HAZARDS IN WELDING: Preventions, Protections, and Safety Issues

Welding, like most jobs that require the use of machinery and specialized tools, involve potential occupational hazards which can impact the safety

of workers involved. Since all welding and cutting processes are performed at very high temperatures, burns are the most common hazard that

welders experience. Burns are categorized as first degree, second degree, or third degree depending on their severity.

Anyone working in a welding shop should be careful as everything out there is hot even if it is not glowing. Open flames, electric arcs, molten metal,

sparks, and spatter, which are ready sources of ignition are a part of every welding process. Fire-related damage and injury caused during the process

of welding can be prevented with proper precautions. Performing welding and cutting in designated areas away from combustibles can minimize the

risk of fire. Other than taking care of the work area, it is necessary to make available appropriate fire extinguishing equipment in the floor. Skin burns and

damage to the eye are also likely hazards caused by radiation during welding operations. Use of safety glasses with UV-protective side shields, welding

helmet with the correct filter plate, in addition to the use of adequate body and hand PPE are some ways to minimize the risk.

The fumes and gases produced during welding processes are harmful and can cause nausea, headache, dizziness, dermatitis, chronic or acute systemic

poisoning, metal fume fever, pneumoconiosis, irritation of the respiratory tract, and even cancer. Therefore, all welding professionals in the work area need

to be protected from overexposure to these fumes and gases. Appropriate ventilation system can provide clean air for welding operations as well as

complete protection to welding professionals in the work area.

Electric shock is another potential hazard for welding personnel. If electrical equipment is not used properly and with required precautionary measures,

individuals may be injured seriously or even killed. It is important to correctly install, use, and maintain all electrical equipment as per the manufacturer’s

instructions or safety manuals.

High level of noise caused during cutting operations is yet another welding hazard. Prolonged exposure to such noise can cause hearing impairment. It is

therefore utmost important for operators to use ear protection such as earplugs or earmuffs.

A very important aspect of prevention of welding risks and hazards is associated with handling gases stored in cylinders. Mishandling of these cylinders

may result in leaks or explosions, leading to damage, injury, or death. It is therefore necessary to maintain required precautions in the use and storage of

gas cylinders.

To prevent welding risks and hazards, a welding shop must have signs informing everyone that they are entering an area which requires the use of safety

glasses and PPE. Ear-marked area for welding, cutting, and grinding or specific welding booths can also minimize welding hazards. Maintaining the shop

area properly, keeping it clean, well-ventilated, and as per safety guidelines can go a long way in the prevention of welding hazards.

The use of appropriate Personal Protective Equipment (PPE) in the workplace should never be ignored. The use of PPE can minimize and avert the risk of

most of the hazards associated with a welding job. Welding helmets, safety glasses or goggles, appropriate clothing, welding gloves, leather shoes or boots,

and earplugs or earmuffs designed to suit specific welding requirements are part of the PPE. Additionally, respirators must be used whenever necessary.

Specialized PPE that can cover a welder from head to toe, fire-resistant welding caps, bibs, aprons, shoe spats, etc. are also available as per requirement.

Lastly, it is a priority that all employers and schools must make applicable ‘Safety Data Sheets’ readily available to their employees and train them to read

and understand their contents. These data sheets contain important information about products used in welding operations and the means to protect welders

and others from potential hazards.

(Source: Fundamentals of Welding, American Welding Society, 2019)

American Welding Society’s ‘Safety in Welding’ Course:

The American Welding Society’s ‘Safety in Welding’ is a free course. The purpose of this course is to educate individuals on the fundamental principles of safe

welding practices. The course aims to provide a comprehensive overview of the hazards associated with welding, including exposure to radiation, electrical

shock, fire, and toxic fumes. Participants will learn about the appropriate personal protective equipment (PPE) to wear when welding, as well as safe welding

procedures and techniques. By the end of the course, participants will be equipped with the knowledge and skills necessary to ensure their safety and the

safety of others while performing welding tasks.

Participants have access to the course content 24 hours a day for a period of 30 days from the date of registration. After this 30-day period, participants will

have an additional 10 days to pass the completion exam. The exam can be activated before the end of the 30-day period if the participant has completed all

the modules.

Upon completion of the final course module, participants are prompted to take an exam designed to evaluate their comprehension of the subject matter.

The completion exam consists of 35 multiple-choice questions and must be completed within a 60-minute period. Participants who do not attain the 85%

passing score may attempt to retake the exam a second time. Participants who attain a score of 85% or more on the completion exam earn an AWS

Certificate of Completion and 3 Professional Development Hours (PDHs). The AWS Certificate of Completion can be downloaded and printed directly from

the webpage. Professional Development Hours (PDHs) earned through AWS online courses can be applied towards recertification provided the PDHs are

earned during the certification period.

This course can be taken up by anyone involved in the welding industry or anyone wishing to learn about or refresh knowledge of best safety practices in

welding and cutting. Prior to taking this course, learners should be familiar with basic welding processes and welding terminology. This prerequisite

knowledge can be obtained by –

(i) Taking the AWS Welding Fundamentals I online course and

(ii) Obtaining and reading a copy of AWS A3.0 Standard Terms and Definitions and ANSI Z49.1 Safety in Welding, Cutting, and Allied Processes.

This course teaches students how to identify common safety hazards in welding, cutting, brazing, and soldering; choose proper PPE to avoid common

hazards; and apply best practices to avoid safety hazards.

Course Modules –

• MODULE 1 – Introduction to Welding Safety: The Importance of Safety, Locating Safety Guidelines, and Safety Roles and Responsibilities

• MODULE 2 – Radiation: Hazards and Prevention

• MODULE 3 – Electric Shock

• MODULE 4 – Fires and Burns

• MODULE 5 – Fumes and Gases

• MODULE 6 – Noise Hazards

• MODULE 7 – Controls and PPE

• MODULE 8 – Environmental Hazards, Confined Spaces, and Ventilation Safety

• MODULE 9 – Oxyfuel Welding and Cutting Safety

• MODULE 10 – Arc Welding and Cutting Safety

• MODULE 11 – Resistance Welding, Electron Beam Welding, Brazing and Soldering.

By Dr. Payel Dutta Chowdhury, Marketing and Communications Content Specialist – Asia, Africa & Oceania – for the American Welding Society