Safety Policy and Procedure

Policy Number
Title:

015

Welding and Cutting Hazard Assessment Program

Authorized By:

The Cianbro Companies

Alan Burton

Effective Date:

09/16/95
Page 1 of 12

Status
1.1

Purpose
2.1

Update of existing policy, effective 06/03/11.

To provide guidelines and requirements to protect team members from the hazards associated
with welding, cutting, and burning operations.

Applicability
3.1

This policy applies to all subsidiary companies and departments of the Cianbro Companies.

3.2

All organizations are required to comply with the provisions of this policy and procedure. Any
deviation, unless spelled out specifically in the policy, requires the permission of the Safety
Director or designee.

Definitions
4.1

Adequate Ventilation: Used in this policy means any of the following: Local exhaust ventilation
is used to capture fumes or in open area with adequate air movement or adequate dilution
ventilation with directional air flow away from team member.

4.2

Air Arc (Carbon Arc): A cutting process by which metals are melted by the heat of an arc using
a carbon electrode. Molten metal is forced away from the cut by a blast of forced air.

4.3

Bug-O BUG-O Systems Inc.: A manufacturer of a system of drives, carriages, rails and
attachments designed to automate welding guns, cutting torches and other hand held tools.

4.4

Cad Welding: An exothermic (gives off heat) welding process that fuses conductors together to
form a molecular bond with a current-carrying capacity equal to that of the conductor. Typically
used in grounding systems.

4.5

Downdraft Table: A downdraft table is a work station for welding (or grinding and cutting) that
provides a ventilated table to work on top of. The air and contaminant is drawn down through
the table and away from the worker.

4.6

Flux: A substance which facilitates welding (and soldering and brazing) by chemically cleaning
the metals to be joined. The primary purpose of flux in welding is to prevent oxidation of the
base and filler materials. Note: Flux typically contains fluorides.

4.7

Flux Core Arc Welding (FCAW): An arc welding process which melts and joins metals by
heating them with an arc between a continuous, consumable electrode wire and the work.
Shielding is obtained from a flux contained within the electrode core. Added shielding may or
may not be provided from externally supplied gas or gas mixture.

4.8

Gas Metal Arc Welding (GMAW) MIG: (also referred to as solid wire welding) Arc welding
process which joins metals by heating them with an arc. The arc is between a continuously fed
filler metal (consumable) electrode and the workpiece. Externally supplied gas or gas mixtures
provide shielding.

Policy: 015 Welding and Cutting Hazard

Assessment Program

Rev. 06/03/11

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4.9

Inadequate Ventilation: As used in this policy means local exhaust ventilation is not being used
or work is inside enclosed spaces with inadequate air movement or any other location with
inadequate air movement or the air movement draws the contaminants through breathing zone
of the team member.

4.10 Lance Rod: Thermal lance rod is a cutting tool that utilizes ignited iron (or aluminum or
magnesium) fed with a stream of pressurized oxygen. A steel tube packed with steel rods (and
aluminum or magnesium) is connected to a valved handle assembly fed by an oxygen line and
tank. An intensely hot (6k - 10 k degrees Fahrenheit) oxy/steel fueled jet is created at the tip.
4.11 The National Institute for Occupational Safety and Health (NIOSH): Federal agency responsible
for conducting research and making recommendations for the prevention of work-related injury
and illness. NIOSH is part of the Centers for Disease Control and Prevention (CDC) in the
Department of Health and Human Services. It is essentially the research arm of OSHA and is
responsible for approving respirators.
4.12 Oxy-Fuel Cutting: A mixture of oxygen and the fuel gas is used to preheat the metal to its
'ignition' temperature which, for steel, is 700C - 900C (bright red heat) but well below its
melting point. A jet of pure oxygen is then directed into the preheated area instigating a
vigorous exothermic chemical reaction between the oxygen and the metal to form iron oxide or
slag. The oxygen jet blows away the slag enabling the jet to pierce through the material and
continue to cut through the material. Typical fuel gases used are acetylene, propane, MAPP
(methylacetylene-propadiene), and propylene.
4.13 Plasma Cutting: Arc cutting process which severs metal by using a constricted arc to melt a
small area of the work. This process can cut all metals that conduct electricity.
4.14 Shielded Metal Arc Welding (SMAW) or (Stick Welding): Arc welding process which melts and
joins metals by heating them with an arc, between a covered metal electrode and the work.
Shielding gas is obtained from the electrode outer coating, often called flux. Filler metal is
primarily obtained from the electrode core.
4.15 Sub-Arc Submerged Arc Welding: A process by which metals are joined by an arc or arcs
between a bare metal electrode or electrodes and the work. Shielding is supplied by a granular,
fusible material usually brought to the work from a flux hopper.
4.16 Threshold Limit Values TLV (TLVs): Guidelines, not standards prepared by the American
Conference of Governmental Industrial Hygienists, Inc (ACGIH) to assist industrial hygienists in
making decisions regarding safe levels of exposure to various hazards found in the workplace.
A TLV reflects the level of airborne exposure that the typical worker can experience without
an unreasonable risk of disease or injury. Cianbro uses the TLV in situations where it is more
protective than the OSHA PEL. Some definitions obtained from the Miller Electric
Manufacturing Co. website
4.17 Tungsten Inert-Gas Welding (TIG) or Gas Tungsten Arc Welding (GTAW) (HELIARC): Joins
metals by heating them with a tungsten electrode which should not become part of the
completed weld. Filler metal is sometimes used and argon inert gas or inert gas mixtures are
used for shielding.
5

