Welding Risks

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Welding Risks
Course presented by:
ALI-PACHA MANCEFHSE Manager and Expert
HSE Consultant.
Occupational Safety & Health Bureau Algeria

0550 463 463 021 38 75 46

boshalgerie@[Link]
Website: [Link]
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At the end of this presentation, the speakers will know:

Identify the dangers related to the activity of

welding/cutting.
and to know the preventive measures to put in place
work to remedy the consequences that may occur
a result.
 SUMMARY
Definition.
The different welding techniques.
Ø Electric welding (Welding machine)
Ø Oxy-gas welding (with a torch)
Welding risks.
Means of protection.
 DEFINITION
Welding is the assembly of metal pieces.
or plastic by fusion with or without added metal.
 Welding Procedures
Welding can be divided into two categories based on
the heat production necessary for fusion of the
metals
Oxy-gas welding (with a torch)
Heat produced by the combustion of combustible gas (such as
butane, propane, acetylene,...) and a combustion gas
(oxygen): It is the welding with a torch.
It is composed of two gas bottles (01 Oxygen + 01
Combustible gas + pressure regulators +
pressure relief valves + flexible hoses + check valves
Return a blowtorch.
 Electric welding (Welding machine)
Heat generated by an electric arc: the welding machine.
§ with flux-cored electrode (manual welding)
§ with refractory electrode wire (non-fusible), under
protective atmosphere, with or without filler metal:
TIG process (tungsten inert gas)
§ with a fusible electrode wire, insulated or not, under
protective atmosphere
full profile: MIG process (metal inert gas); MAG process
(metal active gas)
cored wire: cored wire under gas; cored wire without gas
§ with fused electrode wire, insulated, without atmosphere of
protection
 The milkman at welding
It is called the crust that forms on the bath of
welding. It protects this bath from the air's oxygen and isolates it
thermally.
In stick welding, it is the coating that will,
in fondant, create the milkman.
The electrodes are then distinguished based on their coating:
basic coating (rich in lime), whose implementation is
difficult, but which ensure excellent resistance
mécanique.
acid coating (rich in silica), for easier use.
 TIG welding
TIG welding is a process
arc welding with a
non-fusible electrode.
TIG is an acronym for Tungsten
Inert Gas Tungsten Design
the electrode and Inert Gas
(Inert gas) refers to the type of
Inert gas used.
 MIG - MAG Welding
MIG-MAG welding according to ISO standards, or GMAW according to
the American standards, is a semi- welding process
automatic.
The fusion of metals is obtained by the heat energy released.
by an electric arc that bursts in a protective atmosphere
between a fuse electrode wire and the parts to be assembled.
The terms MIG and MAG stand for Metal Inert Gas respectively.
active gas metal. The difference between the two processes lies in
the composition of the gas. The MIG process uses an inert gas that does not
does not react with molten metal (argon or argon + helium),
unlike the MAG process (mix of argon with carbon dioxide)
of carbon and hydrogen in varying proportions depending on the
soldering metals). The gas is continuously injected onto the arc to isolate
completely the molten metal of the ambient air.
 WELDING/CUTTING RISKS
Welding and cutting of materials are among the activities that
most often take place on construction sites, that this
whether for the execution of metal framework work,
piping, boilermaking, industrial mechanics, etc.
Although performed very frequently, welding activities
and cutting always carries its share of risks:
specific risks associated with each welding and cutting process;
risks associated with mechanical work: Grinding, Brushing, Bending,
Découpe
burn risks;
risks attributable to radiation;
Risks related to foreign bodies in the eye;
risks related to the emission of smoke and gases
risks associated with specific tasks such as welding and the
cutting inside enclosed spaces, at height, outdoors.
If attention is not paid to these risks, it can result in
accidents or diseases whose consequences are sometimes very
graves.
RISKS RELATED TO DIFFERENT PROCESSES
 Welding Fumes
During welding, fumes are produced, the importance of which varies depending on the

process used, are released.

