Common Risks Associated with Welding Process

As a mechanical engineer you are well aware that there are many types of welding processes, having different risks associated with them.

On this page we shall mention the risks associated with electric arc welding, which is very common in the industries.

Welding is safe profession if necessary protective measures are taken to safeguard the welder from potential hazards.

If necessary health and safety control measures are not taken following dangers are there for a welder:

Electric Shock Risk During Welding

Remember that a workplace situation can be electrically hazardous if you are working in damp atmosphere/locations, your clothing is wet, you are working on metallic/conducive platforms/surfaces i.e. aluminium scaffolds, gratings and floors.

Similarly if you are working in cramped positions i.e. laying, sitting or kneeling the risk of your contact with the welding work piece increases.

In order to keep yourself safe try to protect your body from touching the welding metal and always try to use a rubber mat or wooden board for standing or lying during welding works.

Never ever try to rest your arms, or other body parts on the work piece i.e. the metal being welded.

Always keep your welding machine healthy and if you observe any problem inform your supervisor and don’t use until it is checked and cleared by competent person.

Use mandatory PPE (personal protective equipment) to protect yourself from any hazard involved.

Fire and Explosion Welding Risk

The hazard of fire and explosion is always there during the welding process if a flammable material is present near the welding area.

Therefor the welders must ensure that flammable substances that could ignite or explode are not present nearby.

In order to safe guard from the fire risk, normally the hot work permit is mandatory from safety supervisors.

This process ensures that the area has been checked and is clear for welding without the hazard of fire.

Additionally fire extinguishers are provided in the work environment and welder are trained to use the same.

If you need to work in the area where flammable materials can not be avoided you must use fire blankets to protect the substances from welding sparks.

Similarly if flammable material is present within the 35 feet from welding area a watcher must be deployed to monitor the movement of sparks and to respond in case of fire.

Risk of Toxic Welding Gases and Fumes

Welding fumes and gases has been reported dangerous if overexposed.

The most common welding fumes are chromium, iron, manganese and nickel etc. contributed by both electrodes and base metals.

Welders can suffer from asthma and lung cancer if overexposed to chromium and nickel.

Similarly overexposure to manganese can cause malfunction of central nervous system.

To avoid these harmful effects always follow the safety instructions given with the welding electrodes/accessories.

A material safety data sheet is very useful for understanding the hazardous behavior of the material you are using.

In order to keep yourself healthy always try to keep your breathing away from welding fumes and use proper ventilation at the welding point.

If adequate ventilation is not possible then you must use approved respirators.

There are always permissible exposure limits defined by regulatory authorities therefore yo must check the laws and limits applicable in your locality, in USA OSHA has defined permissible exposure limit.

These values are available as part of MSDS of the chemicals and any dangerous materials or hazardous substances.

Eye Injury during Welding Process

The welding arc produces the radiations i.e. IR (infrared)  and UV (ultra violet) that are harmful for the eyes.

IR can cause your retinal burning since it is in the form of heat.

UV can cause eye burn also known as welder’s flash.

Therefore welders must wear a recommended welding helmet with good quality glasses.

Summary:

These are few common risks that are associated with the welding process and can be avoided by taking necessary preventive measures and using proper PPE i.e. helmet, goggles, gloves, ventilators etc. Finally it is good practice to always implement the permit to work system for any kind of welding job.