Occupational Safety

1. General Welding
Safety Practices
OCCUPATIONAL SAFETY II
11

2. Definition
A method of manufacture or repair involving joining
two pieces of metal or plastic by fusion. Heat is
normally used such as an open flame (i.e. acetylene,
propane or butane), laser light or electric arc, and the
fusion may be autogenous or with the addition of a
similar substance to the weld pool
22

3. Types of Welding Hazards
Radiation exposureRadiation exposure
•Can cause retinal burning and cataractsCan cause retinal burning and cataracts
•Proper lenses with the appropriate shadingProper lenses with the appropriate shading
must always be wornmust always be worn
•UV radiation cannot be sensed by heat orUV radiation cannot be sensed by heat or
brightnessbrightness
33

4. Electric shockElectric shock
•Two kinds of electric shock: primary voltageTwo kinds of electric shock: primary voltage
shock and secondary voltage shockshock and secondary voltage shock
•Primary voltage shock involves 230 or 460Primary voltage shock involves 230 or 460
volts and is caused by touching both the leadvolts and is caused by touching both the lead
inside the welding equipment and theinside the welding equipment and the
welding equipment case or other groundedwelding equipment case or other grounded
metal while the equipment is powered ONmetal while the equipment is powered ON
Types of Welding Hazards
(continued)
44

5. Electric shockElectric shock (continued)(continued)
•Secondary voltage shock involves 60 to 100Secondary voltage shock involves 60 to 100
watts and is caused by touching a part of thewatts and is caused by touching a part of the
electrode circuit and the side of the weldingelectrode circuit and the side of the welding
circuit.circuit.
Types of Welding Hazards
(continued)
55

6. Electric shockElectric shock (continued)(continued)
•Do the following to avoid electric shock:Do the following to avoid electric shock:
➤ Keep dry and wear dry gloves.
➤ Stand or lie on plywood, rubber mats or
other insulation.
➤ Do not rest any part of the body on the
workpiece.
➤ Keep electrodes and electrode holders in
good condition.
➤ Do not touch electrodes or metal parts with
either the skin or wet clothing.
Types of Welding Hazards
(continued)
66

7. Fires and explosionsFires and explosions
•The welding process can produce extreme heat;The welding process can produce extreme heat;
however, fire hazards are not caused by the heat buthowever, fire hazards are not caused by the heat but
by the effect of the heat on the workpiece, such asby the effect of the heat on the workpiece, such as
sparks and molten metal.sparks and molten metal.
Types of Welding Hazards
(continued)
•Keep the work area and all surrounding areas freeKeep the work area and all surrounding areas free
of combustible items.of combustible items.
•Be cautious when working in dusty areas where
sparks and dust particles can easily oxidize without
warning, which can result in a flash fire or an
explosion.
77

8. Fires and explosionsFires and explosions (continued)(continued)
•Do the following to protect from fire and explosions:
➤ Always know where the fire exits and fire
extinguishers are located.
➤ If welding within 35 feet of a combustible
object, utilize a fire watcher, who can watch
for landing sparks.
Types of Welding Hazards
(continued)
88

9. Fumes and gasesFumes and gases
•Fumes contain particles from base metal and baseFumes contain particles from base metal and base
metal coatingmetal coating
Types of Welding Hazards
(continued)
•Effects from fumes are normally temporaryEffects from fumes are normally temporary
•Symptoms caused by short-term exposure to fumesSymptoms caused by short-term exposure to fumes
can include burning eyes, burning skin, dizziness,can include burning eyes, burning skin, dizziness,
nausea, and fever.nausea, and fever.
•Long-term exposure to fumes can cause siderosisLong-term exposure to fumes can cause siderosis
(which are iron deposits in the lungs) and can affect(which are iron deposits in the lungs) and can affect
pulmonary function.pulmonary function.
99

