Arc Welding Safety

Guide for Safe Arc Welding

1
Safety Practices in Welding

INTRODUCTION Because of its durability and resistance to fire, wool

Arc welding is a safe occupation when sufficient clothing is suggested over synthetics (which should
measures are taken to protect the welder from never be worn because it melts when exposed
potential hazards. When these measures are to extreme heat) or cotton, unless it is specially
overlooked or ignored, however, welders can treated for fire protection. If possible, keep your
encounter such dangers as electric shock, clothes clean of grease and oil, as these substances
overexposure to fumes and gases, arc radiation, may ignite and burn uncontrollably in the presence
and fire and explosion; which may result in of oxygen.
serious, or even fatal injuries.
Avoid rolling up your sleeves and pant-cuffs,
This bulletin is written with the arc welding because sparks or hot metal could deposit in the
operator in mind, containing both mandatory folds; also, wear your trousers outside your work
safety practices and those based on shop boots, not tucked in, to keep particles from falling
experience. Be sure to read ANSI Z49.1, and into your boots. While were on the subject, we
refer to the other publications listed at the end suggest leather high-tops with steel toes (especially
of the bulletin for more detailed information on when doing heavy work), or metatarsal boots.
specific topics of arc welding safety, as well as the
manufacturers instructions and material safety Other protective wear for heavy work or especially
data sheets (MSDSs). hazardous situations includes: flame-resistant
suits, aprons, leggings, leather sleeves/shoulder
capes, and caps worn under your helmet.
Important Note:
So that you can protect yourself against these Heavy, flame-resistant gloves, such as leather,
hazards, every welder should be familiar with should always be worn to protect your hands from
American National Standard ANSI Z49.1, burns, cuts, and scratches. In addition, as long as
Safety in Welding and Cutting, and should they are dry and in good condition, they will offer
follow the safety practices in that document. some insulation against electric shock.

Z49.1 is available for download at no charge at: As to preventing electric shock, the key word is
http://www.lincolnelectric.com/safety dry! Well have more on the subject later, but for
or at the AWS website http://www.aws.org. now keep in mind that moisture can increase the
potential for and severity of electric shock. When
Download and read it! working in wet conditions, or when perspiring
heavily, you must be even more careful to insulate
your body from electrically live parts and work on
PERSONAL PROTECTIVE EQUIPMENT grounded metal.
Protective Clothing
Welders, like firemen, must wear clothing to
protect them from being burned. Of all injuries to WARNING!
welders, burns are the most common due to sparks
landing on bare skin. Welding arcs are very intense ARC RAYS can burn.
and can cause burns to skin and eyes with just a Wear eye, ear and body protection.
few minutes of exposure.

The actual gear varies with the job being

performed, but generally protective clothing
must allow freedom of movement while providing
adequate coverage against burns from sparks, Note to Arc Welding Educators and Trainers:
weld spatter, and arc radiation. Many types of This Arc Welding Safety brochure may be
clothing will protect you from ultra-violet radiation freely copied for educational purposes if
exposure, which appears as a skin burn (much like distributed to welders and welding students
sunburn). Under the worst conditions, however, at no additional charge.
severe burns and skin cancer may result from
excessive radiation.

2
 Safety Practices in Welding

NOISE Other than simply not looking at an arc, the

There are two good reasons to wear ear muffs primary preventive measure you can take is to
or plugs: use the proper shade lens in your helmet. Refer to
to keep flying sparks or metal out of your ears; the lens shade selector chart in Supplement 1 for
and the recommended shade numbers for various arc
to prevent hearing loss as a result of working welding processes. The general rule is to choose a
around noisy arc welding equipment, power filter too dark to see the arc, then move to lighter
sources, and processes (like air carbon arc shades without dropping below the minimum
cutting or plasma arc cutting). rating. The filters are marked as to the manufactur-
er and shade number, the impact-resistant variety
As with radiation exposure to the eyes, the length
are marked with an H.
and number of times that you are exposed to high
levels of noise determine the extent of the damage
Helmets and hand-held face shields (see Figure A)
to your hearing, so be sure to avoid repeated
exposure to noise. If it is not possible to reduce offer the most complete shading against arc
the level of noise at the source (by moving either radiation. The shade slips into a window at the
yourself or the equipment, utilizing sound shields, front of the shield so that it can be removed and
etc.), then you should wear adequate ear protection. replaced easily. The shields are made from a hard
plastic or fiberglass to protect your head, face, ears,
If the noise in your work area is greater than 85 dB, and neck from electric shock, heat, sparks, and
or when levels become uncomfortable, causing a flames. You should also use safety glasses with
headache or discomfort of the ears, you could be side shields or goggles to protect your eyes from
damaging your hearing and should immediately flying particles.
put on ear muffs or plugs.
Visible light can also be harmful, but it is easy
In fact, the use of ear protection at all times is a to tell if the light is dangerous: if it hurts to look
good idea, as hearing loss is both gradual and adds at, then its too bright. The same is true for
up over time. Damage to your hearing may not be infrared radiation: it can usually be felt as heat.
noticed until you have a complete hearing test, and However, theres no real way for you to tell
then it could be too late. if youre being over exposed to UV radiation,
so just dont take chances: always wear eye
ARC RAYS protection (see Supplement 1 for recommended
It is essential that your eyes and skin are lens shade numbers). UV radiation can also burn
protected from radiation exposure. Infrared exposed skin. Always cover or shield potentially
radiation has been known to cause retinal exposed skin to prevent burns.
burning and cataracts. And even a brief exposure
to ultraviolet (UV) radiation can cause an eye burn
known as welders flash. While this condition is
not always apparent until several hours after
exposure, it causes extreme discomfort, and can
result in swelling, fluid excretion, and temporary
blindness. Normally, welders flash is temporary,
but repeated or prolonged exposure can lead to
permanent injury of the eyes.

