WELDING SAFETY

Welding joins pieces of metal by the use of heat,

pressure, or both.
There are more than 80 different types of welding
and associated processes.
Some of the most common types of welding
include: arc welding, which includes shielded
metal arc welding (SMAW), the gas-shielded
methods of metal inert gas (MIG) and tungsten
inert gas (TIG), plasma arc welding (PAW), and
submerged arc welding (SAW).
Other welding processes may use oxy-acetylene
gas, electrical current, lasers, electron beams,
friction, ultrasonic sound, chemical reactions, heat
from fuel gas, and robots.
Control of welding hazards includes avoiding eye
injury, respiratory protection, ventilation of the
work area, protective clothing, and having safe
equipment to use.
Health Hazards of Welding
 Gases and Fumes
Welding “smoke” is a mixture of very fine particles
(fumes) and gases.
Many of the substances in welding smoke, such as
chromium, nickel, arsenic, asbestos, manganese, silica,
beryllium, cadmium, nitrogen oxides, phosgene,
acrolein*, fluorine compounds, carbon monoxide,
cobalt, copper, lead, ozone, selenium, and zinc can be
extremely toxic.
Exposure to welding smoke may have short-term and
long-term health effects.
* colourless poisonous chemical
Short-term (acute) health effects
Exposure to metal fumes (such as zinc, magnesium,
copper, and copper oxide) can cause metal fume fever.
Welding smoke can also irritate the eyes, nose, chest,
and respiratory tract, and cause coughing, wheezing,
shortness of breath, bronchitis, pulmonary edema (fluid
in the lungs), and pneumonitis (inflammation of the
lungs).
Cadmium, can be fatal in a short time. Secondary gases
(ultraviolet radiation)given off by the welding process
can also be extremely dangerous.
These gases are deadly at high doses, and can also cause
irritation of the nose and throat and serious lung disease.
Long-term (chronic) health effects
Welders have an increased risk of lung cancer, and
possibly cancer of the larynx (voice box) and urinary
tract.
Welders may also experience a variety of chronic
respiratory (lung) problems, including bronchitis,
asthma, pneumonia, emphysema, decreased lung
capacity, silicosis (caused by silica exposure), and
siderosis (a dust-related disease caused by iron oxide
dust in the lungs).
Heart disease, skin diseases, hearing loss, chronic
gastritis , gastroduodenitis (inflammation of the
stomach and small intestine), and ulcers of the
stomach and small intestine.
Safety Hazards of Welding
Electrical hazards
Electric shock (Falls and other accidents can result
from even a small shock; brain damage and death
can result from a large shock.)
Dry gloves, wear rubber soled shoes, insulating
layer, such as a dry board or a rubber mat, for
protection on surfaces
The piece being welded & the frame of all
electrically powered machines must be grounded.
The insulation on electrode holders and electrical
cables should be kept dry and in good condition.
Fires and explosions
The intense heat and sparks can cause fires or
explosions if combustible or flammable materials are
in the area.
Welding should only be performed in areas that are
free of combustible materials and those that can not be
removed should be covered with a tight-fitting flame-
resistant material.
Never attempt to weld containers that have held a
flammable or combustible material unless the
container is thoroughly cleaned or filled with an inert
(non-reactive) gas.
A fire inspection should be performed before leaving
the work area and within 30 minutes after the
Hazards of Welding in Confined Spaces
The worker inside the confined space should be
equipped with a safety harness, a lifeline, and
appropriate personal protective clothing, including a
self-contained breathing apparatus.
Gas cylinders and welding power sources should be
located in a secure position outside of the confined
space.
Continuous air monitoring may be necessary during
welding. No worker should enter a confined space
where the percentage of oxygen is below 19.5%
unless he or she is equipped with a supplied-air
respirator.
Use continuous mechanical ventilation and a
Hazards of Compressed Gases
All cylinders should have caps or regulators.
Only pressure regulators designed for the gas in
use should be fitted to cylinders.
Compressed gas cylinders, all pressure relief
valves, and all lines should be checked before and
during welding operations.
Blowpipes, Hoses and fittings should be kept in
good condition and checked regularly.
Cylinders must be stored upright so that they will
not fall over.
Oxygen and fuel cylinders must be stored
separately, away from heat and sunlight, and only
in a dry, well-ventilated, fire-resistant area that is at
least 20 feet away from flammable materials
Be aware of backfires and flashbacks that are
usually caused by defective or incorrectly operated
equipment.
SAFETY IN HAND TOOLS
& PORTABLE TOOLS
Common Causes of Accidents
using the wrong tool for the job
tools falling from overhead
sharp tools carried in pockets
using cheaters on tool handles
excessive vibration
using tools with mushroomed heads
failure to support or clamp work in position
carrying tools by hand up or down ladders
using damaged electrical cords or end connectors
failure to use ground fault circuit interrupters
(GFCIs), especially outdoors.
Using tools in poor condition & in wrong ways
Keeping tools in work places
Basic Safety Rules For Hand Tools
ALWAYS WEAR EYE PROTECTION.
 Wear the RIGHT SAFETY EQUIPMENT for the job.
 Use tools that are the RIGHT SIZE & RIGHT TYPE
for your job.
 Follow the correct procedure for using EVERY tool.
 Keep your cutting tools SHARP and in good condition.
 DON’T work with OILY or GREASY hands.
 Handle SHARP-EDGED and POINTED TOOLS with
care.
Always carry pointed tools by your side with the
points and heavy ends DOWN.
 SECURE all small work & short work with a vise
or clamp.
 NEVER carry tools in your pockets.
 DON’T use tools which are LOOSE or
CRACKED.
 KEEP your punches & chisels in good condition.
Mushroomed heads can chip & cause injuries.
DON’T use a file without a HANDLE.
 DON’T pry or hammer with a FILE. It may
shatter.
 DON’T use screwdrivers as chisels or pry bars.
 DON’T try to increase your leverage by using a
“cheater” with a wrench. Wrenches are designed at
the right strength for their size and length.
 AFTER USING A TOOL - clean it and return it to
