Ergonomics in Welding

What You Will Learn:

 How to identify Work-Related Musculoskeletal
Disorders (WMSD’s) in welding jobs

 Propose solutions for hazardous exposures

 Find further information about ergonomics in

welding operations
 Common Hazards

Common hazards found in welding are:

Inhaling metals fumes
Eye exposure to welding arc light
Foreign objects in eyes
Burns
Noise
 WMSD Hazards
Welding also includes musculoskeletal disorder
(WMSD) hazards such as:
Awkward body postures
Lifting heavy equipment or materials
Static postures for prolonged periods
Awkward postures of the wrist
 WA State-funded compensable
claims 1994-2004
Welders, Cutters, Solderers

By Nature of Injury
Other
13%

Sprains account for Neural

5%
Sprains
32%

more than 1/3 of the Ill-Def

compensable claims Symptoms

9%

among welders in the

State of Washington. Hearing loss
11%
Contussion/
Fracture/ Cut/

Some of those could Dislocation Scratches

14% 16%

be caused by
hazardous WMSD
exposures.
 WA State-funded compensable
claims 1994-2004
Welders, Cutters, Solderers
By Body Part
Other Back/Neck/
15%
The back, neck and
Shoulder
28%

shoulder together with Ears

the arm and hand 11%

regions make up more

than one half of the
injuries among welders Foot/

in Washington State. Leg

20%
Hand / Arm
26%

Preventive efforts
Welding is a strenuous occupation involving
should therefore focus work in awkward postures and handling
on those body parts heavy equipment, usually with a high degree
of sustained stress to arm and shoulders.
among welders at your
workplace.
 Consequences of a poor
working environment

 Absences due to injury or illness and

the transfer of welders to other tasks

 Overtime for replacement workers.

Welders are skilled employees

 High employee turnover

 Increased training and supervisory

time

 Reduced productivity and quality

 WMDS hazards most
common in welding
OFTEN, MORE THAN 1 RISK FACTOR IS PRESENT

 Rigorous manual precision

requirements
– High degree of uniformity

 Awkward and static postures

– Difficult work position

 Heavy lifting, difficult material handling

– Heavy objects, heavy welding equipment

 Repetition
– High work intensity
 Hazard Elements

Duration (how long?)

Frequency (how often?)

Intensity (how hard?)

 Common postures
adopted in welding

Working in Working at
front ground level,
precision work

Working at Working at
ground ground level,
level confined space

Working Working above

above the shoulders,
shoulders confined space
 Awkward Postures

Severe torso postures

Awkward flexion in welding

Torso twisting

Kneeling, squatting

Bent wrists

Neck flexion/extension

Shoulder flexion/abduction (separation)

 The goal of a healthy work
environment

To simplify the welding tasks for the welder

and reduce the physical load during the work

Automate physically demanding or repetitive jobs

Expand the work content of welders (provide

flexibility between jobs)
– (Multi-skilled workers who are able to perform
different tasks within a group)
 The Real World

 Often cost, ease of maintenance, space

considerations drive the design of the
workplace
 When hazards can’t be engineered out, using
best practices is a good alternative
 Examples of good design: providing
opportunities for work station adjustments,
providing different types of tools, using good
planning to eliminate unnecessary work
Ergonomic Solutions for Welding
 Heavy Lifting

Use:
• Manipulators
• Lighter weight
welding equipment
• Lighter weight cables
with low stiffness
• Cable supporting
balancers
• Overhead hoists
• Lifting and turning
tables
 Awkward Postures

• Position work between

waist and shoulder
when possible
• Provide lifting tables
• Use motorized
positioning devices
• Use welding guns with
swivels and designed
for use in both hands
• Try work stools
 Team Lifting
BEFORE AFTER

Team lifting helps

reduce heavy,
awkward lifting of
equipment and
materials.

From: SIMA San Diego Ergonomics Program

 Tables
BEFORE AFTER

This picture shows Because the work is

the worker with on a table, the
considerable bending worker doesn’t have
over at the waist to bend over as far

From: Shipyard Ergonomics, 2003

 Pre-Assembly

Pre-assembly and
material handling
equipment helps reduce
unnecessary lifting or
any other kind of
manual material
handling
 Ergonomic improvements

This rotational clamp

for pipe helps reduce
awkward postures for
the neck, shoulders
and arms.
 Ergonomic improvements

Use wheeled tables for

welding work and to
transport stock and
jobs.
This reduces lifting
and carrying of heavy
materials.
 Ergonomic improvements

Welding leads on
pulleys help reduce
heavy and awkward
lifting, and minimize
static postures.
 Ergonomic improvements

Robotic automation is a
feasible solution to
highly repetitive motion
with the arms and
hands. May also reduce
the exposure to fumes.
Possible Consequences
Not
Not implementing
implementing
some
some oror all
all these
these
ergonomics
ergonomics guidelines
guidelines
may
may result
result in
in the
the
following…
following…
 Work-related musculoskeletal
disorders
They are cumulative (occur over
time and not a result of a single incident):

•Occur when the physical

demands of work cause
wear and tear on the body.

•Involve soft tissues such

as muscles, tendons,
ligaments, joints, nerves,
blood vessels.
 Work-related
musculoskeletal disorders
They are not acute injuries such as:

•Broken bones
•Cuts
•Slips
•Falls
•Trips
•Motor vehicle accidents
•Being struck by or
caught with objects
 Common disorders among
welders
 Back
Back injuries
injuries
 Shoulder
Shoulder pain/loss
pain/loss of
of range
range of
of motion
motion
 Tendinitis/Bursitis
Tendinitis/Bursitis
 Reduced
Reduced muscle
muscle strength
strength
 Carpal
Carpal tunnel
tunnel syndrome
syndrome
 White
White finger
finger
 Knee
Knee joint
joint diseases
diseases
 The Ergonomics Cycle

ManagementEmployee
Support Involvement

The ergonomics cycle Evaluate Problem

progress Identification
shows an organized
way to start your
ergonomics effort. Training
Solution
Implementation
Address
Injuries
 Credits
The technical contents of this
slideshow are based upon the
presentation developed by
Ninica Howard, MS, CPE,
SHARP
Safety & Health Assessment &
Research for Prevention

research ergonomist with the

SHARP program at the
Washington state Dept. of Labor
and Industries.
 More resources

NIOSH’s Ergonomic Interventions in the Building, Repair, and Dismantling of

Ships

SHARP Program

Easy Ergonomics. A practical approach for improving the workplace OR OSHA & CAL
OSHA Services. www.cbs.state.or.us/osha/pdf/pubs/3347.pdf

On WMSD hazardous exposures visit the DOSH webpage at:

www.lni.wa.gov/Safety/Topics/Ergonomics

Example Template of an accident prevention program :

www.lni.wa.gov/Safety/Basics/Programs/Accident

Ideas to reduce hazardous exposures can be found at the Ergonomics Ideas Bank

You may also write us at:

ergonomics@LNI.WA.GOV
Thank you
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