(a) (b)

Figure A.
A helmet (a) required for protecting the welders
eyes and face and (b) a hand-held face shield that is
convenient for the use of foremen, inspectors, and
other spectators.

3
Safety Practices in Welding

INSPECTION AND MAITNENANCE OF EQUIPMENT Are the cables the right size for your job? Be
AND WORK sure any damaged cable insulation is repaired.
Before starting any arc welding operation, you Are they spread out and run neatly to
should make a complete inspection of your prevent overheating?
equipment. All it takes on your part is 5-10 minutes Is the gas cylinder connected properly?
before you turn on your welder; is that too much Is the cylinder secure?
to spend in preventing injury to yourself or your Is the work stable and easy to reach from where
co-workers? youre standing?
Is the Work Lead connected securely?
To begin with: Is there enough dry insulation between your
Have you read the instruction manual and do body and the work piece?
you understand the instructions? The instruction Is there adequate ventilation in your work area?
manual for your welder is available upon request
to your welding distributor or the manufactur- Take some personal responsibility for your own
er. Manuals for Lincoln Electric welders may safety. Notify your supervisor if equipment is in
be downloaded from lincolnelectric.com at no need of repair or not working properly or any
charge. unsafe condition. You have the most to lose if
Have you read the warnings and instructions on you get hurt. Dont allow yourself to work in a
the equipment nameplates and decals as well as hazardous situation without taking appropriate
the consumables labels and material safety data safety precautions.
sheets? (For older equipment see Supplement 5
to request a FREE Warning Label.) If the hazard is serious and cannot be corrected
readily, the machine should be shut down until
For the welder: the needed repairs are made. If the problem is
Are all the connections tight, including the limited to the outside of the welder, such as a
earth ground? loose connection or a damaged cable that needs
OSHA regulations require output terminals to to be replaced, disconnect power to the welder
be insulated. Rubber boots are available for and correct the problem per the manufacturers
that purpose. instructions in the operating/service manual. If
Are the electrode holder and welding cable well the hazard requires repairs to the inside of the
insulated and in good condition? welder or to the electrical input supply lines, call a
Are the settings correct for the job youre about service technician or an electrician. Never attempt
to begin? to make these repairs if you are untrained.

For an engine-driven welder:

Is it running OK? Important Safety Note:
Are all the hoses on tight? Consider whether the area in which you will
Is the fuel cap on tight? be working creates or increases the level of
Is the engine leaking fuel or oil? Some jobsites hazard to you thus requiring special procedures
look for this and may refuse entry if your engine or equipment. Factors such as electrical safety,
is leaking. fume ventilation/exhaust and risk of fire or
Take caution not to spill fuel when refueling. explosion may be affected. See later sections
Have a fire extinguisher handy just in case. Fuels on those topics and other documents in
present a fire hazard and we must always follow Bibliography and Suggested Reading for
appropriate hot work procedures. further information.
Is the original enclosure and fan guarding in
place? Check with your welding equipment
distributor if you are unsure. (See Supplement 6.)

For the work in general: (See also Supplements

4 and 7)
Are the work area conditions such that normal
safety precautions can be observed or must
special equipment (i.e., ventilation, exhaust,
or respirator, welding equipment, protective
equipment, safety equipment) or procedures
be used?
Many jobsites require permits for any welding
or cutting. Be sure you have any permits you
will need. Make sure that applicable hot work
procedures are followed.
If you will be working in a confined space,
many special OSHA regulations and jobsite
requirements may apply in addition to the
arc welding precautions in this brochure.
Understand which of these apply to your
jobsite and comply with them.

4
 Safety Practices in Welding

CARE AND CLEANING OF THE WORK AREA welder to touch a cylinder. Crack the valve open
Keeping the area around your work neat is as to prevent dirt from entering the regulator; open
important as maintaining your equipment. Perhaps the cylinder valve only when standing to one side of
even more-so, as the risk of injury is amplified by the cylinder, away from welding or other sources of
the larger group of people involved. You may have ignition. Return damaged cylinders to the supplier.
already inspected your equipment and found it to Refer to the Compressed Gas Association pamphlet
be OK, but all your caution wont matter when, for P-1, Safe Handling of Gas Cylinders, for further
example, a co-worker trips over your cable, causing information.
you, and/or the people around you, to be injured by
shock, hot metal, or from falling. WARNING!
Keep all your equipment, cables, hoses, CYLINDER may explode if damaged.
cylinders, etc. out of any traffic routes such as Keep cylinder upright and chained
doors, hallways, and ladders. A good practice is to to support.
avoid clutter and clean up your work area when Never allow welding electrode to
youre done! Not only will it help to protect yourself touch cylinder.
and others, youll find it much easier for you to
work efficiently.
ELECTRIC AND MAGNETIC FIELDS
Also, bear in mind that while youre paying Electric current flowing through any conductor
attention to your work, other welders may be causes localized Electric and Magnetic Fields
preoccupied with their own tasks and not (EMF). Welding current creates EMF fields around
watching where theyre going. So be sure that welding cables and welding machines. EMF fields
there are protective screens in place, just in case may interfere with some pacemakers, and welders
somebody happens to be passing into your work having a pacemaker should consult their physician
area or walks into a shower of sparks or spatter. before welding. Exposure to EMF fields in welding
may have other health effects which are now not
GAS CYLINDERS known. All welders should use the following
Because of the high pressure gas in cylinders, procedures in order to minimize exposure to EMF
you must pay particularly close attention to their fields from the welding circuit:
storage and use. Examine the cylinders as you did
the rest of your equipment; check the cylinder label Route the electrode and work cables together
to make sure it is the correct shielding gas for the Secure them with tape when possible.
process, and that the regulators, hoses, and fittings Never coil the electrode lead around your body.
are the right ones for that gas and pressure, and are Do not place your body between the electrode
in good condition. and work cables. If the electrode cable is on your
right side, the work cable should also be on your
Cylinders must be secured in an upright position, right side.
with the valve caps in place, in an area away from Connect the work cable to the workpiece as close
combustibles and fuels, and safeguarded from as possible to the area being welded.
damage, heat, and flames. When in use, keep them Do not work next to welding power source.
out of traffic routes and flying sparks, with all hoses
run neatly to the welding area. Never allow the
electrode or other electrically hot parts of your