Policy
5.1

Adequate ventilation is required during welding and cutting operations. If adequate ventilation is
not provided then respiratory protection is required.

Responsibilities
6.1

The top Cianbro manager of the job site is responsible for the implementation of this policy on
the job site.

6.2

Corporate Safety is responsible for maintaining this document.

Policy: 015 Welding and Cutting Hazard

Assessment Program

Rev. 06/03/11

Page 2

Welding and Cutting Hazard Assessment Program Index

7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
9.1
9.2
9.3

Health Effects ......................................................................................................................................... 3

Pre-Job Welding and Cutting Hazard Evaluation ................................................................................... 3
Engineering and Administrative Controls ............................................................................................... 6
Respiratory Protection ............................................................................................................................ 7
Exposure Monitoring............................................................................................................................... 7
Medical Surveillance............................................................................................................................... 8
Training................................................................................................................................................... 8
Physical Hazards .................................................................................................................................... 8
Safety At Home....................................................................................................................................... 9
Appendix A Minimum Respiratory Protection for Cutting and Welding Processes .............................. 10
Appendix B Exposure Guidelines for Welding Fumes and Gases ....................................................... 11
Appendix C Associated Guidelines for Gases Associated with Welding and Cutting.......................... 12

7.1

Health Effects
Welding, burning, and cutting produce metal fumes and gases that can be hazardous to your
health. Breathing in these fumes and gases can and does make people sick. Luckily, a healthy
body clears most toxic substances including welding fumes. Still, you can be exposed to too
much of any fume or have a medical problem that makes you more likely to get sick from
exposure to welding and cutting fumes. The length of time that you are exposed to these gases
and fumes, the type of hot work you do, the work environment, and the protection you use
determine the risks to your health and how you will be affected.
Like most other toxic substances, welding and cutting fumes have acute effects that may
occur as soon as or shortly after you are exposed. Acute effects can include headache, cough,
shortness of breath, eye irritation, or metal fume fever. Welding and cutting fumes also have
chronic effects that may not be noticed for years. These effects may include lung, kidney,
bone or joint disease and even cancer. Most acute effects are caused by brief overexposures.
These effects almost always go away within a day or two and dont cause any permanent
damage. Chronic effects from lower exposures over longer periods of time, like lung disease or
cancer, are more serious and can sneak up on you before you know it. Any time you think you
are having any unexplained symptoms or effects, let your safety specialist know as soon as
possible.
Pay attention to what you weld or cut, where you are welding or cutting, and which process you
are using. Be sure to provide for appropriate ventilation and use all required PPE. Remember,
the best treatment for any toxic exposure is prevention!

7.2

Pre-Job Welding and Cutting Hazard Evaluation

Before starting any task that involves welding, cutting and burning a pre-task hazard analysis is
required. This should be done as part of the activity planning process and will include both
health hazards and physical hazards (see section 7.6). Once the hazards are identified,
appropriate engineering and administrative controls and personal protective equipment (PPE)
can be selected to keep team member exposure to as low as reasonably practicable. When
doing a hazard evaluation, make sure to include surrounding workers that could also have
exposure and make provisions to protect them as well. Special precautions and planning are
required when welding, cutting or heating on hollow metal. Containers and structures to ensure
flammable or combustibles are not present.
The following four factors need to be considered:

Policy: 015 Welding and Cutting Hazard

Assessment Program

Rev. 06/03/11

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What base metals are being worked on?