10. Fumes and gasesFumes and gases (continued)(continued)
•Zinc fumes can cause metal fume fever, which is aZinc fumes can cause metal fume fever, which is a
temporary illness similar to the flu.temporary illness similar to the flu.
Types of Welding Hazards
(continued)
•Cadmium fumes can cause symptoms similar toCadmium fumes can cause symptoms similar to
metal fume fever; however, it can be fatal, evenmetal fume fever; however, it can be fatal, even
under brief exposureunder brief exposure
•When shielding gases are released into the air, theyWhen shielding gases are released into the air, they
can cause dizziness, unconsciousness, and evencan cause dizziness, unconsciousness, and even
death if clean oxygen is withheld for a long enoughdeath if clean oxygen is withheld for a long enough
period.period.
1010

11. Fumes and gasesFumes and gases (continued)(continued)
Types of Welding Hazards
(continued)
•UV radiation forms gases when it hits the air, whichUV radiation forms gases when it hits the air, which
can cause headaches, chest pains, eye irritation,can cause headaches, chest pains, eye irritation,
and itchiness in the nose and throat.and itchiness in the nose and throat.
1111

12. Fumes and gasesFumes and gases (continued)(continued)
•Do the following to protect from fume and gas exposure:Do the following to protect from fume and gas exposure:
➤➤ Ensure adequate ventilation in the work area.Ensure adequate ventilation in the work area.
➤➤ Wear appropriate personal protectiveWear appropriate personal protective
equipment,equipment, such as a respirator.such as a respirator.
➤➤ Read material safety data sheets beforeRead material safety data sheets before
beginning work to learn what fumes can bebeginning work to learn what fumes can be potentiallypotentially
released.released.
➤➤ Familiarize yourself with the metals that areFamiliarize yourself with the metals that are
being used to determine if a paint or coating canbeing used to determine if a paint or coating can
cause toxic fumes or gases.cause toxic fumes or gases.
Types of Welding Hazards
(continued)
1212

13. Fumes and gasesFumes and gases (continued)(continued)
•Do the following to protect from fume and gas exposure:Do the following to protect from fume and gas exposure:
➤➤ If symptoms of dizziness, headache, or nauseaIf symptoms of dizziness, headache, or nausea
occur, turn off the welding equipment, notifyoccur, turn off the welding equipment, notify
supervisors and coworkers, and get fresh airsupervisors and coworkers, and get fresh air
immediately.immediately.
Types of Welding Hazards
(continued)
1313

14. Confined spacesConfined spaces
•Examples of confined spaces include a boiler, tank, orExamples of confined spaces include a boiler, tank, or
hold of a ship where all the welding hazards arehold of a ship where all the welding hazards are
amplified, such as insufficient ventilation, fume and gasamplified, such as insufficient ventilation, fume and gas
exposure, and chances of fire or explosion.exposure, and chances of fire or explosion.
Types of Welding Hazards
(continued)
1414

15. Confined spacesConfined spaces (continued)(continued)
Types of Welding Hazards
(continued)
•Do the following to protect yourself when working inDo the following to protect yourself when working in
confined spaces:confined spaces:
➤➤ Make sure your body is insulated from the workpieceMake sure your body is insulated from the workpiece
and ground.and ground.
➤➤ Wear dry gloves.Wear dry gloves.
➤➤ Use only a well-insulated electrode holder.Use only a well-insulated electrode holder.
➤➤ Verify that there is sufficient ventilation.Verify that there is sufficient ventilation.
➤➤ Always make sure there is a trained person outsideAlways make sure there is a trained person outside
the confined space at all times to disconnect power andthe confined space at all times to disconnect power and
pull the welder out if a dangerous situation occurs.pull the welder out if a dangerous situation occurs.
1515

16. Loud noiseLoud noise
•Can cause temporary or permanent hearing lossCan cause temporary or permanent hearing loss
Types of Welding Hazards
(continued)
•Do the following to protect against noise:Do the following to protect against noise:
➤➤ Reduce the sound level when possible.Reduce the sound level when possible.
➤➤ Wear ear muffs or ear plugs.Wear ear muffs or ear plugs.
1616

17. •Follow the rules.Follow the rules.
General Shop Safety Rules
•Stay alert.Stay alert.
•Properly use all tools and other materialsProperly use all tools and other materials
•Respond immediately and appropriately to allRespond immediately and appropriately to all
safety-related incidents.safety-related incidents.
•Wear appropriate clothing.Wear appropriate clothing.
1717

