Strive to maintain a safe working environment and avoid incidents when handling pressurised gases, and during welding and cutting operations.
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Help and Support Health and safety - Welding and cutting safety
Arc process safety
The severity of the hazards created by arc welding processes such as Manual Metal Arc (MMA) welding, Metal Inert Gas (MIG) welding, air-arc gouging and plasma cutting depends on the working environment and process types and conditions.
- These all produce fumes that can cause long-term damage to your respiratory health and impact the ventilation of your workspace. These risks can be reduced by ventilation/extraction systems that remove the fumes from the work area, as well as respiratory type welding screens or masks which filter the air that the operators breathe.
- Gas-shielded processes that use compressed and cryogenic gases also present a range of unique safety risks. As most shield gases are inert, there is a risk of oxygen displacement and asphyxiation. It is important that all operators/equipment users are trained and competent, and that thorough risk assessments are carried out. If hazards relating to confined space are identified, measures such as permit to work, forced air extraction, oxygen monitoring devices and buddy systems can assist in reducing/controlling the risks.
- A welding arc emits UV radiation which can be hazardous to the eyes and skin. Appropriate PPE including a welding screen, safety glasses, gloves and overalls should be worn to reduce these risks. Heat and spatter produced from the welding arc can burn the skin if flame resistant clothing and heat-resistant gloves aren’t worn to protect the operator. Additionally, the work area should be clear of flammable materials to prevent the risk of fire.
- Risk of electric shock when arc welding can be reduced by ensuring operators are trained and competent in the safe use of welding equipment. All equipment including welding plant, electrode holders, cables etc should be well maintained and in good condition. Operators should wear the appropriate protective clothing at all times, including the appropriate gloves for the welding process type.
We offer a range of practical and theory courses which can assist in ensuring welders and operators are aware of the hazards and risks associated with arc welding and cutting processes.
Fuel gas process safety
Oxy-fuel gas processes involve working with flammable and oxidising gases, gas equipment and welding and cutting equipment.
With gas most frequently supplied in pressurised cylinders, one of the most serious safety risks to be aware of is ‘flashback’, which is the reverse flow of flames or hot gases through the cylinder hose. This can happen for several reasons, including not following correct set-up and lighting up procedures or incorrect gas pressures, and can lead to potentially serious safety incidents.
- All portable fuel gas equipment such as regulators, flashback arrestors, hoses, torches, burners and nozzles should be set up, maintained and inspected to BCGA CP7 code of practice. This code of practice details the type of equipment and safe working conduct required for the safe use of portable oxy-fuel systems, e.g. flashback arrestors.
- Oxygen enrichment with the use of oxy-fuel systems is another process-specific hazard that can lead to an increased risk of fire/explosion. This risk can be reduced by conducting robust risk assessments and setting workplace procedures in place, e.g. for confined space working. Ensuring trained and competent operators, equipment set up and safe working procedures complying with BCGA CP7 will also assist in reducing this risk.
- The heat and swarf produced during cutting present the risk of burns - take care when handling hot materials and dress in flame and heat-resistant PPE and tinted goggles. Additionally, keep the work area clear of flammable materials to prevent the risk of fire.
- Additional physical hazards can emerge during the manual handling of cylinders and fitting of regulators, such as impact injuries from falling cylinders, muscular strains and pinching and crushing wounds.
Our range of gas safety training workshops covers the safe use, handling and storage of industrial compressed gas cylinders and associated equipment.
Thermal and plasma spraying process safety
- The main safety concerns when using High Velocity Oxygen Fuel (HVOF), a detonation gun and flame spraying, are with the maintenance and use of high-pressure fuel gas and oxygen gas systems.
- In arc spraying and plasma spraying, issues are electrical safety and UV radiation.
- All thermal and plasma spraying processes are susceptible to risks from heat and the intense glare from the flame, hot metal, equipment, and fume generation. All of these hazards may be exacerbated when working in confined spaces.
- Protective equipment such as safety glasses, flame-resistant clothing, heat-resistant gloves and safety shoes should be worn as a minimum.
- Thermal and plasma spraying is typically conducted in secure booths, allowing only authorised personnel access. If you identify any hazards relating to confined space, implementing measures such as controlled access, a permit to work, forced air extraction or oxygen monitoring devices can help reduce and control the risks.
Laser process safety
- Operating high power laser beams in materials processing applications brings with it several serious risks to safety, most significantly the threat of direct exposure to the laser beam, which can cause retinal damage to the eye.
- Industrial lasers are categorised as Class 4 the most hazardous to exposed skin or eyes. Complete enclosure of the laser beam should be in place to protect users and other personnel in the area - these enclosures have safety features such as beam detectors, laser-safe viewing screens and interlocked shutters, which ensure that the machine itself is categorised in Class 1 – safe.
- Handheld laser welding machines are also labelled as Class 4 and must also be used within a suitable enclosure. As the operator can work within the enclosure, additional safety equipment and PPE are necessary to prevent skin exposure, including specialist eyewear, welding screens, heat-resistant clothing and gloves.
- The inhalation of laser-generated airborne contaminants (LGAC) produced by vaporization and combustion pose another threat to the health and wellbeing of those operating. Preventative measures include respiratory protection, the installation of local exhaust ventilation and a thorough understanding of the relevant Safety Data Sheets.
BOC disclaimer: The above does not represent an exhaustive list of risks that can occur during these welding and cutting techniques.
General welding and cutting hazards
It is vital that your employees are aware of the hazards and injuries that can occur in the workshop, and that all necessary precautions are in place. All operatives should be trained and competent in the manual handling of cylinders and equipment and have a full understanding of the hazards and risks of the gases being used and their effect on the working environment. Risk assessments for all tasks should be carried out by competent and authorised personnel, and control measures put in place to manage any identified hazards. Gas equipment must be well maintained and inspected to the appropriate standards.
Burns
The skin and eyes are vulnerable to burns, which can occur when handling molten metal or working around an open flame without the correct precautions.
Confined spaces
Working in a restricted space can increase the risk of ventilation issues from a build-up of toxic, flammable or hazardous gas. Individuals working in confined conditions must be appropriately trained, equipped and supervised, and follow a formal ‘safe system of work’.
Electric shock
In addition to burn injuries, more serious threats like electrocution can occur as a result of negligent handling of live electrical components like electrodes. Care should be taken to follow the manufacturer’s instructions, and to ensure that the appropriate PPE is worn when installing and using electrical welding and cutting equipment.
Eye damage
One of the most common injuries to occur during welding and cutting, damage to the eyes can be due to radiation, foreign bodies, fumes and gases: Radiation from welding arcs can cause eye damage including:
Gaseous fume
Undetectable pollutant gases including nitrogen oxides, ozone and carbon monoxide are produced during the welding process and can easily enter the lungs.
Heat
Working in an excessively hot environment can cause the body to overheat if the appropriate fluids aren’t consumed. Precautions should be taken and work regimes adjusted to ensure that every worker's core body temperature is maintained.
Noise
Usually deemed to be 85dB(A) and above, loud noises are likely to exceed this in welding and cutting environments. Hearing protection, in the form of ear plugs and ear defenders, is available from our shop, and can help to stop noise-induced industrial deafness.