This smoke production is very important during welding.
to the electrode arc, from shielded metal arc welding to plasma arc welding and during
M.A.G processes and stuffed sons.
The chemical composition of welding fumes and gases depends
of the welded material, the process used, and the electrodes used.
These fumes have a complex composition, including two
distinct fractions:
a gaseous phase and a particulate phase.
Prolonged exposure to welding fumes and gases in
high concentrations can cause:
siderosis (iron oxide)
the fever of founders (zinc oxide, magnesium oxide, copper,
aluminum
nervous system disorders (manganese)
an irritation of the respiratory system
an irritation of the eyes, nose, and throat
chest pains
a kidney disease (cadmium oxide, fluorides)
cancer (cadmium oxide, nickel, chromium (VI))
• the accumulation of fluid in the lungs (cadmium oxide,
fluorides, ozone, nitrogen oxide
an hemorrhage (ozone)
• dermatitis or eczema (nickel, chromium (VI))
bone and joint disorders (fluorides)
headaches and nausea
 RISKS RELATED TO NOISE
Exposure to noise in the workplace is a phenomenon
that it is important to take into account, because
exposure to excessive noise levels can lead to
a gradual loss of hearing that may lead to deafness.
Welding/Cutting processes Noise levels generated (dBA)

Tungsten electrode welding 50 to 60

Welding with flux-cored wire 50 à 86
Oxy-fuel welding less than 70
Shielded metal arc welding 62 to 82
Gas shielded welding 70 to 82
Arc cutting with carbon electrode and air jet 96 to 116
 FOREIGN BODIES IN THE EYE
During the preparation of the parts to be welded
(brushing, grinding), and from the picking of the slag,
notably during arc welding with the electrode
coated, sharp and hot shards can
cause eye injuries including the
consequences, with the formation of scars
translate, in the long run, by a decrease more or
less important of visual acuity.
 Heat-related risks
Les symptômes les plus courants de la réaction du corps à la chaleur
include notably:
• sweating due to a high internal temperature
• a high heart rate
• a urinary elimination frequency lower than normal
• a urine of low volume and dark color
• irritability
• a lack of coordination
• a lack of discernment
Excessive and prolonged exposure to a work environment
High temperature can cause diseases, including:
• hot flashes
• heat cramp
• heat exhaustion
• heat syncope (loss of consciousness)
 ELECTRICAL RISKS
Effects of electric current on the human body

Effect Intensity of c. c. (mA)

Dead 120+

Ventricular fibrillation 50 to 120

Diaphragmatic paralysis 20 to 50

Muscle cramp preventing the person from relaxing their 16 to 20

embrace

Involuntary reactions 4 to 9

Perception 1 to 4

When a person touches a live electrical conductor, the current can

traverse its body to complete the circuit to the ground, and the organism undergoes a shock called
electric.
The more contact with the earth is important, the higher the risk of electric shock.
It is important to avoid working with your feet in water or on a wet surface, your hands
wet, or skin and clothes wet from sweat.
Even a weak electric shock can surprise you, make you lose your footing, and cause
a fall, which can be serious if the welder is working at height.
 RISKS OF ASPHYXIA
For TIG and MIG welding, there is a risk
d’asphyxie provoqué par l’usage de gaz inertes lorsque
these are implemented in confined spaces.
 THE RISKS OF OXYACETYLENE WELDING
The splashes and burns if the melting bath is overheated or if the nozzle
come into contact with molten metal (thus wearing cotton clothing
fire-resistant, mandatory covering
ENT irritations from fumes emitted by paint strippers,
UV is of little importance, so glasses with protection index 4 to 7 are sufficient.
Fire or explosion during use or storage.