18. Appropriate Clothing and Personal
Protective Equipment
ClothingClothing
•Shirts—Wear heavy, long-sleeved shirts with pocketShirts—Wear heavy, long-sleeved shirts with pocket
flaps; remove pockets or tape themflaps; remove pockets or tape them
shut if they do not have pocket flaps; keep collar andshut if they do not have pocket flaps; keep collar and
sleeves buttoned to keep out sparks.sleeves buttoned to keep out sparks.
1818

19. Appropriate Clothing and Personal
Protective Equipment (continued)
•Pants—Wear pants that have no cuffs and are long
enough to cover the top of your shoes or boots.
•Welding cap—Wear a cap with a flexible bill thatWelding cap—Wear a cap with a flexible bill that
can be slipped around to cover either ear to keepcan be slipped around to cover either ear to keep
sparks and metal splatter out of the ear opening.sparks and metal splatter out of the ear opening.
1919

20. Appropriate Clothing and Personal
Protective Equipment (continued)
•Boots—Wear steel-toed boots made of heavyBoots—Wear steel-toed boots made of heavy
leather with uppers that reach above the ankle.leather with uppers that reach above the ankle.
•Gloves—Wear heavy leather gloves with gauntlets;Gloves—Wear heavy leather gloves with gauntlets;
gauntlets may be short or extend to the shoulder.gauntlets may be short or extend to the shoulder.
2020

21. Appropriate Clothing and Personal
Protective Equipment (continued)
•Jackets and aprons—Wear leather jackets andJackets and aprons—Wear leather jackets and
aprons for additional protection, especially whenaprons for additional protection, especially when
welding in confined areas.welding in confined areas.
2121

22. Eye protectionEye protection
Appropriate Clothing and Personal
Protective Equipment (continued)
•Safety glasses—Wear at all times in the weldingSafety glasses—Wear at all times in the welding
area; include side protection when flying objects arearea; include side protection when flying objects are
possible.possible.
2222

23. Appropriate Clothing and Personal
Protective Equipment (continued)
•Face shield—Wear a face shield, along with safetyFace shield—Wear a face shield, along with safety
glasses, when grinding, chipping, cutting, or shapingglasses, when grinding, chipping, cutting, or shaping
metal with any type of power tool.metal with any type of power tool.
2323

24. Appropriate Clothing and Personal
Protective Equipment (continued)
•If you wear contact lenses, check with your doctorIf you wear contact lenses, check with your doctor
to see if the type of lens you wear requires anyto see if the type of lens you wear requires any
special precautions in the work area.special precautions in the work area.
•If your wear prescription lenses, either wear eyeIf your wear prescription lenses, either wear eye
protection that incorporates that prescription into theprotection that incorporates that prescription into the
lens or appropriate eye protection that can be wornlens or appropriate eye protection that can be worn
over your existing lenses.over your existing lenses.
•Select the appropriate lens shade when wearingSelect the appropriate lens shade when wearing
safety glasses, goggles, or a welding hood.safety glasses, goggles, or a welding hood.
2424

25. Welding hoodsWelding hoods
Appropriate Clothing and Personal
Protective Equipment (continued)
•Stationary filter lens—Contains a fixed lens housingStationary filter lens—Contains a fixed lens housing
with the shaded lens held in by a spring retainerwith the shaded lens held in by a spring retainer
from where a lens can be slipped out and replacedfrom where a lens can be slipped out and replaced
as welding requires.as welding requires.
2525

26. Welding hoodsWelding hoods
Appropriate Clothing and Personal
Protective Equipment (continued)
•Flip-front filter lens—Contains a lens housing with aFlip-front filter lens—Contains a lens housing with a
front side that can be flipped up so that it leaves afront side that can be flipped up so that it leaves a
clear-glass lens that permits the hood to be wornclear-glass lens that permits the hood to be worn
while chipping.while chipping.
2626

27. Welding hoodsWelding hoods
Appropriate Clothing and Personal
Protective Equipment (continued)
•Auto darkening lens—Used in helmets specificallyAuto darkening lens—Used in helmets specifically
designed for auto darkening lenses; contains sensorsdesigned for auto darkening lenses; contains sensors
that automatically change the shade from clear to darkthat automatically change the shade from clear to dark
in a fraction of a second when you start to weld andin a fraction of a second when you start to weld and
gradually changes back to clear when you stopgradually changes back to clear when you stop
welding; can be manually adjusted for a variety ofwelding; can be manually adjusted for a variety of
shades.shades.
2727