5
Safety Practices in Welding

SPECIFIC CONCERNS properly. Also, your welder should be installed by

Possible Shock Hazards a qualified electrician so it will be correctly wired
The hazard of electric shock is one of the most for the primary voltage which supplies it power and
serious and immediate risks facing you as a so the case will be connected to an earth ground.
welder. Contact with metal parts which are When electrical supply lines are connected to a
electrically hot can cause injury or death because welder, check the welder capacity nameplate and
of the effect of the shock upon your body or a fall connection instructions to be sure the input is the
which may result from your reaction to the shock. correct phase (single phase or three phase) and
The electric shock hazard associated with arc voltage. Many welders may be set up for single
welding may be divided into two categories which phase or three phase and for multiple input
are quite different: voltages. Be certain the welder is set up for the
electrical supply to which it is connected. Only a
Primary Voltage Shock (i.e., 230, 460 volts); and qualified electrician should connect input power.
Secondary Voltage Shock (i.e., 20-100 volts). The case must be grounded so that if a problem
develops inside the welder a fuse will blow,
WARNING! disconnecting the power and letting you know
that repair is required. Never ignore a blown fuse
HIGH VOLTAGE can kill. because it is a warning that something is wrong.
Do not operate with covers removed.
Disconnect input power before servicing.
Do not touch electrically live parts. WARNING!
ELECTRIC SHOCK can kill.
Do not touch electrically live parts or
Primary Voltage Shock electrode with skin or wet clothing.
The primary voltage shock is very hazardous Insulate yourself from work and ground.
because it is much greater voltage than the welder
secondary voltage. You can receive a shock from
the primary (input) voltage if you touch a lead
inside the welder with the power to the welder If welding must be performed under electrically
on while you have your body or hand on the hazardous conditions (in damp locations or while
welder case or other grounded metal. Remember wearing wet clothing; on metal structures such as
that turning the welder power switch off does not floors, gratings or scaffolds; when in cramped positions such as
sitting, kneeling or lying, if there is a high risk of unavoidable or
turn the power off inside the welder. To turn the
accidental contact with the work piece or ground) use the following
power inside the welder off, the input power cord
equipment:
must be unplugged or the power disconnect switch
Semiautomatic DC Constant Voltage Welder
turned off. You should never remove fixed panels
DC Manual (Stick) Welder
from your welder; in fact, always have a qualified AC Welder with Reduced Voltage Control
technician repair your welder if it isnt working

Metal jaws are

electrically hot

Screws are electrically hot.

Keep tight and recessed so they
cannot be touched.

Electrode is
Insulated cable electrically hot
with no exposed
conductor

Figure B.
Always inspect your electrode holder before turning the welder on.

6
 Safety Practices in Welding

Secondary Voltage Shock exposed (and it should not be if you are dressed
A secondary voltage shock occurs when you touch properly). In addition to the normal safety
a part of the electrode circuit perhaps a bare spot precautions, if welding must be performed
on the electrode cable at the same time another under electrically hazardous conditions (in damp
part of your body is touching the metal upon which locations or while wearing wet clothing; on metal
youre welding (work). To receive a shock your body structures such as floors, gratings or scaffolds;
must touch both sides of the welding circuit when in cramped positions such as sitting,
electrode and work (or welding ground) at the kneeling or lying, if there is a high risk of
same time. To prevent secondary voltage shock, unavoidable or accidental contact with the work
you must develop and use safe work habits. piece or ground) use the following equipment:
Remember the voltage at the electrode is highest
when you are not welding (open circuit voltage). Semiautomatic DC Constant Voltage Welder
DC Manual (Stick) Welder
Wear dry gloves in good condition when welding. AC Welder with Reduced Voltage Control
Do not touch the electrode or metal parts of the
electrode holder with skin or wet clothing. The condition of your electrode holder and
Keep dry insulation between your body electrode cable is also very important. The
(including arms and legs) and the metal being plastic or fiber insulation on the electrode holder
welded or ground (i.e., metal floor, wet ground). protects you from touching the metal electrically
Keep your welding cable and electrode holder hot parts inside. Always inspect your electrode
in good condition. Repair or replace any holder before turning the welder on. Replace the
damaged insulation. holder if it is damaged dont try to repair it
unless you have replacement parts.
These rules are basic to welding and you should
already know them. Check out the warning on The same is true of the electrode cable except
your welder or electrode box next time you weld. that when not replaced it may be repaired using
You will probably not have a shock while welding good electrical tape. If your cable has been
if you follow these rules. repaired, be sure to check and see that the tape
is secure before you turn the welder on.
Though it may be more difficult to follow the
rules under some conditions, the rules still apply. Remember, a stick electrode is always
Keep your gloves dry even if you have to keep an electrically hot when the welder is on treat it
extra pair. Use plywood, rubber mats, or some with respect. If you do experience a shock, think
other dry insulation to stand or lie upon. Insulate of it as a warning check your equipment, work
your body from the metal you are welding. Dont habits and work area to see what is wrong before
rest your body, arms, or legs on the workpiece, continuing to weld.
especially if your clothing is wet or bare skin is

7
Safety Practices in Welding

If you are not sure of the combustible or

WARNING! volatile nature of residue or dust in the work
WELDING SPARKS can cause fire area, no welding or cutting should take place
or explosion. until a responsible person has inspected the
Keep flammable material away. area and given approval for the work.