Base Metal

Contaminant Generated

Carbon (Mild) Steel

Stainless Steel
Galvanized
Aluminum
Exotic metals

Iron oxide, manganese

Iron oxide, hexavalent chromium, nickel, ozone gas, manganese
Iron oxide, zinc oxide, manganese
Aluminum, ozone
Beryllium, titanium (examples)

Iron, Zinc, Aluminum have relatively high exposure limits. If welding outdoors, natural
ventilation and limiting actual welding time during the day should suffice for controlling
exposures. For indoor welding or confined spaces, available mechanical or natural ventilation
will need to be reviewed on a case-by-case basis along with daily duration of welding. If
respirators are required, any 100 efficiency particulate respirator should be adequate
(assuming sufficient oxygen is present).
Chromium, Nickel, Cadmium - are suspect human carcinogens, have very low recommended
exposure limits and therefore will require more careful planning in regards to ventilation. There
is a new OSHA standard for Hexavalent chromium with a very low permissible exposure limit
(5.0 ug/m3). Limiting the amount of welding time per day is not allowed as a control option for
cadmium or chromium. If respirators are required, 100 efficiency respirators and possibly air
supplied respirators should be used. See 29CFR1926.1127 for cadmium specific regulations
and 29CFR1926.1126 the hexavalent chromium standard.
Note: Working with stainless steel is much more dangerous than working with galvanized steel
because the hexavalent chromium and nickel in stainless have serious long term health effects
while the zinc from galvanized causes metal fume fever but has no known long term health
effects.
Manganese - Manganese is a highly reactive gray-white metal resembling iron, and adding
manganese to steel increases its hardness, stiffness and strength. Manganese is a major
component of welding fumes, particularly those from mild steel welds using shielded metal arc
welding (SMAW). Mild steel is the most common steel used in industry, and SMAW is the most
common type of commercial welding, but manganese exposures can result from other types of
welding as well.
Exotic Metals - contact Safety Department for consultation.
7.2.1

What type of welding process is being used?

Welding Process

Contaminant Generated

Flame cutting
Gas metal arc welding (MIG)
Gas tungsten arc welding (heli-arc or TIG)
Plasma cutting
Carbon arc (air arc) cutting
Flux cored arc welding
Shielded metal arc welding (stick)
Cad Welding
Lance rod cutting

Carbon monoxide, oxides of nitrogen

UV radiation, ozone, CO if CO2 gas is used, low
oxygen, manganese
UV radiation, ozone, oxides of nitrogen
Ozone, oxides of nitrogen, noise, low oxygen
Noise, iron oxide, copper
Barium, iron oxide, aluminum, magnesium
UV radiation, fluorides, manganese
Copper oxide, aluminum, fluorides, heat (exothermic
reaction)
Magnesium or Aluminum oxides, O2 enrichment

Ozone, Oxides of nitrogen are irritating to the eyes, nose and throat. Excessive
exposure may cause pulmonary edema (fluid in the lungs) that can lead to heart failure.
Ventilation is the only way to feasibly control both gases. Respirators (except air line)
are not an option. Reducing the welding arc amperage to the lowest level that still
allows an acceptable product will help reduce ozone levels and welding fume in
general. Arc welding, especially on stainless steel, aluminum and when using argon
gas tends to generate the most UV radiation and therefore the most ozone.

Policy: 015 Welding and Cutting Hazard

Assessment Program

Rev. 06/03/11

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Noise - Exposure to excessive noise may cause noise induced hearing loss. All welding
operations should be reviewed for noise exposure. Plasma arc, arc air gouging, and
metal spraying will almost always require use of hearing protection devices.
Low oxygen - Oxygen deficiency (less than 19.5%) is possible whenever gas shields
are use in confined spaces, or areas with poor ventilation. Note: Improper use of
oxygen in a confined space can produce an oxygen-enriched atmosphere - a serious
fire and explosion hazard.
Oxygen Enrichment Oxygen present at levels higher than 21% makes flammable and
combustible materials burn violently when ignited.
Aluminum, magnesium, and copper fume may cause metal fume fever and irritation
of the respiratory tract. Aluminum and magnesium have relatively high exposure limits
while copper fume has a relatively low exposure limit of 0.2 mg/m3.
UV Radiation - See Section 7.6
7.2.2

What is in the welding rod or filler rod being used?

