p er s on in work ing ar e a. or p ar titions to minimize the
Allow any unauthorize d Us e p or tab le s cr ee ns , b ooths
b uc ke ts e tc .
Gas C utter. p or table e xting uis he r, water
or We lde r Allow untr ained K e ep an ob s er ve r re ady with a
a 10. m ater ials .
d 9. ne ar by and re m ove all was te
d 8. Us e b ar e e le c tr ic c ab le . Swe e p the f loor and the ar ea
a 7. s e le c te d , installe d and us ed .
c 6. b re ak s. ap p lianc es ar e pr ope rly
op e n dur ing lunc h or te a hos e pipe s, tor c hes and other
d 5. Le ave the g as cy linder s v alv es Ens ur e that g as c ylinde rs ,
a 4. le as t 20 f e e t.
c 3. m ater ials to a s afe dis tanc e at
d 2. Allow any loose c onne c tion. R em ov e all c om b us tible
a 1. Don’ts Do’s
Pre-Test Activity 1 – Where do I belong

d 10.
a 9.
d 8.
c 7.
b 5. a 6.
c 4. a 5.
May Vary c 4.
a 3.
Students Answer d 3.
e 2.
d 1. a 2.
d 1.
Activity 2 – Meant to be! Reflection Post -test

References
Ferguson, Alan. 2020. The Many Hazards of Welding Work. Accessed on February 13,
2021. Retrieved from: https://www.safetyandhealthmagazine.com/ articles/19334-
the-many-hazards-of-welding-work

Unknown Author.Do’s And Don’ts - Welding And Gas Cutting. Accessed on February
13, 2021. Retrieved from: http://www.ehsdb.com/dos-and-donts--welding-and-
cutting.php

Unknow Author. 2020. General Safe Work Practices for Welders. Accessed on
February 13, 2021. Retrieved from: https://safetyculture.com/ topics/welding-
safety/

Martinelli, Katie. 2018. Welding Hazards in the Workplace: Safety Tips & Precautions.
Accessed on February 13, 2021. Retrieved from:
https://www.highspeedtraining.co.uk/hub/welding-hazards-in-the-workplace/

Shielded Metal Arc Welding NC I, Learner’s Material. Welding Fillet On Carbon/ Mild
Steel Plates (1F). Accessed on October 31, 2020. Retrieved from:
https://drive.google.com/drive/u/0/folders/0B7Id7ud2BU4oWW9UdG02QnN0Skk