Before you start welding, inspect the surface

of your work, looking for flammable coatings
FIRE HAZARDS or any unknown substances that would ignite
Because of the extreme temperatures associated when heated. Because of the extreme fire and
with any arc welding process, you should always explosion hazards inherent to welding on or
be aware of fire hazards. The heat of the welding around containers and piping that may have
arc can reach temperatures of 10,000F, but this combustible materials, such work should be
heat in itself is not generally a fire hazard. The handled only by experienced welders who review
danger of fire actually results from the effects and follow the safety practices recommended in
of this intense heat upon your work and in the the American Welding Society document F4.1,
form of sparks and molten metals. Because these Recommended Safe Practices for the Preparation
can spray up to 35 feet from your work, for Welding and Cutting of Containers and Piping
you must recognize and protect combustible Which Had Held Hazardous Substances.
materials from the welding arc, sparks and
spatter. It is also important to be sure the work Know where the fire alarms and fire extinguishers
is not in contact with any combustible which are located, and check the pressure gauges so
it may ignite when heated. These materials fall you dont rely upon one thats empty. If there
into three categories: liquid (gasoline, oil, paints, are none in the area, make sure that you have
and thinners); solid (wood, cardboard, and paper); access to fire hoses, sand buckets, fire-resistant
and gaseous (acetylene and hydrogen). blankets, or other fire fighting equipment. If
youre welding within 35 feet or so of flammable
Watch where the sparks and metals are materials, you should have a fire watcher to see
falling from your work: if there are flammable where your sparks are flying, and to grab an
materials including fuel or hydraulic lines in extinguisher or alarm if needed. Both you and
your work area and you cant move either your the fire watcher should wait for a half hour after
work or the combustible substances, put a all welding is finished to find and put out any
fire-resistant shield in place. If youre welding smoldering fires that may have resulted from
above the ground or off a ladder, make sure your welding.
that there are no combustibles underneath.
Also, dont forget about your co-workers, and As with other emergencies that may result
everybody else who may be in the work area, as from welding accidents, the first rule is: dont
they probably wouldnt appreciate being hit with panic. Depending on the size of the fire, sound
slag or sparks from your work. the fire alarm to warn others and call the fire
department; shut off your welder; and get to
Particular care must be taken when welding or the fire exits as quickly as possible.
cutting in dusty locations. Fine dust particles
may readily oxidize (burn) and without warning
result in a flash fire or even an explosion when
exposed to the welding arc or even sparks.
Remove combustible materials and protect
yourself and the facility in which you are working
from possible fires or explosions. Always have
fire extinguishers readily available and follow hot
work practices.

8
 Safety Practices in Welding

WARNING! Cadmium fumes can be fatal even under brief

overexposures, with symptoms much like those
FUMES & GASES can be dangerous to your of metal fume fever. These two conditions should
health. not be confused. Overexposure to cadmium can
Keep fumes and gases from your breathing be enough to cause fatalities, with symptoms
zone and general area. appearing quickly, and, in some circumstances,
Keep your head out of the fumes. death a few days later.
Use enough ventilation or exhaust at the
arc, or both, to keep fumes and gases from Chromium, hexavalent chromium (Cr+6) and/or
your breathing zone and general area. nickel: Hexavalent chromium (Cr+6) is on
the IARC (International Agency for Research on
Cancer) and NTP (National Toxicology Program)
lists as posing a carcinogenic risk to humans.
Fumes from the use of stainless steel, hardfacing
and other types of consumables contain
chromium, Cr+6, and/or nickel. Some forms of
FUMES AND GASES these metals are known or suspected to cause
Because of the variables involved in fume and gas lung cancer in processes other than welding and
generation from arc welding, cutting and allied asthma has been reported. Therefore, it is
processes (such as the welding process and recommended that precautions be taken to keep
electrode, the base metal, coatings on the base exposures as low as possible. OSHA, in 2006,
metal, and other possible contaminants in the adopted a lower PEL (Permissible Exposure Limit)
air), well have to treat the subject in a rather for hexavalent chromium (see Supplement 3).
general way, lumping all but the more hazardous The use of local exhaust and/or an approved
situations together. The precautions we describe respirator may be required to avoid overexposure.
will hold true for all arc welding processes.
Coatings on the metal to be welded, such as
The fume plume contains solid particles from the paint, may also contain toxic substances, such as
consumables, base metal, and base metal coating. lead, chromium and zinc. In general, it is always
For common mild steel arc welding, depending best to remove coatings from the base metal
on the amount and length of exposure to these before welding or cutting.
fumes, most immediate or short term effects are
temporary, and include symptoms of burning Cobalt: Exposure to cobalt can cause respiratory
eyes and skin, dizziness, nausea, and fever. For disease and pulmonary sensitization. Cobalt
example, zinc fumes can cause metal fume fever, in metallic form has been reported to cause
a temporary illness that is similar to the flu. lung damage and is a listed IARC suspect
carcinogenic compound.
Long-term exposure to welding fumes can lead
to siderosis (iron deposits in the lungs) and may Copper: Prolonged exposure to copper fume may
affect pulmonary function. Bronchitis and some cause skin irritation or discoloration of the skin
lung fibrosis have been reported. and hair.

Most consumables contain certain compounds Manganese: Manganese overexposure may

in amounts which require ventilation and/or affect the central nervous system, resulting
exhaust while welding. If welding indoors, in poor coordination, difficulty in speaking,
use local exhaust. If welding outdoors, a and tremor of arms or legs. This condition is
respirator may be required. Consult an industrial considered irreversible.
hygienist to ensure that the weld fume exhaust
measures that you are taking properly protect Nickel: Nickel and its compounds are on the IARC
you. Various compounds, some of which may be (International Agency for Research on Cancer)
in welding fume, and reported health effects, in and NTP (National Toxicology Program) lists as
summary, are: posing a carcinogenic risk to humans.

