Chapter 2 Welding Safety
Objectives After completing this chapter, you will be able to: Explain how to work safely Identify each degree of burn and describe how to provide first aid List the types of protective clothing a welder should wear Explain the importance of proper ventilation and respiratory protection
Objectives (cont d.) Describe how to safely lift, climb, and handle materials Demonstrate electrical safety
Welding fabrication Introduction Very large and diverse industry Light welding fabrication Has a number of potential safety hazards Safety is your own responsibility Accident consequences Injury Local, state, or national investigations
Classifications First-degree burns Burns Skin surface is reddish, tender, and painful Do not involve broken skin Immediate treatment: cold water or compress Second-degree burns Skin is severely damaged Result in blisters and possibly breaks Immediate treatment: cold water or compress
FIGURE 2-1 First-degree burn only the skin surface (epidermis) is affected. Cengage Learning 2012 FIGURE 2-2 Second-degree burn the epidermal layer is damaged, forming blisters or shallow breaks. Cengage Learning 2012
Burns (cont d.) Third-degree burns Skin surface appears white or charred Immediate treatment: cold cloth or cool water on burns of the face, hands, or feet and cover Burns caused by light Types of light: ultraviolet, infrared, and visible Ultraviolet light waves: most dangerous
FIGURE 2-3 Third-degree burn the epidermis, dermis, and the subcutaneous layers of tissue are destroyed. Cengage Learning 2012 FIGURE 2-4 Portable welding curtains. Frommelt Safety Products
Eye and Ear Protection Face and eye protection Safety glasses with side shields or goggles Face shield Flash glasses Welding helmets Ear protection Earmuffs Earplugs
Respiratory Protection Equipment should be certified by NIOSH Air-purifying respirators Atmosphere-supplying respirators Demand respirators Positive pressure respirators Powered air-purifying respirators Self-contained breathing apparatuses Supplied-air respirators Filtering facepiece
FIGURE 2-14 Typical respirator for contaminated environments. The filters can be selected for specific types of contaminant. MSA
Ventilation Actual welding area Should be outside or well-ventilated Natural ventilation is the best Forced ventilation may be required Forced ventilation Required in small shops or shops with a large number of welders May be general or localized Using fixed or flexible exhaust pickups
Material Specification Data Sheet (MSDS) Give detailed information about hazards resulting from product use Provided to anyone using the products or working in the area where they are in use Often posted on a bulletin board Right-to-know laws Require specific training of employees who handle or work in areas with hazardous materials
Waste Material Disposal Welding shops generate waste materials Mostly scrap metal All scrap metal can be easily recycled Good for the environment Source of revenue Hazardous waste disposal Consult local, state, and federal regulations
Ladder Safety Falls: major cause of injury and death Improper ladder use is often a factor Types of ladders Stepladders, straight ladders, and extension-type ladders Ladder inspection Inspect for wear and damage with each use
Ladder Safety (cont d.) Rules for ladder use Follow all recommended practices Do not exceed maximum weight limit Surface should be level and solid Never use in a wet or muddy area Tie ladder securely in place Climb and descend cautiously Don t carry tools Never use a ladder around electrical wires Never use a ladder too short for the job Wear well-fitted shoes
Electric shock Electrical Safety Can cause injuries and even death Proper precautions must be taken Electrical safety systems Standard portable tool safety systems External grounding or double insulation FIGURE 2-21 Typical portable power tool nameplate. Cengage Learning 2012
Voltage Warnings Voltage supplied Should be same as specified on tool nameplate Extension cords Conductors must be large enough to prevent an excessive drop in voltage Safety rules for portable electric tools Observe safety precautions
General Work Clothing Should minimize burn chances Wool is the best choice All-cotton is a good second choice Guidelines Shirts: long-sleeved, collared, long enough to tuck in, and flapped pockets Pants: cover top of boots and without cuffs Boots: high tops and steel toes Caps: thick
Special Protective Clothing Includes: Hand protection: all-leather, gauntlet-type gloves Body protection: full leather jackets and capes Waist and lap protection: bib or full aprons Arm protection: full- or half-sleeves Leg and foot protection: leather pants or leather aprons with leggings
Handling and Storing Cylinders Cylinders with flammable materials: stored separately Securing gas cylinders Chain or other device must be used Storage areas Considerations: location and temperature Cylinders with valve protection caps Cap is in place unless the cylinder is in use
Handling and Storing Cylinders (cont d.) General precautions FIGURE 2-31 Move a leaking fuel gas cylinder out of the building or any work area. The pressure should slowly be released after a warning of the danger is posted. Cengage Learning 2012
Fire Protection Fire: constant danger to the welder Fire watch Provided by anyone who knows how to sound the alarm and use a fire extinguisher Fire extinguishers Type A, B, C, and D Should be located near materials Work by breaking the fire triangle of heat, fuel, and oxygen
Equipment Maintenance Routine schedule of maintenance Aids in detecting potential problems Hoses Examples: leaking coolant, loose wires, poor grounds, frayed insulation, or split hoses Must be used only for the gas or liquid for which they were designed
Work Area Should be kept picked up and swept clean FIGURE 2-42 An easy-to-build electrode caddy can be used to hold both electrodes and stubs. Larry Jeffus
Uses Hand Tools Assembly and disassembly of parts Routine equipment maintenance Types Adjustable wrench, hammer, chisels, etc. Hand tool safety Treat properly and do not abuse Hammer safety Follow precautions
Power Tools Must be properly grounded Prevents accidental electrical shock Types Grinders and grinding stones Drills FIGURE 2-48 Always check to be sure that the grinding stone and the grinder are compatible before installing a stone. Larry Jeffus
Metal Cutting Machines Many types Examples: shears, punches, cut-off machines, and band saws Shears and punches Frequently used in fabrication of metal for welding FIGURE 2-52 Power shear. Cengage Learning 2012
Material Handling Proper lifting, moving, and handling of large, heavy-welded assemblies Important to worker and weldment safety Follow specific precautions for: Lifting Hoists or cranes Hauling
Summary Safety in welding fabrication Utmost importance When done correctly, welding and fabrication are safe Read and follow all manufacturer literature Perform maintenance and servicing Perform safety checks Keep equipment in good working order