MSDS must be reviewed to determine what components (e.g. filler metals, fluxes) may
be in the welding rod being used. Hazards and controls will vary with the specific rod
used. Some rods will be copper coated (e.g. gas metal arc). Excessive exposure to
copper may cause metal fume fever. Other rods contain manganese. Fluoride fluxes
may cause irritation to the eyes, nose and throat.

7.2.3

Are there any coatings or cleaning solvents residue on the object to be welded?
Coating or Solvent
Paint primers or coatings
Plating or corrosion protection
Polyurethanes, isocyanate based paints
Marine coatings, anti-fouling
Chlorinated solvents
Anti-spatter (may contain chlorinated solvents)
Residue from previous contents

Contaminant
Lead, Cadmium, Zinc, Hexavalent
Chromium (lead chromates, zinc chromates)
Cadmium
Variety of organic pollutants (e.g.
diisocyanates)
Mercury, tin
Decomposition products (e.g. phosgene
gas)
Refer to MSDS
Varies, refer to MSDS

Note: Preferred control method is to remove coating or solvent prior to welding.

Lead, Cadmium and Chromium - For lead see Cianbros Workplace Lead and Other
Heavy Metals Safety Policy and Procedure and 29CFR1926.62 for lead specific
regulations. For hexavalent chromium see 29CFR1926.1126 and for cadmium see
29CFR1926.1127. Cadmium plating on bolts and nuts is common in high corrosion
areas.
Chlorinated solvents (e.g. trichloroethylene, perchloroethylene) - Chlorinated
decomposition products (e.g. phosgene) especially common with high UV producing
welding.
Isocyanates, polyurethane coatings - Numerous materials can be generated depending
on the situation. Even at low concentrations, many of them are extremely irritating.
These materials can also be sensitizers. Always refer to MSDS.
Mercury - Low Permissible Exposure Limit. Excessive exposure may cause tremors,
headache, and weakness. Respirators with mercury specific filter or mechanical
ventilation will probably be required. May be absorbed through intact skin.

Policy: 015 Welding and Cutting Hazard

Assessment Program

Rev. 06/03/11

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Anti-spatter compounds - May contain chlorinated solvents.

Residue from previous contents - Know what material was present in the tank or line
before beginning hot work. Refer to the MSDS.
If caustic was present, it may leave traces of mercury in the metal due to the process
used to manufacture the caustic.
Paper mill stock lines may contain hydrogen due to anaerobic bacteria called Clostridia:
There have been several reported cases of explosions in the literature attributed to
hydrogen. The anaerobic condition required is most likely to be present during
shutdown conditions. Ventilation of stock lines and tanks can control this hazard.
Hydrogen may show up as a reading of carbon monoxide and LEL on a multigas
monitor. It can be tested for using colorimetric (detector) tubes.
7.3

Engineering and Administrative Controls

7.3.1

Once the hazards are identified, determine what controls will reduce or eliminate the
risks. The most effective way to protect you from the hazards associated with hot work
is to substitute less hazardous materials or methods, make physical changes in the
work environment, and use administrative controls (safe work practices). Below are
some engineering and administrative controls that should be considered for each task.

Spec areas to be welded on new material to be left bare of coatings.