Barium: Soluble barium compounds may cause Silica: Crystalline silica is present in respirable
severe stomach pain, slow pulse rate, irregular dust from submerged arc flux. Overexposure
heart beat, ringing of the ears, convulsions can cause severe lung damage (silicosis) and
and muscle spasms. In extreme cases can lung cancer.
cause death.
Zinc: Overexposure to zinc (from galvanized
Cadmium also requires extra precautions. This metals) may cause metal fume fever with
toxic metal can be found on some steel and symptoms similar to the common flu.
steel fasteners as a plating, or in silver solder.

9
Safety Practices in Welding

The gases that result from an arc welding There are also steps that you can take to
process also present potential hazard. Most of identify hazardous substances in your welding
the shielding gases (argon, helium, and carbon environment. First, read the product label and
dioxide) are non-toxic, but, as they are released, safety data sheet for the electrode posted in the
they displace oxygen in your breathing air, work place or in the electrode or flux container to
causing dizziness, unconsciousness, and death, see what fumes can be reasonably expected from
the longer your brain is denied the oxygen it use of the product and to determine if additional
needs. Carbon monoxide, ozone and nitrogen ventilation is needed. Secondly, know what the
dioxide can also be developed and may pose a base metal is, and determine if there is any paint,
hazard if excessive levels are present. plating, or coating that could expose you to toxic
fumes and/or gases. Remove it from the metal
The heat and UV radiation can cause irritation to being welded, if possible. If you start to feel
the eyes and lungs. Some degreasing compounds uncomfortable, dizzy or nauseous, there is a
such as trichlorethylene and perchlorethylene possibility that you are being overexposed to
can decompose from the heat and ultraviolet fumes and gases, or suffering from oxygen
radiation of an arc. Because of the chemical deficiency. Stop welding and get some fresh
breakdown of vapor-degreasing materials under air immediately. Notify your supervisor and
ultraviolet radiation, arc welding should not co-workers so the situation can be corrected
be done in the vicinity of a vapor-degreasing and other workers can avoid the hazard. Be
operation. Carbon-arc welding, gas tungsten-arc sure you are following these safe practices,
welding and gas metal arc welding should be the consumable labeling and SDS and improve
especially avoided in such areas, because they the ventilation in your area. Do not continue
emit more ultraviolet radiation than other welding until the situation has been corrected.
processes. Also, keep in mind that ozone and
nitrogen oxides are formed when UV radiation
passes through the air. These gases cause NOTE: The SDS for all Lincoln Electric
headaches, chest pains, irritation of the eyes, consumables is available on the website:
and an itchiness in the nose and throat. www.lincolnelectric.com

There is one easy way to reduce the risk of

exposure to hazardous fumes and gases: keep Before we turn to the methods available to
your head out of the fume plume! As obvious as control welding fume exposure, you should
this sounds, the failure to follow this advice is understand a few basic terms:
a common cause of fume and gas overexposure
because the concentration of fume and gases Natural Ventilation is the movement of air
is greatest in the plume. Keep fumes and gases through the workplace caused by natural forces.
from your breathing zone and general area using Outside, this is usually the wind. Inside, this
natural ventilation, mechanical ventilation, fixed may be the flow of air through open windows
or moveable exhaust hoods or local exhaust at and doors.
the arc. Finally, it may be necessary to wear an
approved respirator if adequate ventilation Mechanical Ventilation is the movement of
cannot be provided (see Ventilation section). air through the workplace caused by an electrical
device such as a portable fan or permanently
As a rule of thumb, for many mild steel electrode, mounted fan in the ceiling or wall.
if the air is visibly clear and you are comfortable,
then the ventilation is generally adequate for Source Extraction (Local Exhaust) is a
your work.The most accurate way to determine mechanical device used to capture welding
if the worker exposure does not exceed the fume at or near the arc and filter contaminants
applicable exposure limit for compounds in out of the air or otherwise remove them from
the fumes and gases is to have an industrial the work environment.
hygienist take and analyze a sample of the air
you are breathing. This is particularly important The ventilation or exhaust needed for your
if you are welding with stainless or hardfacing application depends upon many factors such as:
products. All Lincoln SDS have a Maximum Fume
Guideline number. If exposure to total fume is workspace volume
kept below that number, exposure to all fume workspace configuration
from the electrode (not coatings or plating on the number of welders
work) is estimated to be below the TLV. welding process and current
consumables used (mild steel, hardfacing,
stainless, etc.)
allowable levels (TLV, PEL, etc.)
material welded (including paint or plating)
natural airflow

10
 Safety Practices in Welding

Spaces that do not meet these requirements

Your work area has adequate ventilation when should be equipped with mechanical ventilating
there is enough ventilation and/or exhaust to equipment that exhausts at least 2000 cfm of
control worker exposure to hazardous materials air for each welder, except where local exhaust
in the welding fumes and gases so the hoods or booths, or air-line respirators are used.
applicable limits for those materials are not
exceeded. See Supplement 2 for the legal limits,
the OSHA PEL (Permissible Exposure Limit), and Important Safety Note:
the recommended guideline, the ACGIH TLV When welding with electrodes such as
(Threshold Limit Value), for many compounds stainless or hardfacing (see instructions on
found in welding fume. container or SDS) or on lead or cadmium
plated steel and other metals or coatings
which produce hazardous fumes, keep
exposure as low as possible and below
exposure limit values (PEL and TLV) for
materials in the fume using local exhaust
and/or mechanical ventilation. In confined
spaces or in some circumstances, for
example outdoors, a respirator is required
unless exposures have been confirmed to be
below the PEL or TLV. (See SDS and
Supplement 3 of this brochure.) Additional
precautions are also required when welding
on galvanized steel.