28. Hazards Caused by Fumes and
Gases
2828

29. Hazards Caused by Fumes and
Gases (continued)
2929

30. Hazards Caused by Fumes and
Gases (continued)
3030

31. Hazards Caused by Fumes and
Gases (continued)
3131

32. Hazards Caused by Fumes and
Gases (continued)
3232

33. Information Included on a Material
Safety Data Sheet (MSDS)
•Chemical IdentityChemical Identity
•Hazardous IngredientsHazardous Ingredients
•Physical and Chemical CharacteristicsPhysical and Chemical Characteristics
•Fire and Explosion Hazard DataFire and Explosion Hazard Data
•Reactivity DataReactivity Data
•Health Hazard DataHealth Hazard Data
•Precautions for Safe Handling and UsePrecautions for Safe Handling and Use
•Control MeasuresControl Measures
3333

34. Common Safety Signs
3434

35. Common Safety Signs (continued)
3535

36. Fire Extinguisher Ratings
•Class A – Ordinary combustibles like wood,Class A – Ordinary combustibles like wood,
paper and clothpaper and cloth
•Class B – Flammable liquids like grease,Class B – Flammable liquids like grease,
gasoline, paints and oilgasoline, paints and oil
3636

37. Fire Extinguisher Ratings (continued)
•Class C – Energized electrical equipment likeClass C – Energized electrical equipment like
motors, switches, and computersmotors, switches, and computers
•Class D – Combustible metals like titanium,Class D – Combustible metals like titanium,
sodium, and magnesiumsodium, and magnesium
3737

38. Fire Extinguisher Ratings (continued)
•Class K – Oils or fats used with cookingClass K – Oils or fats used with cooking
appliancesappliances
3838

39. First Aid Procedures for Various
Emergency Situations
CutsCuts
•Stop the bleeding by applying gentle,Stop the bleeding by applying gentle,
continuous pressure with a clean cloth orcontinuous pressure with a clean cloth or
bandage.bandage.
•Clean the wound with clear water.Clean the wound with clear water.
•Apply an antibiotic to the wound to keep itApply an antibiotic to the wound to keep it
moist.moist.
•Cover the wound with a bandage to keep itCover the wound with a bandage to keep it
clean and protected.clean and protected.
3939

40. First Aid Procedures for Various
Emergency Situations (continued)
CutsCuts (continued)(continued)
•Change the dressing at least once a day orChange the dressing at least once a day or
when it becomes wet or dirty.when it becomes wet or dirty.
•Get stitches for deep wounds.Get stitches for deep wounds.
•Be alert to signs of infection.Be alert to signs of infection.
•Get a tetanus shot within 48 hours if yourGet a tetanus shot within 48 hours if your
wound is severely dirty, more than five yearswound is severely dirty, more than five years
have passed since your last tetanus shot,have passed since your last tetanus shot,
and it is recommended by your physician.and it is recommended by your physician.
4040

41. First Aid Procedures for Various
Emergency Situations (continued)
BurnsBurns
•Determine the type of burn.Determine the type of burn.
•Apply appropriate treatment.Apply appropriate treatment.
•Use clean, lukewarm water to flush the eyeUse clean, lukewarm water to flush the eye
for at least 20 minutes.for at least 20 minutes.
•Thoroughly wash the hands with soap andThoroughly wash the hands with soap and
water.water.
Chemicals in the eyeChemicals in the eye
4141

42. First Aid Procedures for Various
Emergency Situations (continued)
Chemicals in the eyeChemicals in the eye (continued)(continued)
•Remove contact lenses if they do not fall outRemove contact lenses if they do not fall out
while flushing the eye with water.while flushing the eye with water.
•Seek medical assistance if necessary.Seek medical assistance if necessary.
4242

