Avoid these welding and cutting hazards
Welding and cutting processes have been around for thousands of years. Since their discovery, little has changed about their purpose. Workers in construction continue using these hot work activities to join metals together or to cut them apart.
There are three main types of hot work activities that occur on jobsites. These are:
- Oxygen-fuel gas welding and cutting,
- Arc welding and cutting, and
- Resistance welding.
The most common type, though, is oxygen-fuel gas welding and cutting. During this type of welding, workers heat a steel welding rod until it pools and becomes molten metal. Next, the welder directs the molten metal into the joint. As it cools, the metal parts join, forming one part.
During oxygen-fuel gas cutting, metal is heated and forms molten metal. Then, a stream of oxygen is directed at the molten metal, creating a by-product called slag. Finally, an oxygen jet stream blows slag away from the cut area, creating a cut line.
Three primary hazards with oxygen-fuel gas welding and cutting activities are:
- Health
- Physical
- Fires
Although welding and cutting hot work isn’t limited to just these hazards above, they’re the most common ones that workers encounter. So, at a minimum, address these hazards before oxygen-fuel gas welding and cutting occurs.
Health
Health hazards from welding include:
- Air contaminants from welding
- Burns
- Flash Burn
If engineering and safety controls aren’t effective in eliminating workers’ exposure to health hazards, use personal protective equipment (PPE) to protect workers. For example, control welding fumes with mechanical ventilation. However, when ventilation isn’t adequate, consider using respiratory protection devices to protect workers from harmful fumes.
It’s difficult to prevent every spark or slag from becoming a line-of-fire hazard. Instead, minimize exposure to workers by using specific safety controls. However, PPE will most likely be needed to prevent burns from occurring. PPE includes a welding jacket, sleeves, gloves, and a hood.
Flash burns are very harmful and painful. This type of burn occurs when workers have exposure to ultraviolet and infrared light at the torch head during welding or cutting activities. Workers must use welding goggles or hoods with proper lens shading to avoid getting flash burns.
Physical
Tripping over welding hoses is a common physical hazard for workers. Route hoses away from walking-working surfaces where they could be a tripping hazard to workers. Set up tree stands to help elevate hoses off the ground. Tree stands are portable, and workers can build them onsite.
Injuries often occur while workers swivel welding-gas cylinders on their bottom edges. Therefore, use proper care while manually moving cylinders. If available, use mechanical means to transport cylinders. Transport them using a special carrier or manufactured-lifting cap.
Fires
Fires and explosions can occur from the ignition of welding and cutting gasses and also from improper storage. If dust and dirt accumulate in the regulator value, it can ignite and cause an explosion. To prevent this, open the regulator and close it quickly to remove dust or dirt and prevent them from entering the regulator. Doing this is known as “cracking.”
Separate oxygen cylinders away from fuel cylinders and combustible materials by 20 feet. If this isn’t possible, OSHA allows employers to use barriers instead. Barriers must be at least five feet high with a ½ hour fire-resistance rating.
Key to remember: While developing a safety plan for welding activities, address health, physical, and fire-related safety hazards. Of course, these aren’t the only safety hazards encountered while welding; they’re the most common ones, though.