SOURCE EXTRACTION EQUIPMENT

Mechanical ventilation is an effective method
of fume control for many welding processes.
Because it captures fume near the arc or source
of the fume, which is more efficient in most
cases, local exhaust, also called source
extraction, is a very effective means to control
welding fume.
VENTILATION
There are many methods which can be selected Source extraction of welding fumes can be
by the user to provide adequate ventilation for provided by mobile or stationary, single or
the specific application. The following section multi-station, exhaust and/or filtration
provides general information which may be equipment designed with adjustable fume
helpful in evaluating what type of ventilation extraction arms nozzles or guns, by fixed
equipment may be suitable for your application. enclosures, booths or tables with extraction
When ventilation equipment is installed, you canopies also known as down-draft, or by
should confirm worker exposure is controlled back-draft or cross-draft tables/booths.
within applicable OSHA PEL and/or ACGIH TLV. Source extraction of weld fume falls into two
According to OSHA, when welding and cutting categories: low vacuum/high volume, or high
(mild steels), natural ventilation is usually vacuum/low volume.
considered sufficient to meet requirements,
provided that:

1. The room or welding area contains at least

10,000 cubic feet (about 22 x 22 x 22 ft.) for
each welder.
2. The ceiling height is not less than 16 feet.
3. Cross ventilation is not blocked by partitions,
equipment, or other structural barriers.
4. Welding is not done in a confined space.

11
Safety Practices in Welding

LOW VACUUM/HIGH VOLUME

Mobile or stationary, single or multi-station, large
centralized exhaust and/or filtration equipment
designed with adjustable fume extraction arms
are usually low vacuum/high volume systems.
When correctly positioned, the capture rate of
adjustable fume extraction arms is suitable for all
position welding and cutting. For more difficult
to reach work areas, flexible hose may be used in
place of adjustable fume extraction arms.

These arms generally move between 560 and 860

cubic feet per minute (CFM) (900 1400 m3/hr)
of air, but use low vacuum levels (3 to 5 inches
water gauge [750 1250 Pa]) to minimize power
requirements. Water gauge (WG) is a measure of
negative pressure: higher numbers mean more
negative pressure (more suction). With this
volume of airflow, the end of the arm can be
placed 6 to 15 inches (160 375 mm) away from
the arc and still effectively capture weld fume.

Fume extraction arms generally use a 6 or 8 inch

diameter hose, or hose and tubing combinations. Mobiflex 200-M low vacuum mobile fume
Arm lengths are typically 7, 10, or 13 feet (2, 3, or extraction unit.
4 m), with boom extensions available. The arms
may be wall mounted, attached to mobile units,
or incorporated into a centralized system. back or bottom of the work space rather than
above it to capture the weld fume. The weld fume
In general, the farther the extraction hose is from is extracted through the plenum and away from
the arc, the more volume of air movement is the breathing zone of the operator that is
required to effectively capture welding fume. welding or cutting. Down-draft or back-draft
Overhead hoods (canopies), for example, capture booths/tables can be mobile or stationary, single
most of the fume, but care must be taken to be or multi-station, exhaust and/or filtration
sure fume is not pulled through the breathing systems. They are particularly suitable for
zone of the operator. in-position bench welding or cutting jobs and can
be effective when small parts are being welded.
Fixed enclosures, booths or tables with extraction The airflow required for effectiveness varies
canopies also known as down-draft, back-draft depending upon the installation design, but may
or cross-draft booths/tables are a variation of be 1,000 CFM or higher.
overhead hood technology and can be used as
source extraction equipment. A booth is a fixed There are advantages and limitations
enclosure that consists of a top and at least two associated with low vacuum/high volume
sides that surround the welding operation. These source extraction systems.
systems use a plenum with openings to the side,

ADVANTAGES LIMITATIONS
Source extraction with large volume of air being extracted from welder If not using filtration unit, exhausting air to outside requires make-up air
breathing zone. systems and make-up heaters (i.e. large volumes of displaced air need to
be replaced, resulting in increased utility costs).

Auto-stop delay assists with removal of residual fumes. Welder must stop to reposition arm over weld area(s).

Low noise level. Filtration systems larger due to volume of air flow.

Flexible arm for repositioning. Depending on design, ductwork can be large.

Low installation costs (ductwork).

Low energy consumption (small fan unit with low rpm).

Adjustable arms suitable for all-position welding.

12
 Safety Practices in Welding

HIGH VACUUM/LOW VOLUME

High vacuum/low volume fume extraction
systems are designed for close proximity (2 to
4 inches) positioning. High vacuum/low volume
weld fume extraction is achieved with lower
airflow rates than those encountered when
utilizing low vacuum/high volume systems.
There are two methods of high vacuum
extraction: welding guns with built-in
extraction (fume extraction guns), or separate
suction nozzles of various designs.