RISKS PRECAUTIONS
Gas bottles Main
High pressure Keep bottles and containers away from
Leak, asphyxiation sources of heat
or bursting or explosion of the container
Adiabatic compression Slowly open the bottle tap
rapid opening = brutal compression of O² => T Control and maintain the regulators
=500°c
Violent inflammation
Inflammationcombination of the 3 => read the pictograms
Oxidizer (O²) No flame in the presence of O²
Combustible (acetylene) Do not grease the fittings
Energy source (spark, high temperature) Degrease the equipment
STANDARDIZED COLORS OF GAS CYLINDERS
Oxygène ........................................ O2Blanc
Acétylène ....................................... C2 H2Marron clair
Butane ........................................... C4 H10Bleu
Propane ......................................... C3 H8 Blue
CO2 Carbonic anhydride ........... Grey ogive
Argon ............................................. Dark green ogive
New European Standard
Argon + CO2 mixture.................... Light green ogive
(New European Standard)
Nitrogen. ............................................. Black ogive
COLOR OF FLEXIBLE TUBES
O2 = blue (oxidizer),
Acetylene H2 = red (flammable)
propane = rouge
Means of protection
 RESPIRATORY PROTECTION
Welding fumes are harmful and must therefore be captured at their source.
source of broadcasting by prioritizing, according to the methods implemented and the
configuration of the rooms, the following ventilation devices:
Welding cabin (the size of the piece to be welded must not exceed that
from the cabin)
Fixed aspiration at source (for fixed positions and small parts)
Mobile aspiration at the source (flexible suction hose attached to a support arm
adjustable according to the location of the welding cord)
Aspiration associated with the tool or tooling (suction torch whose
the end is equipped with a smoke suction nozzle suitable for
MIG and MAG systems
A breathing apparatus should be used when the places are not
sufficiently ventilated to remove welding fumes, or when there is
risk of oxygen depletion in the air.
In addition, to minimize exposure to welding fumes and gases, it
It is important to remove any coating product from a part before
proceed with welding or cutting to prevent the release of products
harmful.
 Eye protection
The welder's eyes can be damaged by the
bright light and the UV radiation generated by the arc
electric as well as by slag projections in
fusion during the execution of welding or
hardened slag particles during operations of
stitching and sanding for this you need:
• Protecting your eyes from the effects of the arc
electric while wearing a welding helmet equipped
of an appropriate filter for the work to be carried out.
• In the absence of wearing a welder's helmet, wear some
safety glasses with side shields during
operations of slag picking and sanding of
welds.
In welding, cutting, and gas brazing, the intensity of
the light produced is significantly lower than that
of the electric arc, and the welder can wear, for these
operations, glasses equipped with a tinted filter
less dark instead of the welding helmet.
BODY PROTECTION
Wearing heavy work clothes
and tightly woven to protect the skin
against UV rays.
Buttoning up his shirt completely
to protect the throat and neck.
Wearing long pants and a
long-sleeved shirt.
Wearing a fabric cap for
protect the scalp against the
UV rays
Wearing a balaclava for protection
the back of the head and the nape.
Wear high resistance gloves
temperatures.
The fabric clothes must be
heat, flame resistant and
to the sparks. Wear clothes
clean and free of substances
flammable fuels
fire on contact with a spark.
 ELECTRICAL PROTECTION
Regularly check the condition of the insulating sleeves. It is necessary
not hesitate to repair a cable whose insulating sheath is
deteriorated.
 Fire and Explosion Prevention
Welding work presents significant fire risks due to
very high temperatures reached during these operations as well as
inevitable projections of sparks and hot metal debris.
the measures applicable to prevent the risks of fire and explosions.
Never perform welding and cutting work nearby
combustible materials or in places containing dust, gases
or flammable or explosive vapors, unless precautions are taken
measures should be taken to prevent fire or explosions.
Protect combustible material floors using tarps
fireproof or plywood panels.
Never perform cutting, welding, or any work with an open flame on
a container, a tank, a pipe or any other vessel that can
to contain a flammable or explosive substance unless one has
collected air samples indicating that the work can be done without
danger (explosimeter)
Ensure that a portable ABC type fire extinguisher is always placed at
proximity to the site where the work is being carried out.
Once the work is completed, carry out an inspection of the work area and
the surroundings by paying particular attention to the places where there are
flammable or combustible materials.
 STORAGE OF GAS CYLINDERS
To prevent gas buildup in the air, store the
compressed gas cylinders in a dry, well-ventilated place,
consisting of a fireproof platform (e.g., concrete) and,
preference, outside. If storage is done indoors,
make sure that the room is sufficiently ventilated.
Never store an oxygen bottle less than 6 m away
from a flammable gas cylinder (e.g., acetylene) or a
combustible material (e.g.: oil, grease), unless it
be separated by a partition made of non-combustible material,
with a minimum height of 1.5 m and a fire resistance of
minus 30 minutes.
Do not store bottles near the stairs, exits and
elevators.
Remove the safety cap from the bottles and attach them.
vertically.
Protect the bottles against drops and handling.
abrupt and excessive shocks.
Mark the empty bottles and separate them from the full bottles.
Handling of compressed gas cylinders
Before moving a bottle, always
make sure that the valve is closed.
Remove the caps from the bottles
safety and attach them vertically.
Preferably, transport the bottles
of gas mounted on a cart designed for
this end. If the transport of the bottles is
done manually, take care to remove,
au préalable, le manodétenteur et de
put the safety cap on for
protect the faucet.
Use a suitable cart or cage
to hoist the bottles.
Never lift the bottles by their
safety cap or by their collar, nor
by means of metallic cables.
 PHENOMENON OF BACKFLOW OF GAS OR FLAME
Two particular phenomena at risk
to lead to unfortunate consequences may
occur during welding or
cutting with a blowtorch: it is about gas returns
and backfire.
Here are some security measures to
apply to prevent gas returns and the
backfire.
See to keep the equipment always in good condition.
Ensure that the torch is equipped with a valve.
gas backflow and a backflow prevention device
flame at the gas supply point
fuel and at the supply point in
oxygen located at the handle of the torch.
ORGANIZATIONAL PROTECTION
All the mentioned protections complement each other with the implementation
in place of hot work permits.
The SMATECH School
thank you for
your attention.