General Industry Hazards

When beginning employment in a large fabrication shop or other similar environment, it is easy to be overwhelmed. Noise, flashing of arc lights, sparks, smoke, overhead cranes moving materials, and large machines in an area that may or may not seem organized or clean can also be a bit frightening at first. Hopefully, your experience in a school welding lab will prepare you for your first day in the industry.

OSHA identifies the most common health hazards associated with welding as exposure to metal fumes and ultraviolet radiation, and the most common safety hazards are injuries such as burns, eye damage, and electrical shock. See the OSHA Welding, Cutting, and Brazing website for specific hazards and safety solutions associated with welding.

Welding, by its nature, presents hazards: fumes and particulates; UV and IR rays, heat, flames, and sparks; high amounts of electrical energy and electromagnetic pulse; and gasses that may be explosive or could cause suffocation due to oxygen displacement. These are hazards directly resulting from welding processes. Welding employment has related hazards in the workplace, such as muscle strain from lifting and handling heavy objects, noise, repetitive motion injuries, being struck by or crushed by heavy equipment, etc.

Welding produces smoke and fumes. GMAW and GTAW tend to produce less visible smoke than SMAW or FCAW-S but do not be deceived into believing this means they are without hazards. For example, welding stainless steel produces hexavalent chromium, a known carcinogenic. Yet, the lack of a heavy smoke plume in the process makes it seem that GTAW on stainless steel is relatively harmless. A welder may weld on stainless steel for years without respiratory protection and not feel any immediate ill effects, yet be stricken with cancer as a result of that exposure.

Lead (from welding on lead paint), zinc oxide (from welding galvanized steel), stainless steel, and exotic metals such as INVAR (an iron/nickel alloy) all produce hazardous fumes that require respiratory protection. Many of these heavy metals accumulate in your tissues and, over time, can cause severe chronic illness. This buildup of toxins in your body does not give you resistance to the effects of exposure. Instead, as you are exposed to more toxins over time, the likelihood of illness increases. For example, fume fever from welding on galvanized steel creates fever, chills, nausea, and other flu-like symptoms. Each time you are exposed to fumes, it takes less exposure to bring on a possibility of sickness. Do not believe your veteran co-worker who tells you milk is an antidote for welding on galvanized steel. It only masks the bad taste of zinc oxide.

Other fumes in the workplace can be dangerous. Welding on chlorinated brake cleaner residue can produce phosgene gas. This is the same as nerve gas used during WW1. Welding on cyanoacrylate glue (instant-bonding glue) can produce cyanide gas. Some degreasers or solvents produce toxic or explosive fumes and may cause illness, as they can be absorbed into your body simply by coming into contact with your skin. SDS or safety data sheets are mandatory in every shop. These documents contain important information regarding every chemical you may be exposed to in your workplace.

particulates, such as silica, carbide, and asbestos, become embedded into your lungs. These become airborne by grinding, drilling into concrete, or disturbing fireproofing in buildings or ships. Being an irritant, yet too small for your lungs to expel, your lungs form scar tissue over the particles. This can result in silicosis or mesothelioma. Both are incurable, take a long time to kill you, and you get sicker and weaker the whole time you are slowly dying. Also, be aware that clothing may trap contaminants, which are then brought home, exposing family members.

In the future, OSHA may require all employers to provide fume extractors and other respiratory protection. While you are in school, get in the habit of wearing a respirator at all times in the shop. When you get into the industry, you will meet industry veterans who do not wear respiratory protection. Wear your mask even if they don’t!

Light waves given off from arc welding processes include visible, infrared (IR), and ultraviolet (UV). UV and IR are both capable of causing third-degree burns on the skin and capable of causing permanent damage to the eyes, including blindness. IR light waves give off heat and can be felt. Examples of IR are heat lamps in restaurants that keep food warm before serving. UV light doesn’t feel like heat, physically, yet it can produce third-degree burns in a short amount of time. This author first experienced a third-degree burn after one shift of GMAW welding on a factory assembly line. My welding helmet did not cover the base of my neck, which was exposed to the arc flash. The resulting burn and the medical treatment required was excruciatingly painful. You have been warned. NEVER weld without adequate skin protection such as leather sleeves, gloves, and eye protection with the appropriate shade as described in this OSHAfactsheet about Eye Protection. Notice that the American Welding Society recommends a darker shade than OSHA does. You should weld using the darkest shade that will still allow you to see the puddle clearly. Make sure you keep your clear cover plates clean and replace them when your vision becomes obscured. Also, remember, reflected light from behind you can do as much harm as direct light. Set up flash screens whenever possible to protect yourself and others from light and sparks.