Spec bolt-up connections rather than welds.
Use mechanically guided welding processes (e.g. Bug-O) so welder can stay back
away from the plume.
Use welding guns that capture the fume. These units are highly recommended for
all work using wire feeders. They control the contaminants at the point of
generation.
Use general ventilation (air movers to blow or exhaust the fumes away from you)
making sure the fumes are not drawn through your breathing zone or exposing
other workers. As a rule of thumb, visible welding fume should clear within 30
seconds of the welding stopping or it is probably not adequate.
Use local exhaust ventilation positioned 4-6 from the work to remove fumes and
gases at their source. This is the most effective form of ventilation and should be
used whenever possible, especially in fab areas and fixed locations.
Stay out of the plume! Make sure you position yourself so the plume does not pass
through your breathing zone. Also, pay attention to other welders as they may not
even realize that they are in the plume.
Move the work into open areas if possible. Do not work in confined or enclosed
spaces if it is not necessary.
Use mechanical means rather than hot work (sawcut grating rather than burning to
size or rivet bust rather than burn rivets off, etc.). There is a circular saw available
that cuts grating, angle, pipe, etc. up to 2 inches thick as easily as cutting plywood.
Limit the length of time you weld during a shift. Sampling results should be used to
determine safe lengths of time to weld.
Use long-handled torches.
Remove all coatings and residues from the pieces to be welded. For paint and
other preservative coatings remove at least 4 inches back from the point of heat
generation. Far enough back that the operation does not raise the temperature of
the coating appreciably.
Use less hazardous flux materials if process allows.
Use the safest welding method for the job (e.g. Stick welding makes less fume than
flux core welding but may take longer).
Use low fume rods if process allows.
Use downdraft tables to weld small pieces on.
Know what materials and hazards you are dealing with. Refer to MSDS for the
electrodes, base metals, and coatings.

Policy: 015 Welding and Cutting Hazard

Assessment Program

Rev. 06/03/11

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7.3.2

Is the Ventilation Adequate or Poor?

Adequate Ventilation: The following situations would be considered adequate
ventilation.
Local exhaust ventilation is used to capture fumes (must be positioned within one
to two duct diameters of the work) or
Work is in an open area with adequate air movement or
There is adequate dilution ventilation with directional airflow away from team
member (the fume cannot be drawn through the team members breathing zone) or
Fume capture guns are used.
Poor Ventilation: The following situations would be considered poor ventilation.
Local exhaust ventilation is not used and
The work is inside enclosed spaces with poor air movement or
The air movement draws the contaminant(s) through the breathing zone of the
team member.
If you are not sure if you have an adequate or a poor ventilation situation, then consider
it poor ventilation. If adequate ventilation can not be provided, respirators are required.

7.4

Respiratory Protection
If adequate ventilation cannot be provided, all jobs will require a respirator until air sampling
proves otherwise! If a respirator is required you must follow the requirements of
29CFR1910.134 and Cianbros Respiratory Protection Program Safety Policy and Procedure.
Respirators are a last resort and should be used only when feasible engineering and
administrative controls are not enough. Refer to Appendix A of this Safety Policy and
Procedure for minimum respiratory protection requirements for the most common hot work
activities. Respiratory protection is almost always required when welding in a confined space.

7.5

Exposure Monitoring
OSHA has limits for exposure to the metals, gases, and fumes during welding. However some
of these limits are out of date and may not protect you enough. Other more protective published
limits may be used like the ACGIH Threshold Limit Values. These more protective suggested
limits should be used in most cases to better protect the health of our team members. NIOSH
has reported that the levels of sickness and death are higher than expected in welders, even
when the exposures are below the current OSHA PELs for the many individual components of
welding emissions. NIOSH also says welding fumes may cause cancer. Therefore it is very
important to keep exposure to welding fumes as low as possible.
When deciding what to sample or monitor for the safety specialist needs to be involved and will
use the information obtained in the pre-job hazard evaluation required in Section 7.2 of this
Safety Policy and Procedure. Sampling is the only way to know whether or not our team
members are being protected from the airborne hazards associated with the welding process.
7.5.1

Metals
The metals will be sampled using the same procedure as for lead and multiple metal
contaminants can be tested from a single sample. Typical sampling would include
manganese for mild steel and hexavalent chromium for stainless steel. Hexavalent
chromium requires a different type of filter than the other metals. Sample should be
positioned on the welders collar so that it is underneath the welding hood as close to
the welders breathing zone as possible. Contact the Manager of Health and
Environmental Hazards, the Scott Lawson Group, Travelers Laboratory, or other
approved laboratory when sampling for a metal contaminant you have not sampled for
previously. Reference Appendix B for exposure limits.

Policy: 015 Welding and Cutting Hazard

Assessment Program

Rev. 06/03/11

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7.5.2

Gases
Gases can usually be monitored using direct reading instruments such as multi-gas
monitors and detector tubes. These should be used to determine if ventilation and other
controls are adequate and to determine if further monitoring should be done. To
determine actual team member exposure however, personal air sampling needs to be
done using either passive monitors or a sample pump and appropriate collection media
such as cassettes or charcoal tubes. Contact the Manager of Health and Environmental
Hazards, the Scott Lawson Group,
Travelers Laboratory, or other approved laboratory to obtain the correct sampling
media and method. Reference Appendix C for exposure limits.

