Arc Welding

What is Arc Welding?

Generalized term used to describe
welding that uses an electric arc between
an electrode and the base material to
melt and join the metals.
Common Names and Variations:
Shielded Metal Arc Welding (SMAW) Stick
Welding
Gas metal arc welding (GMAW) = Metal
inert gas (MIG), Flux-cored arc welding
(FCAW), Submerged arc welding (SAW)
Gas tungsten arc welding (GTAW) or
Tungsten inert gas (TIG) welding

Stick Welding Cut-Away

Photo Courtesy of Lincoln Electric (http://www.lincolnelectric.com/knowledge/articles/content/arcweldfund.asp)

Hazards
Welding
is
an
inherently
dangerous
occupation.
Even without malfunction the process
exposes those around it to heat, radiation,
foreign objects (slag), gases, and high
electrical current.
Malfunctions in equipment often leads to very
dangerous situations.

Hazard: Heat
The arc produced during welding can
exceed 3000 degrees Celsius.
Molten metal particles splash off the
weld and can cause burns and fires.

Protection: Heat
Personal Protective Equipment
(PPE) is used to protect the
worker from heat, light and slag.
Welding blankets are used to
protect surrounding areas from
slag.
Wearing PPE in hot climates
poses the risk of overheating.
Hydration and ventilation are a
must.

Hazard: Radiation

1.

2.

Welding exposes the welder and anyone around the

work area to Ultraviolet (UV) Radiation. This exposure
poses two risks:
Flash Burn - A burning of the surface of the eyeballs
and/or skin caused by the UV rays. Same effects as sun
burn.
Retinal Burn - Burning of the retinal nerve caused by
the projecting of the extremely bright arc on the back of
the eyeball.

Protection: Radiation
Flash burn and retinal burn can be prevented through the proper use of PPE. A high quality shade can prevent eye
damage and is required (OSHA 1926.353(e)). The shade number used should correspond to the work being performed.
Clothes that completely cover the body prevent flash burn to the skin.

Those working near the welder should be protected from flash burn by a welding barrier that is set-up around the area.

Hazard: Gases

1.

A welder is faced with different hazards related

to the gases they are exposed to.
The welding process produces toxic fumes. The
zinc oxide and magnesium oxide fumes can
cause Metal Fume Fever. The symptoms of
which can include: headache, fever, chills, muscle
aches, thirst, nausea, vomiting, chest soreness,
fatigue, gastrointestinal pain, weakness, and
tiredness. (American Welding Society)

Hazard: Gases
2.

3.

The shielding gases used in welding, while

inert, can cause asphyxiation in enclosed
spaces. The gases are used in the welding
process to displace oxygen from the area of
the weld. If the gases are contained in a
small area the workers oxygen levels will be
depleted.
The gas cylinders used in the welding carry
the same risks of rupture and explosion as
any compressed gas cylinder.

Protection: Gases
In order to protect the worker from toxic gases
and from the displacement of available oxygen
proper ventilation is required (OSHA 1926.353(a)).

OSHA regulation (1926.353(b)) requires lifelines

and full-time spotters to be used for welding in
confined spaces.
Care should be taken in the transport and use of
all gas cylinders.

Hazard: Electrical Current

Arc welding draws a large amount
of current and passes it through
the piece of material in front of the
worker. Anytime electricity is
involved there is a risk of
injury/death.

Protection: Electrical
Current

In order to avoid electrical shock welding should

be done in a dry environment. Avoid moist
conditions and standing water.
In hot climates there is the possibility of sweat
soaked clothing becoming an electrocution
hazard.
Electrical equipment should be inspected
frequently. Splices must be rated at least as high
as the conductors they are joining and no splices
can be present in the 10 feet of conductor
closest to the welding torch (OSHA 1926.351(b)).

The Numbers
The risk from fatal injuries from welding is more
than four deaths per 1,000 workers over a
working lifetime.
For the construction industry, welders flash (burn
to the eyes) accounts for 5.6% of all construction
eye injuries.
1/4 of all welding injuries are eye injuries.
Explosions and electrocutions are rare but tend to
be very serious.

Specific Cases
A construction worker was killed on June 30,
2004 in when a welding torch apparently
ignited his clothes while he was working
inside a steel drainage pipe at a construction
site at Highway 29 in Napa. The man was
trapped inside the pipe and burned to death.
On August 21, 1989 in British Columbia a
welder was discovered unconscious inside a
titanium tank he had been finish welding
valves. The argon gas used to shield the weld
displaced the oxygen in the bottom of the
tank and worker died of asphyxiation.