Welding produces heat and often sparks that can cause burns or fires. Sparks are not merely tiny bits of flame but rather tiny bits of molten or glowing hot metal. Sparks produced by grinding can travel over long distances, and some sparks, such as from aluminum, are not visible yet can still cause severe eye injuries. When grinding or otherwise producing sparks, wear appropriate PPE such as leather sleeves, gloves, safety glasses, ear plugs, and a face shield (See Chapter 3). Be sure sparks are not directed toward people or machines that could be damaged. Glass is susceptible to being pitted and damaged by sparks and should be protected. Remove flammable materials from hot work areas. Fires can start and spread quickly. Always have a fire extinguisher handy when doing hot work.

Arc welding equipment, including plasma arc and carbon arc cutting equipment, operates with high primary and secondary electrical energy that can produce a fatal electrical shock. It is a good practice to wear gloves when handling electrodes, grounds, and other components that may be “live.” If possible, avoid working in wet environments or out in the rain. If you must work in wet conditions, wear rubber gloves and rain gear, and be aware that if you become the component that completes the electrical circuit, you will experience an electric shock, possibly fatal. GTAW, especially when using AC polarity, can introduce a powerful shock via the hand-held filler metal. DO NOT WEAR METAL RINGS OR BRACELETS WHILE WELDING! These currents can melt a ring worn on your finger, resulting in a severe burn. Avoid wrapping your welding lead around your arm or draping it across parts of your body, especially your reproductive organs. The electromagnetic pulse produced by the current may be harmful to you and a welding lead wrapped around you can injure you if passing heavy equipment snags it or becomes entangled in it.

Many types of welding use gasses either as a source of combustion or as a shielding gas. If a co-worker tells you breathing in argon or other gasses is good for curing a hangover, do not believe them. It could kill you. Acetylene, propane, and other petroleum-based gasses are combustible or explosive. If you smell gas, cease all hot work immediately, and if possible, locate the source and correct the hazard. You may have to notify your supervisor or warn everyone and ask them to evacuate, depending on the size of the leak and the workplace. NEVER WELD OR CUT ON A TANK OR BARREL THAT ONCE CONTAINED FUEL GASSES OR PETROLEUM PRODUCTS! As a welder, you will likely be asked to fabricate a BBQ grill from an empty metal barrel. People die from cutting or welding on barrels that explode due to tiny amounts of fumes contained in them. If you wish to safely do hot work on a barrel, first determine what it originally contained. If it is a metal barrel, it likely contained petroleum. Water is stored in plastic barrels that do not rust. To safely weld or cut on a steel barrel that still has both ends attached, first thoroughly steam clean it using tri-sodium phosphate (TSP). It should then be filled with water or inert gas such as argon or CO2 to displace any remaining fumes before proceeding with hot work.

Shielding gasses such as argon are heavier than air, and may displace air in the same way water pushes air out of a ditch or pool when it is poured in. When working in a low area or confined space, be aware that heavier-than-air gasses may accumulate there and suffocate you. In one report from 2008, OSHA recorded that a welder in the bottom of a ship succumbed to argon shielding gasses filling the bottom of the ship.

Welding requires one to maintain fine motor control and often contort oneself into uncomfortable positions for long periods of time. In addition, many welding jobs require the worker to do more than just weld. Often, one must lift heavy materials or equipment by hand (up to 100 pounds). For these reasons, you should keep yourself physically fit and practice pre-work stretches to reduce the chance of injury. Use your legs rather than your back to lift, and use machines such as forklifts and cranes to assist you whenever possible. When moving long materials with others, avoid placing your hands in a “pinch point.” For example, when lifting a large pipe with another person, putting your hand on the end of the pipe can result in injury if your co-worker pushes the end of the pipe you are holding into a wall. This author has seen people nearly lose fingers to pinch point accidents on two different occasions. Chains or wire ropes can also cause injury. When using them to hoist or drag materials, keep your hands clear of them at all times. NEVER PUT YOUR HAND OR FINGER IN A PLACE THAT COULD CUT IT OFF IF SOMETHING WERE TO GO WRONG! Never use your hand when you can use a tool, be it a hammer or pry bar.

Most welding shops are noisy places due to grinding, hitting steel with sledgehammers, or high-frequency AC GTAW. Earplugs should be used to protect you not only from sparks but also from hearing loss. Once hearing is lost, it cannot be restored. If you work in a loud environment, try the radio test. Before leaving your car to begin work, turn your car stereo volume down to the lowest setting you can hear it. After your workday is complete, see if you can still hear the radio when you return to your car. If you cannot hear your radio, you need better hearing protection. You are slowly losing your hearing.

Many shops have overhead cranes and use large machines and other equipment. Do not operate any shop equipment without proper training from your employer or qualified trainer. Maintain an awareness of any moving equipment. Avoid wearing earbuds to listen to music or podcasts, as they distract or isolate you from your surroundings. Do not let an overhead crane transport a load over you. Move out of its path of travel. Be aware of forklifts or other vehicles. Make eye contact with the operator and get approval from them before crossing their path. Many employers require their workers to wear high-visibility clothing to minimize the chance of workers being struck by heavy equipment.