43. First Aid Procedures for Various
Emergency Situations (continued)
Traumatic shockTraumatic shock
•Identify the symptoms of traumatic shock:Identify the symptoms of traumatic shock:
Early stages➤
Late stages➤
•Lay the victim down.Lay the victim down.
•Elevate the legs slightly.Elevate the legs slightly.
•Cover the body with a blanket to preventCover the body with a blanket to prevent
loss of heat.loss of heat.
4343

44. First Aid Procedures for Various
Emergency Situations (continued)
Electrical accidentElectrical accident
•Do not provide any medical aid until theDo not provide any medical aid until the
electrical current has been shut off.electrical current has been shut off.
•Administer CPR if necessary, and you haveAdminister CPR if necessary, and you have
the proper training.the proper training.
•Treat for traumatic shock and electricalTreat for traumatic shock and electrical
burns.burns.
4444

45. First Aid Procedures for Various
Emergency Situations (continued)
ChokingChoking
•Recognize the signs of choking.Recognize the signs of choking.
•Perform the Heimlich maneuver.Perform the Heimlich maneuver.
4545

46. First Aid Procedures for Various
Emergency Situations (continued)
Head injuryHead injury
•Keep the person still and lying down, withKeep the person still and lying down, with
the head and shoulders slightly elevated.the head and shoulders slightly elevated.
•Do not move the person unless necessary.Do not move the person unless necessary.
•Apply light pressure with a sterile gauze toApply light pressure with a sterile gauze to
stop any bleeding.stop any bleeding.
•If the person stops breathing, perform CPRIf the person stops breathing, perform CPR
if you are properly trained.if you are properly trained.
4646

47. First Aid Procedures for Various
Emergency Situations (continued)
Head injuryHead injury
•Keep the person still and lying down, withKeep the person still and lying down, with
the head and shoulders slightly elevated.the head and shoulders slightly elevated.
•Do not move the person unless necessary.Do not move the person unless necessary.
•Apply light pressure with a sterile gauze toApply light pressure with a sterile gauze to
stop any bleeding.stop any bleeding.
•If the person stops breathing, perform CPRIf the person stops breathing, perform CPR
if you are properly trained.if you are properly trained.
4747

48. First Aid Procedures for Various
Emergency Situations (continued)
Heat exhaustionHeat exhaustion
•Recognize the symptoms:Recognize the symptoms:
Extreme perspiration➤
➤ Pale, clammy skin
➤ Rapid, weak pulse
➤ Rapid shallow breathing
•Immediately move the victim to a cool place.Immediately move the victim to a cool place.
•Lay victim flat and elevate the feet slightly.Lay victim flat and elevate the feet slightly.
4848

49. First Aid Procedures for Various
Emergency Situations (continued)
Heat exhaustionHeat exhaustion (continued)(continued)
•Remove as much of the victim’s clothing asRemove as much of the victim’s clothing as
possible.possible.
•Sponge the skin with cool water.Sponge the skin with cool water.
4949

50. Guidelines for Proper Lifting
•Check the box or item for nails, splinters, roughCheck the box or item for nails, splinters, rough
areas, grease, or slippery surfaces.areas, grease, or slippery surfaces.
•Wear appropriate personal protective equipment.Wear appropriate personal protective equipment.
•Plan your route before you liftPlan your route before you lift
•Check your path of travel and remove anyCheck your path of travel and remove any
obstructions from your path.obstructions from your path.
5050

51. Guidelines for Proper Lifting
•Make sure you can handle the weight of the load byMake sure you can handle the weight of the load by
yourself before trying to lift it.yourself before trying to lift it.
•Place your feet close to the object and aboutPlace your feet close to the object and about
shoulder-width apart.shoulder-width apart.
•Bend your knees and grip the object securely.Bend your knees and grip the object securely.
•Using your leg muscles, push up with your legs,Using your leg muscles, push up with your legs,
keeping your back straight.keeping your back straight.
5151

52. Guidelines for Proper Lifting
(continued)
•Keep the load close to your body as you travel.Keep the load close to your body as you travel.
•Turn your feet to turn your body.Turn your feet to turn your body.
•Lower the load by bending your knees, againLower the load by bending your knees, again
making sure to keep your back straight.making sure to keep your back straight.
•Carefully set the load down, being careful to watchCarefully set the load down, being careful to watch
your fingers.your fingers.
5252