7.6

Medical Surveillance
Any team member who performs welding or cutting for Cianbro is required to fill out the welding
and cutting section of the periodic medical questionnaire. Cianbros Medical Director will use
this information along with other information (like the PFT results every third year) to determine
the need for a welding physical and/or other medical testing. Reference the welding/cutting
portion of the periodic medical questionnaire in Appendix B. If there are any symptoms possibly
caused by exposure to welding processes report it to your supervisor and safety specialist.
Symptoms can be very similar to many other types of illnesses so it is important to report them.
The job site will contact Occupational Medical Consulting as soon as possible to help determine
the proper care and to recommend specialty evaluation. Cianbros Medical Director will make
recommendations for medical removal from the welding environmental, PPE, and other actions
to reduce ill effects from exposure as necessary.

7.7

Training
Team members who perform welding or operate and maintain oxygen/fuel gas equipment for
Cianbro must be trained initially and annually in the contents of this Safety Policy and
Procedure and the content of applicable OSHA standards. Team members in charge of
oxygen/fuel gas supply equipment must be trained and deemed competent to do so. In
addition, the OSHA Hazard Communication standard 29CFR 1926.59 requires team members
to be trained in the hazards of the materials that they may come into contact with. To meet this
requirement, the results of the pre-job welding and cutting hazard assessment must be covered
with the crew as part of the activity plan review.

7.8

Physical Hazards
7.8.1

Radiation arc welding produces three types of radiation:

UV radiation burns exposed skin much like an sunburn and affects the cornea of
the eye which causes flashburn that feels like sand in the eye.
Visible radiation produces an intense light from the arc that can damage the retina
of the eye.
IR radiation generates intense heat that can cause burns when sparks and spatter
fly off the welding process or hot metal and sparks blow out from the cutting
process. Burns can also occur when touching hot work pieces or equipment.
For eye protection, use lens shade as recommended by OSHA 29CFR1926.102 Table
E-2. Welding helmets are considered secondary eye protection and must be used with
primary protection (e.g. safety glasses side shields and UV protection). Other workers
in the area need to be protected as well using welding screens and UV protective
safety glasses.
For skin protection use personal protective equipment, welding gloves, shirts with long
sleeves, welding leathers, coveralls or aprons. Clothing should be of fire resistant
material like wool, heavy tight weave cotton or Nomex. No pockets or cuffs. Avoid
synthetic materials, as many are extremely flammable. Fire resistant shoulder covers,
head covers, ear covers are needed for overhead work. Sunscreen (SPF 15 or higher)
should be used on all exposed skin.

Policy: 015 Welding and Cutting Hazard

Assessment Program

Rev. 06/03/11

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7.8.2

Electrical Shock
Inadequate grounding of equipment, worn or damaged leads, lack of proper gloves and
working in wet conditions can lead to electrical shock. Electrical shock from welding
and cutting equipment can kill, cause severe burns, or result in serious injury form falls
caused by the shock. Equipment and sometimes the work piece should be grounded.
Use a separate connection to ground the equipment or work piece to the earth. Clothes
and work surfaces should be dry. If the work area is wet you must eliminate the hazard
by moving out of the wet area, protecting from dripping, raising the work up out of the
wet, etc.

7.8.3

Fire and explosion can result from welding or cutting close to combustible materials,
from leakage of welding or cutting gases through poorly fitting or leaking hoses, from
vapors given off by flammable liquids too close to the work (the vapors can travel until
they encounter a source of ignition and then flash back), from welding on tanks or
containers that have held flammable or combustible materials. To reduce the risk from
fire and explosive wear flame retardant clothing (gauntlet gloves, wool or tight weave
cotton or leather long sleeved shirt, coveralls without cuffs), inspect the work area and
remove or protect all combustibles prior to starting, use a trained fire watch, have
appropriate extinguishing media available. Report any equipment defects or other
potential hazards to your supervisor. Remove any defective equipment from service
immediately and either replace it or have it repaired by a qualified person. Use a hot
work permit when appropriate to ensure the area is safe for hot work. Refer to
Cianbros Watch for Fire, Smoke, and Sparks Safety Policy and Procedure for
additional information and for a Hot Work Permit form.
Never carry a butane lighter when doing hot work; sparks or slag may cause it to
explode.