Maritime Industry Hazards

Working in maritime such as in shipyards can expose you to all the hazards a welder encounters in shops and construction. In addition, there are some hazards other welders may not encounter, such as performing hot work around fuel tanks, working over water, and working in confined spaces that pose potential hazards such as physical entrapment and dangerous atmosphere. Working on boats and ships that have been in use can expose you to chemicals such as lead paint and asbestos.

Welders in maritime industries are at risk for chronic illness (illnesses that take place over a long period of time), such as respiratory hazards from fumes, chemicals, and particulates containing heavy metals. Shipyard welders in particular have higher rates of lung cancer and leukemia.

According to the National Institution of Occupational Safety and Health OSH, fatal and nonfatal illness rates are higher among maritime workers than welders in other industries (NIOSH, 2022).

Construction Industry Hazards

Construction sites, especially on large projects, can be intimidating to a new hire. Often, you are exposed to the weather, you may be required to work high off the ground, and there may be heavy equipment, including cranes operating around you. Add to this the fact that the job site is constantly changing: New walls are going up, holes may be cut into the floors, and a staircase you used a couple of days ago may have been demolished and removed. Due to the changing nature and activity of other workers, one must be alert at all times. This is in addition to the “normal” hazards one faces as a welder: fume exposure, electrical hazards, burns, etc.

The number one cause of fatalities in construction is falls (36%), followed by struck-by (15%), electrocution (7%) and caught in/between (5%) (NIOSH, 2023).

Falls are a hazard on many construction sites. Even a fall from an 8’ tall step ladder is often fatal due to feet being tangled in the ladder rungs, resulting in the person falling backward onto their head. Be sure to follow basic safety rules when working at elevated heights. Stay on the proper side of the safety railing, use proper fall arrest PPE, use appropriate tie-off points, and use ladders and aerial lifts per the manufacturer’s recommendations.

“Struck by” often involves heavy equipment or heavy objects being moved. Always wear a high visibility vest, never turn your back on a crane load or even an empty hoisting hook when it is moving in your vicinity, and be sure heavy equipment operators are aware of your presence.

Electrocution is death by a fatal electric shock. Be aware of overhead high power lines. The rubber coating on the lines is there primarily to protect the wires from corrosion, not to prevent electric shock. Contacting them with the load line of a crane or other equipment can result in a fatality. Many construction-grade welding machines operate with a primary power of 480V. Accidentally cutting into a power cable, becoming grounded while wet, or otherwise exposing yourself to shock can result in your death.

“Caught between” usually means getting in between heavy equipment and a wall or other stationary object. Again, be sure the equipment operator is aware of your presence, and never put yourself in a pinch point or a place where you can be crushed.

When considering a career in construction, you should seriously consider entering an apprenticeship training program that can provide industry-specific safety training on the job and/or in a classroom. OSHA 10, OSHA 30, and C-STOP are all safety training certifications that are construction-specific and should be obtained at the beginning of your construction career.

The Importance of LockOut TagOut Procedure

Lockout/ tag out is the practice of physically disabling and de-energizing equipment before working on it or in its vicinity. There are many examples of people being killed while working on equipment because someone else turned on the machine, not knowing it was being worked on. Powering the machine on could result in electrocution, or activating the machine could result in the physical crushing or entrapment of the worker. According to one Accident Report Detail from OSHA, In 2012, a worker was cooked to death in an oven load of tuna due to the oven he was cleaning not being properly locked out/tagged out (OSHA, 2012).

Lock out/tag out is a practice intended to prevent these types of death and injury. In its simplest terms, when working on equipment that has the potential to cause injury, the power supply is disabled or disconnected, and a lock is placed over the connection point. Modern power disconnects have a special eyelet allowing a padlock to be placed on them to prevent access. The worker who placed the lock is the only authorized person to have the key for that lock. A tag is also placed on the disconnect with the reason for the disconnect, time and date, and name and contact information of the person who placed the lock. That person is the only person authorized to remove the tag and lock. If multiple people are working on a piece of equipment, a special “gang lock” mechanism will accept each person’s padlock. It will remain locked out until each person removes their individual lock.

According to OSHA’s PDF Factsheet: Lockout/Tag out, It is the employer’s responsibility to develop and enforce a lockout/ tag out procedure applicable to their job site that protects their employees (OSHA, 2002).

Attributions

1. Figure 2.7: Melting by Lisa Ouellette is released under CC BY-NC-ND 2.0
2. Figure 2.8: image released under the Pixabay License
3. Figure 2.9: 2008-07-24 Bundle of compressed gas bottles by Ildar Sagdejev (Specious) is released under CC BY-SA 4.0
4. Figure 2.10: 55-Gallon Drum BBQ by James Bastow is released under CC BY-SA 2.0
5. Figure 2.11: image released under the Pexels License
6. Figure 2.12: Overhead Crane 200(100)(5)T by ORITCRANES by Alex.huang is released under CC BY-SA 4.0