Fume extraction guns use fume capture

nozzles built into the gun tube and handle.
The extraction airflow is approximately 35 to
60 CFM (60 100 m3/hr) for integrated fume
extraction guns. Therefore, no repositioning is
required, since the suction automatically follows
the arc. The vacuum level is high (40 to 70 inches
WG [9.96 X 103 to 1.74 X 104 Pascal]) permitting
the use of hose featuring longer lengths (10 to 25
feet) and smaller diameters (1.25 to 1.75 inches).
Fume extraction gun designs have been improved
to be more ergonomic and user friendly. Miniflex high vacuum portable fume extraction unit.
Depending upon the type of welding, particularly
in position welding, extraction guns may be a Fume extraction is only one component in
good solution. reducing welding fume. Users should also
consider the selection of the welding process,
Suction nozzles are positioned near the weld, welding procedure, or consumable. Many times
and commonly use capture distances of less than a combination of fume extraction, training,
four inches. Depending upon the design, airflow process change, and/or consumable change is
of suction nozzles is typically between 80 to 100 needed to reduce the amount of fume to accept-
CFM (135 170 m3/hr). Suction nozzles must be able levels. Solutions to a particular application
kept near the arc to be used effectively. may involve one or all of these factors and the
user must determine which solution best fits
The capture rate for fume extraction guns their application.
or nozzles is highest when used in flat and
horizontal welding positions. High vacuum OSHA regulations include specific requirements
equipment ranges from small, portable, mobile for exhaust systems which should be reviewed
units to stationary, single or multi-station, large when selecting fume extraction systems (see
centralized filtration systems. Supplement 2).

There are advantages and limitations

associated with high vacuum/low volume
source extraction systems.

ADVANTAGES LIMITATIONS
When using a fume extraction gun, welder does not need to stop and Required when using a suction nozzle. Welder may need to stop to repo-
reposition extraction device. sition extraction device.

Low volume of air is displaced-results in energy efficiency and conser- High noise level due to increased air velocity and high motor rpm of the
vation fan unit.

Ductwork smaller in diameter (3 to 10 inches) vs. low vacuum Possible removal of shielding gases affecting weld integrity if nozzle or
systems. gun placed too close to source.

Low obstruction of welder vision. Greater energy consumption (large fan unit with high rpm).

Suitable for heavier particulate (ie. grinding dust). Residual fumes not extracted.

Suitable option for confined, difficult to reach work spaces. Less effective in out-of-position welding.

Smaller filter systems due to less volume of airflow.

13
Safety Practices in Welding
EXHAUST VS. FILTRATION WORKING IN CONFINED SPACES
Source extraction exhaust equipment captures When arc welding in a confined area, such as a
and extracts weld fumes from the source and boiler, tank, or the hold of a ship, bear in mind
exhausts the fumes to the outside atmosphere. that all the hazards associated with normal
This technique removes welding fume from arc welding are amplified, so the precautions
the breathing zone of the welder but can also mentioned here are even more important. This
displace large volumes of conditioned air which subject is very complicated and only these
may lead to increased utility and heating costs. precautions related to arc welding will be
discussed in this brochure. Per OSHA document
Source extraction filtration equipment captures 29 CFR 1910.146, a particular area is considered
and extracts weld fumes from the source and a confined space if it:
filters the fumes by passing them through a
cellulose and/or polyester filter cartridge or 1) Is large enough and so configured that an
electrostatic filter. Depending on the weld employee can bodily enter and perform
application, environment, federal or local assigned work; and
regulations, and filtration efficiency levels, 2) Has limited or restricted means for entry or
filtered air may be re-circulated back into the exit (for example, tanks, vessels, silos, storage
facility or exhausted to the outside atmosphere. bins, hoppers, vaults, and pits are spaces that
By re-circulating filtered air back into the work may have limited means of entry.); and
environment compared to exhausting to the 3) Is not designed for continuous employee
outside, source extraction filtration equipment occupancy.
can be more economical to operate. Particularly
in winter months, substantially lower heating There is a greater danger that enough flammable
costs may be recognized, as less replacement air gases may be present in the confined space to
is required with filtration versus exhaust systems. cause an explosion. The metal of the enclosure
Of course, filtration systems do not remove the can become part of the welding circuit, so any
gases generated during welding. Therefore, metal you touch (the walls, floor, ceiling)
assessments should be conducted to ensure is electrically hot. Welding fumes can
these gases do not accumulate in the work area accumulate more rapidly, with a higher
at concentrations that may exceed applicable concentration; gases can force out the
exposure limits. breathable air, suffocating you in the process.

Using a cellulose or polyester filter cartridge or Per OSHA document 29 CFR 1910.146(d)(5)(iii);
electrostatic filter will depend upon the weld after an area has been deemed a confined space,
application. Electrostatic filters may also be used the existence of the following atmospheric
however, they lose efficiency if they are not hazards are to be determined:
frequently washed.
1) Test for oxygen
Regardless of the type of mechanical ventilation 2) Test for combustible gases and vapors
(exhaust or filtration) source extraction system 3) Test for toxic gases and vapors
used, the important factor is that it is a tool
designed to control exposure to welding fume The workplace and OSHA rules regarding
and its constituents. All forms of mechanical confined spaces must be followed. Make sure that
ventilation or source extraction equipment your body is insulated from the work-piece using
require routine maintenance. In addition, when dry insulation. Wear dry gloves and only use a
using weld fume source extraction equipment, well-insulated electrode holder. Semiautomatic
sparks from welding, cutting or grinding constant voltage welders with cold electrode or
processes can cause fire within the equipment. stick welders equipped with a device to lower
To control this potential fire hazard, operation, the no-load voltage are recommended, especially
service and maintenance instructions for source when the work area is wet. Make sure that there
extraction equipment should be followed. is adequate ventilation and exhaust (a respirator
or an air-supplied respirator may be necessary
depending on the application), and that there are
Note: no flammable coatings, liquids or gases nearby.
It is the equipment owner and operators
responsibility to comply with Occupational Lastly, you must have someone outside the
Safety, Health Administration (OSHA) enclosure trained to handle emergencies, with
Permissable Exposure Limits (PELs) or rescue procedures and a means to disconnect
American Conference of Governments power to your equipment and pull you out if
Industrial Hygienists (ACGIH) TLVs for danger arises. We cannot stress this strongly
welding fume. It is the responsibility of enough: however experienced you are, do not
the equipment owner to research, test and attempt work of this nature without constant
comply with regulations which may apply communication with the person outside the
to filtered air recirculated inside the facility confined area. When welding within a confined
or unfiltered air exhausted outside of area, problems which arise can immediately
the facility. become very serious and, in some cases,
life-threatening. It is for that reason that OSHA
regulations and workplace procedures for
confined space work must be followed.