7.9

7.8.4

Heat stress must be considered due to the protective clothing worn and the heat
generated from the welding process especially when there are high ambient
temperatures (indoors or out doors), work in confined spaces, or spaces with
inadequate ventilation. Follow Cianbros Exposure to Heat and Cold Safety Policy and
Procedure.

7.8.5

Noise is a hazard in the welding environment because of the process (air arc and
plasma arc cutting are very noisy for example), the power source, other equipment in
the area, and other operations going on like grinding. If engineering or administrative
controls like shielding the noise source or separating operations by distance or time
dont reduce the hazard to an acceptable level, then appropriate hearing protection
must be used. Refer to Cianbros Hearing Conservation Program Safety Policy and
Procedure.

Safety At Home
Welding and other hot work provides the same hazards whether you are at home or at work
other than possibly length of exposure. Please follow the guidelines contained in this policy to
help recognize and control hazards associated with welding and other hot work performed
outside of work.

Budget / Approval Process

8.1

It is the responsibility of each jobsite to procure and provide all materials and PPE required and
to provide necessary training.

Related Documents
9.1

See attachments.

Policy: 015 Welding and Cutting Hazard

Assessment Program

Rev. 06/03/11

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9.1 Appendix A Minimum Respiratory Protection for Cutting and Welding Processes

Minimum Respiratory Protection for Cutting and Welding Processes

Welding Process and Base Metal

Adequate Ventilation: Local exhaust ventilation is

used to capture fumes or in open area with
adequate air movement or adequate dilution
ventilation with directional air flow away from team
member. The fume cannot be drawn through the
team members breathing zone.

Inadequate Ventilation: Local exhaust

ventilation not used or inside enclosed spaces
with inadequate air movement or air movement
draws contaminant through breathing zone of
team member.

Carbon Steel

Not required

1/2 face respirator with 100 efficiency cartridges

Manganese

Other alloys and

galvanized

Not required. Air sampling required to verify

1/2 face respirator with 100 efficiency cartridges

Manganese

Carbon Steel

Not required

Air supplied respirator required

Ozone

Other alloys and

galvanized

Not required. Air sampling required to verify

Air supplied respirator required

Ozone especially with

aluminum

Carbon Steel

Not required

1/2 face respirator with 100 efficiency cartridges

Fume capture guns

considered adequate
ventilation, Manganese

Other alloys and

galvanized

Not required. Air sampling required to verify

1/2 face respirator with 100 efficiency cartridges

Manganese

Carbon Steel

Not required

Air supplied respirator required

Ozone, Manganese

Other alloys and

galvanized

Not required. Air sampling required to verify

Air supplied respirator required

Ozone especially with

aluminum, Manganese

Not required

1/2 face respirator with 100 efficiency cartridges

Creates minimal fume

Air Supplied Respirator Required (unless using local

exhaust ventilation and sampling is being done for
ozone can use 1/2 face respirator with 100
efficiency cartridges with ozone protection)

Air supplied respirator required

Ozone may be able to control

exposure with directed
ventilation (fan) for 100%
water immersion table.
Sampling required.

Carbon Steel

Not required

1/2 face respirator with 100 efficiency cartridges

Other alloys and

galvanized

Not required. Air sampling required to verify

1/2 face respirator with 100 efficiency cartridges

Air Arc/
Carbon Arc

1/2 face respirator with 100 efficiency cartridges

PAPR or full face respirator quantitatively fit, both

with 100 efficiency cartridges

Large amounts of fume

generated

Lance Rod
Cutting

1/2 face respirator with 100 efficiency cartridges

Air supplied respirator required

Typically used on demo jobs

with coated steel present.
See #3 below

Cad Welding

Not required

1/2 face respirator with 100 efficiency cartridges

Should be able to provide

adequate ventilation in most
cases

Shielded
Metal Arc
Welding
(stick)
Gas Tungsten
Arc Welding
(TIG)

Flux Core Arc

Welding

Gas Metal Arc

Welding (MIG)
Sub- Arc
Welding

Plasma
Cutting

Oxy- Fuel
Cutting

Policy: 015 Welding and Cutting Hazard

Assessment Program

Rev. 06/03/11

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Comments

9.2 Appendix B Exposure Guidelines for Welding Fumes and Gases

Exposure Guidelines for Welding Fumes and Gases

Material (Fumes)