its proper storage place.
 If anything breaks or malfunctions - report it to
your instructor AT ONCE.
Use the RIGHT TYPE of tool for the job.
 NEVER place tools & materials where they hang on
the edge of a bench.
 Don’t use tools for things they weren’t meant for.
 Store tools and materials vertically, with the points
and heavy end down.
 Cut away from yourself when you use chisels and
other edged tools.
 DON’T FORCE screws; make sure that the correct
screw for the job is being used.
If a chisel is used as a screwdriver, the tip of the
chisel may break and fly off, hitting the user or other
employees.
If a wooden handle on a tool, such as a hammer or an
axe, is loose, splintered, or cracked, the head of the
tool may fly off and strike the user or other
employees.
If the jaws of a wrench are sprung, the wrench might
slip.
If impact tools such as chisels, wedges, or drift pins
have mushroomed heads, the heads might shatter on
impact, sending sharp fragments flying toward the
user or other employees.
Impact tools such as drift pins, wedges, and chisels
must be kept free of mushroomed heads.
The wooden handles of tools must not be
splintered.
Iron or steel hand tools may produce sparks that
can be an ignition source around flammable
substances.
Power Tools
Power tools used in construction are driven by
gasoline, electricity, compressed air (pneumatic),
hydraulic pressure, and explosive powder.
Causes of injuries include electric shock, flying
particles and dust in the eye, falls, explosive
atmospheres, and falling tools.
Basic Safety in Power Tools
Always wear eye protection. Flying particles and
dust are always problems with power tools.
Wear hearing protection whenever there is chance
of excessive noise exposure.
Always disconnect the power on a portable power
tool before changing or adjusting accessories such
as drill bits and saw blades.
Never operate a power tool with the guard
removed or improperly adjusted.
Power tools should not be left where there is a
chance that the cord or hose may be pulled,
causing the tool to fall.
Cords and hoses left on the floor in high traffic
areas may also create a tripping hazard.
Cords or hoses that must cross access routes or
roadways should be suspended above the ground
or protected by wooden planks.
General Guidelines
Whenever possible, select tools with large handles
relative to the tool body, to reduce vibration.
Select tool handles covered with cork, rubber, or
plastic bonded to steel to reduce vibration.
Use tools with two handles to make holding and
manipulation easier.
Always refer to the operator’s manual before using
a tool the first time.
Make sure there’s adequate lighting for safe tool
use.
 Portable Electric Tools
Systematic Maintenance
Safety Guards in tools
Experienced and authorized operator
Disconnection before repair, service or change of
parts
Operate electric tools within their design limitations.
Use gloves and appropriate safety footwear when
using electric tools.
Store electric tools in a dry place when not in use.
Do not use electric tools in damp or wet locations
unless they are approved for that purpose.
Keep work areas well lighted when operating
electric tools.
Electrical shocks - cause the user to fall off a ladder
or other elevated work surface and be injured due to
the fall.
To protect the user from shock and burns, electric
tools must have a three-wire cord with a ground and
be plugged into a grounded receptacle, be double
insulated, or be powered by a low voltage isolation
transformer.
Double-insulated tools are available that provide
protection against electrical shock without third-wire
grounding.
 Drilling Machine
Punch or drill a pilot hole in the work so that the bit
won’t slip or slide when you start drilling. Align the
drill square with the hole
Material being drilled should always be clamped or
well secured to prevent whipping should the bit bind
in the hole
Always be sure that the switch is off before plugging
in the drill.
Make sure no loose hair or loose or torn clothing can
be caught in the drill bit and cause serious injury.
Standing on a ladder to drill a hole in a wall or
overhead can be hazardous as well as hard on the
 Portable Grinders
Never exceed the safe grinding in rpm for a stone or
disk, which should be specified on the manufacturer’s
label.
Always unplug the tool before making grinder/cutter
installations.
Make sure that the grinding wheel is installed
according to the manufacturer’s instructions.
Use the proper hardware (safety flanges, nuts and
blotters) as recommended for holding the wheel in
position.
Make sure that safety guards are in place and properly
adjusted before operating.
If dropped in floor, inspect it very carefully for damage.
Change disk or stone as recommended by manufacturer.
Grind only on the face or outer circumference of the
grinding wheel unless it is specifically designed for side
grinding.
Always stand aside when starting a grinder, especially
with a newly mounted wheel.
Use light pressure when starting the grinding, especially
with a cold wheel - too much pressure on a cold wheel
may cause failure.
Don’t wear loose clothing when grinding.
Do not use grinders in the vicinity of flammable
materials.
Pneumatic Tools
Pneumatic tools are powered by compressed air
and include chippers, drills, hammers, and sanders.
Pneumatic tools must be checked to see that the
tools are fastened securely to the air hose to
prevent them from becoming disconnected.
A short wire or positive locking device attaching
the air hose to the tool must also be used and will
serve as an added safeguard.
A safety clip or retainer must be installed to
prevent attachments such as chisels on a chipping
hammer from being ejected during tool operation.
Screens must also be set up to protect nearby
workers from being struck by flying fragments
around chippers, riveting guns, staplers, or air drills.
Compressed air guns should never be pointed
toward anyone.
Workers should never “dead-end” them against
themselves or anyone else.
A chip guard must be used when compressed air is
used for cleaning.
Use of heavy jackhammers can cause fatigue and
strains.
Heavy rubber grips reduce these effects by
providing a secure handhold.
Noise is another hazard associated with pneumatic
SAFETY IN CRANE
OPERATIONS
 Types of Cranes
Mobile
Hydraulic
Overhead
Gantry
Tower