53. Proper Use of a Ladder
Inspect the ladder before each useInspect the ladder before each use
•Verify that the ladder has no defects.Verify that the ladder has no defects.
•Verify that the steps or rungs are clean andVerify that the steps or rungs are clean and
not damaged.not damaged.
5353

54. Proper Use of a Ladder (continued)
Properly set up the ladderProperly set up the ladder
•Follow the one-to-four ratio rule forFollow the one-to-four ratio rule for
extension ladders.extension ladders.
•Verify the ladder is standing on firm, dryVerify the ladder is standing on firm, dry
ground.ground.
•Verify that an extension ladder is leaningVerify that an extension ladder is leaning
against a solid structure.against a solid structure.
•Fasten an extension ladder to the structureFasten an extension ladder to the structure
it is leaning against when accessing highit is leaning against when accessing high
places.places.
5454

55. Proper Use of a Ladder (continued)
Properly set up the ladderProperly set up the ladder (continued)(continued)
•Verify that a stepladder is fully open and theVerify that a stepladder is fully open and the
divider locked.divider locked.
•Place the top of extension or straightPlace the top of extension or straight
ladders at least three rungs above the work.ladders at least three rungs above the work.
•If using a ladder in front of a door, lock theIf using a ladder in front of a door, lock the
door before ascending the ladder.door before ascending the ladder.
•Set up a ladder as far away as possibleSet up a ladder as far away as possible
from electrical lines.from electrical lines.
5555

56. Proper Use of a Ladder (continued)
Properly set up the ladderProperly set up the ladder (continued)(continued)
•Verify that a stepladder is fully open and theVerify that a stepladder is fully open and the
divider locked.divider locked.
•Place the top of extension or straightPlace the top of extension or straight
ladders at least three rungs above the work.ladders at least three rungs above the work.
•If using a ladder in front of a door, lock theIf using a ladder in front of a door, lock the
door before ascending the ladder.door before ascending the ladder.
•Set up a ladder as far away as possibleSet up a ladder as far away as possible
from electrical lines.from electrical lines.
5656

57. Proper Use of a Ladder (continued)
Be cautious to avoid accidentsBe cautious to avoid accidents
•Do not climb higher than the third rung onDo not climb higher than the third rung on
extension ladders or second tread from theextension ladders or second tread from the
top of stepladders.top of stepladders.
•When working with both hands, lock one legWhen working with both hands, lock one leg
around a rung.around a rung.
•Do not overreach.Do not overreach.
•Keep your belt buckle between the rails.Keep your belt buckle between the rails.
•Do not put one foot on the ladder and theDo not put one foot on the ladder and the
other on an adjacent surface.other on an adjacent surface.
5757

58. Proper Use of a Ladder (continued)
Be cautious to avoid accidentsBe cautious to avoid accidents (continued)(continued)
•Never stand on the braces, extension arms,Never stand on the braces, extension arms,
or paint shelf.or paint shelf.
•Use a ladder only for the purpose ofUse a ladder only for the purpose of
reaching places you can not reach from thereaching places you can not reach from the
ground.ground.
•Do not work in windy conditions.Do not work in windy conditions.
•Do not leave a ladder unattended.Do not leave a ladder unattended.
5858

59. Lockout/Tagout Policy
LockingLocking
•Obtain permission from a supervisor beforeObtain permission from a supervisor before
you plan to lockout a piece of equipment.you plan to lockout a piece of equipment.
•Shut off the equipment.Shut off the equipment.
•Place the locks on the switches and valves.Place the locks on the switches and valves.
•Try to start the equipment or open the valves.Try to start the equipment or open the valves.
•Begin working.Begin working.
•When the work is completed, verify that allWhen the work is completed, verify that all
employees are cleared of the equipmentemployees are cleared of the equipment
before removing the locks and tags.before removing the locks and tags.
5959

60. Lockout/Tagout Policy (continued)
TaggingTagging
•Write a brief message on the tag, ifWrite a brief message on the tag, if
necessary.necessary.
•Write your name and the date.Write your name and the date.
•Attach the tag in a visible location.Attach the tag in a visible location.
6060

61. Oxygen Regulator
6161