8-Hour Time-Weighted
Average (TWA)
Exposure Limit
1

Potential Effects and Symptoms From Overexposure3

OSHA PEL
3
(mg/m )

TLV
3
(mg/m )

Aluminum

5 (respirable)

Skin irritation, respiratory system irritation, pulmonary fibrosis

Arsenic

0.01

0.01

Respiratory irritation, lung cancer, dermatitis

Beryllium

0.002
4
0.005 (C)

0.002

Lung disease (berylliosis), lung cancer, eye irritation

Cadmium

0.005

0.002
5
0.01 STEL

Respiratory irritation, lung congestion, abdominal pain, kidney damage,

yellow ring on teeth

Chromium II & III Compounds and metal

0.5

0.5

Lung disease, nasal irritation, sensitization, eye irritation

Chromium VI compounds (insoluble)

0.005

0.01

Lung cancer, nasal irritation and perforation, liver and kidney effects

Cobalt

0.1

0.02

Lung disease, wheezing, hypersensitivity, asthma, cardiovascular system effects, eye irritation

Copper

0.1

0.2

Metal fume fever, respiratory irritation, skin and hair discoloration

Fluorides

2.5

2.5

Respiratory irritation, mottling tooth enamel, bone changes, kidney effects

Iron oxide

10

Siderosis (pigmentation of the lung)

Lead

0.05

0.05

Central nervous system effects, lead poisoning, reproductive system effects

Magnesium oxide fume

15

10

Metal fume fever, eye and nose irritation

Manganese fume

5(C)

0.2

Nervous system effects(Parkinsons), pneumonia, reproductive system effects, metal fume fever

0.025

CNS effects, kidney and reproductive effects, eye irritant, cough, chest pain

Mercury

0.1(C)

Molybdenum

Respiratory irritation, liver and kidney effects

Nickel

0.2

Asthma, congestion, lung disease, carcinogen, sensitization

Tin

5 (respirable)

Stannosis-benign lung disease

Titanium dioxide

5 (respirable)

10

Lung fibrosis, potential carcinogen

Vanadium

0.05

0.05

Respiratory irritation, bronchitis, emphysema, pneumonia, green tongue, cough

Zinc oxide fume

5 (respirable)

Metal fume fever, cough, chest pain

Welding fumes not otherwise classified

5 (respirable)

Depends on components of fume, metal fume fever, irritation, cough, pulmonary edema

Policy: 015 Welding and Cutting Hazard

Assessment Program

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9.3 Appendix C Associated Guidelines for Gases Associated with Welding and Cutting

Exposure Guidelines for Gases Associated with Welding and Cutting

Material (gases)

PEL (ppm)

TLV (ppm)

Potential Effects and Symptoms From Overexposure3

Argon

None

None

Simple asphyxiant

Carbon dioxide

5000

30000 STEL

Carbon monoxide

50

25

Hydrogen chloride

5(C)

Hydrogen fluoride

Mild narcotic effects, respiratory effects, headaches

Headaches, drowsiness, asphyxiation, anoxia

5(C)

Strong irritation, dermatitis

3(C)

Skin, eye, respiratory irritations, bone effects

Nitric oxide

25

25

Cyanotic effects, anoxia, eyes and skin irritation

Nitrogen dioxide

5(C)

3
5
5 STEL

Eye, nose, throat irritant, chronic bronchitis, lung congestion, chest pain,
cough

Ozone

0.1

Light work 0.1

Moderate 0.08
Heavy 0.05
Any work 0.2

Respiratory irritation, lung congestion, bronchitis, headache, dry throat, premature aging

Phosgene

0.1

0.1

Lung congestion, chronic lung changes, anoxia, eye irritation

OSHA Permissible Exposure Limit (PEL) as listed in 29CFR 1926.55 and accompanying standards as of 2/1/2000.

Threshold Limit Value (TLV) as published in the 2000 TLV and BEI booklet by the American Conference of Governmental
IndustrialHygienists (advisory guidelines only).

Primary reference sources: 1997 NIOSH Pocket Guide to Chemical Hazards and the TLV Basis-Critical Effects as published
in the 2000 TLV and BEI booklet2.

Ceiling Limit, not to be exceeded without respirator use.

Short Term Exposure Limit.

Policy: 015 Welding and Cutting Hazard

Assessment Program

Rev. 06/03/11

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