36
OSHA identified the major causes of crane accidents to
include:
1.boom or crane contact with energized power lines
(nearly 45% of the cases),
2.under the hook lifting device,
3.overturned cranes,
4.dropped loads,
5.boom collapse,
6.crushing by the counter weight,
7.outrigger use,
8.falls, and
9.rigging failures
Cranes not maintained properly, inspected regularly to
Crane Hazards
Improper load rating o Working too close to
Excessive speeds power lines
No hand signals o Improper exhaust
Inadequate inspection system
and maintenance o Shattered windows
Unguarded parts o No steps/guardrails
Unguarded swing walkways
radius o No boom angle
indicator
o Not using outriggers
 Rigging Equipment Slings
Types of slings include alloy steel chain, wire rope, metal mesh, natural or synthetic fiber
rope, and synthetic web.

Chain Wire rope Metal mesh Synthetic

41
 Planning Before Start-Up
Level the crane and ensure support surface is firm and
able to support the load
Contact power line owners and determine precautions.
Know the location and voltage of overhead power
lines.
Know the basic crane capacities, limitations, and job
site restrictions, such as the location of power lines,
unstable soil, or high winds.
Make other personnel aware of hoisting activities.
Ensure proper maintenance and inspections.
Determine safe areas to store materials and place
42 machinery.
Only trained, qualified and specifically designated
persons shall operate a crane.
Crane operator shall not engage in any practice
that will divert their attention while operating the
equipment.
Operator must make a complete walk around the
equipment to ensure that people are clear of the
equipment, and that all equipment is in a safe
condition.
Barricades, warning signs or other methods must
be used to prevent entry into a lift area or turn
radius of the crane.
All controls must be tested by the operator prior to
operating the equipment.
Any malfunctions must be corrected or repaired
before operating the crane.
Operators will respond to signals only from a
trained signal person.
When there is any doubt as to the safety of rigging
and hoisting activity, the operator has the authority
and responsibility to refuse to handle loads.
The operator is responsible to secure any unattended
hoisting equipment.
At no time shall persons work under a suspended load
and suspended loads shall not be left unattended
without proper safeguards.
All hoisting and rigging equipment and procedures
shall conform to applicable State standards and
requirements.
Preventive measures
Install a grab rail round the perimeter of all surfaces
on which personnel may have to stand
Do not use a crane to hoist workers on a suspended
platform
Use adequate fall restraining equipment when
working on heights.
Inspect ladders before climbing. Never climb on a
shaky ladder or a ladder with broken or slippery
rungs
Wear shoes with slip free soles
All persons in the vicinity of cranes in
construction work must wear hard hats, safety
shoes and other PPE as appropriate to minimize
the effect of blows by falling or moving objects
Allow adequate clearance between moving or
rotating elements of the crane and fixed structures
to prevent crushing or entrapment
Check electrical equipment for safety before use.
Call a qualified electricity technician for testing
and repair of faulty or suspect equipment
Learn and use safe lifting and moving techniques
for heavy or awkward loads
Wear adequate clothing and head-gear for skin and
head protection in adverse weather
 Standard Hand Signals For Controlling Cranes

LOWER. With arm extended downward,

forefinger pointing down, move hand in small
horizontal circle.
HOIST. With forearm vertical, forefinger
pointing up, move hand in small horizontal
circle
TROLLEY TRAVEL. Palm up, fingers closed,
thumb pointing in direction of motion, jerk hand
horizontally.

STOP. Arm extended, palm down, hold

position rigidly.
EMERGENCY STOP. Arm extended, palm
down, move hand rapidly right and left.

MOVE SLOWLY. Use one hand to give any motion

signal and place other hand motionless in front of
hand giving the motion signal.