Welding Health and

Safety
ESAB, North Bethesda, Md., believes
the foundation to company success
begins with protecting those who
are responsible for it. This belief is
demonstrated by transforming the
work environment for the better,
which begins with providing a safer
and healthier setting for its workers,
including employees, contractors, and
visitors. In addition, ESAB has adopted
the ISO 45001 management system
approach (Ref. 2) and identified several
fundamental hazards associated with
welding that shall be mitigated.

■ Electric shock is by far the most

common and serious hazard facing a
welder. It can lead to severe injury or
death from the shock itself or from a
fall caused by the reaction to a shock. It
occurs when welders touch two metal
objects that have a voltage between
them, thereby inserting themselves into
the electrical circuit.
According to Ref. 3, “For instance, if
a worker holds a bare wire in one hand
and a second bare wire with another,
electric current will pass through that
wire and through the welding opera-
tor, causing an electric shock.” Please
also refer to the AWS Safety & Health
Fact Sheets on electrical hazards and
electric and magnetic fields in welding
(Ref. 4).
■ Welding fume and gases can be
hazardous to your health. Welding fume
contains potentially harmful levels of
metals from consumables, base metal,
and/or the base-metal coatings, so it’s
paramount to keep it and gases out of
a worker’s breathing zone. This is most
efficiently and effectively achieved via
local exhaust ventilation arrangements.
In some cases, arrangements are
designed into the building infrastruc-
ture, while in others, they are provided
by portable units. Either shall ensure
adequate ventilation is achieved and
sustained for a given application to
control one’s exposure to substances
in the fume. If the ambient air is noxious
or breathing is uncomfortable, check
to be sure the ventilation equipment
is functioning properly; if not, report
concerns to a member of manage-
Fume extraction guns and portable fume extractors reduce the amount
of fume in the operator’s breathing zone.
ment. If the ventilation is inadequate
or becomes unsuitable, workers may be
required to wear an approved respira-
tor. For specific potential health effects
related to welding consumables, refer-
ence the product’s safety data sheet via
the consumable manufacturer or dis-
tributor. See the AWS Safety & Health
Fact Sheets on this subject, too (Ref. 5).
■ Welding and cutting activities create
extreme temperatures that pose a
significant fire and explosion hazard if
safe practices are not followed. When
these tasks are undertaken, temperatures
at the point-of-operation result in intense
heat generation, generally resulting in
sparks and spatter, which have been
known to reach distances in excess of
20 ft from the welding and/or cutting
activity.
To prevent fires, before commencing
welding or a cutting task, inspect the
work area for any flammable and com-
bustible materials. According to Ref. 3,
“Flammable materials are comprised of
three categories: liquid, such as gaso-
line, oil, and paint; solid, such as wood,
cardboard, and paper; gas, including
acetylene, propane, and hydrogen.”
If any of these materials are present,
remove them from the area by ensur-
ing they are not within 35 ft of where
the work is to be performed. If work
is carried out in an elevated location,
flammable and combustible materials
beneath the work shall also be removed.
As an added precaution, a dedicated
fire watch shall be made available for
the duration of the welding or cutting
task to be performed and a minimum of
30 minutes thereafter to ensure there
are no smoldering fires. This movement
shall be equipped with a compatible,
long-lasting fire extinguisher. Finally, be
sure there is awareness of fire alarms,
extinguishers, and exits.
■ PPE is worn to minimize exposure
to hazards that can lead to serious
workplace injuries and illnesses (see
the lead image in this column). View the
AWS Safety & Health Fact Sheet on PPE
for welding and cutting (Ref. 6).
Protective helmets shall be worn
when persons are working in areas
where there is a potential for injury to
the head from falling objects or from
foreseeable risks of head contact with
objects. Helmets designed to reduce
electrical shock hazards shall be worn
by workers when near exposed elec-
trical conductors, which could contact
the head.
Workers shall use appropriate eye
or face protection when exposed to
eye or face hazards from flying parti-
cles, molten metal, liquid chemicals,
acids or caustic liquids, chemical
gases or vapors, or potentially injuri-
ous light radiation. Requirements for
side protection, prescription lenses,
filter lenses, and identification of the

JUNE 2022 | 19