14
 Supplement 1

GUIDE FOR SHADE NUMBERS

ELECTRODE SIZE MINIMUM SUGGESTED (1) SHADE

OPERATION 1/32 in. (mm) ARC CURRENT (A) PROTECTIVE SHADE NO. (COMFORT)
Shielded metal arc welding Less than 3 (2.5) Less than 60 7
3-5 (2.4-4) 60-160 8 10
5-8 (4-6.4) 160-250 10 12
More than 8 (6.4) 250-550 11 14

Gas metal arc welding and Less than 60 7

flux-cored arc welding 60-160 10 11
160-250 10 12
250-500 10 14

Gas tungsten arc welding Less than 50 8 10

50-150 8 12
150-500 10 14

Air carbon arc cutting (Light) Less than 500 10 12

(Heavy) 500-1000 11 14

Plasma arc welding Less than 20 6 6 to 8

20-100 8 10
100-400 10 12
400-800 11 14

Plasma arc cutting (Light) (2) Less than 300 8 9

(Medium) (2) 300-400 9 12
(Heavy) (2) 400-800 10 14

Torch brazing 3 or 4

Torch soldering 2

Carbon arc welding 14

PLATE THICKNESS
in. mm
Gas welding
Light Under 1/8 Under 3.2 4 or 5
Medium 1/8 to 1/2 3.2 to 12.7 5 or 6
Heavy Over 1/2 Over 12.7 6 or 8

Oxygen cutting
Light Under 1 Under 25 3 or 4
Medium 1 to 6 25 to 150 4 or 5
Heavy Over 6 Over 150 5 or 6

(1) As a rule of thumb, start with a shade that is too dark, then go to a lighter shade which gives
sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding or cutting
where the torch produces a high yellow light, it is desirable to use a filter lens that absorbs the
yellow or sodium line the visible light of the (spectrum) operation.

(2) These values apply where the actual arc is clearly seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.

Data from ANSI Z49.1-1999

15
Supplement 2

BIBLIOGRAPHY AND SUGGESTED READING

ANSI Z87.1, Practice for Occupational and Educational Eye and Face Protection,
American National Standards Institute, 11 West 42nd Street, New York,
NY 10036.

Arc Welding and Your Health: A Handbook of Health Information for Welding.
Published by The American Industrial Hygiene Association, 2700 Prosperity
Avenue, Suite 250, Fairfax, VA 22031-4319.

NFPA Standard 51B, Cutting and Welding Processes, National Fire Protection
Association, 1 Batterymarch Park, P.O. Box 9146, Quincy, MA 02269-9959.

OSHA General Industry Standard 29 CFR 1910 Subpart Q. OSHA Hazard

Communication Standard 29 CFR 1910.1200. Available from the Occupational
Safety and Health Administration at http://www.osha.org or contact your local
OSHA office.

The following publications are published by The American Welding Society,

P.O. Box 351040, Miami, Florida 33135. AWS publications may be purchased
from the American Welding society at http://www.aws.org or by contacting the
AWS at 800-854-7149.

ANSI, Standard Z49.1, Safety in Welding, Cutting and Allied Processes. Z49.1
is now available for download at no charge at http://www.lincolnelectric.com/
safety/ or at the AWS website http://www.aws.org.

AWS F1.1, Method for Sampling Airborne Particulates Generated by Welding

and Allied Processes.

AWS F1.2, Laboratory Method for Measuring Fume Generation Rates and Total
Fume Emission of Welding and Allied Processes.

AWSF1.3, Evaluating Contaminants in the Welding Environment: A Strategic

Sampling Guide.

AWS F1.5, Methods for Sampling and Analyzing Gases from Welding and
Allied Processes.

AWS F3.2, Ventilation Guide for Welding Fume Control.

AWS F4.1, Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers and Piping That Have Held Hazardous Substances.

AWSSHF, Safety and Health Facts Sheets. Available free of charge from the
AWS website at http://www.aws.org.

16
 Supplement 3

LISTED BELOW ARE SOME TYPICAL INGREDIENTS IN WELDING ELECTRODES AND

THEIR TLV (ACGIH) GUIDELINES AND PEL (OSHA) EXPOSURE LIMITS

INGREDIENTS CAS No. TLV mg/m3 PEL mg/m3

Aluminum and/or aluminum alloys (as Al)***** 7429-90-5 1 15

Aluminum oxide and/or Bauxite***** 1344-28-1 1 5**

Barium compounds (as Ba)***** 513-77-9 **** ****

Chromium and chromium alloys or compounds (as Cr)***** 7440-47-3 0.5(b) 0.5(b)

Cr + 6 (hexavalent chromium) 18540-29-9 0.05 0.005

Cobalt 7440-48-4 0.02 0.1

Flourides (as F) 7789-75-5 2.5 2.5

Iron 7439-89-6 5* 5*

Limestone and/or calcium carbonate 1317-65-3 10 15

Lithium compounds (as Li) 554-13-2 10* 10*

Magnesite 1309-48-4 10 15

Magnesium and/or magnesium alloys and compounds (as Mg) 7439-95-4 10* 10*

Manganese and/or manganese alloys and compounds (as Mc)***** 7439-96-5 0.02** 5.0(c)

Mineral silicates 1332-58-7 5** 5**

Molybdenum alloys (as Mo) 7439-98-7 10 10

Nickel***** 7440-02-0 0.1 1

Silicates and other binders 1344-09-8 10* 10*

Silicon and/or silicon alloys and compounds (as Si) 7440-21-3 10* 10*

Strontium compounds (as Sr) 1633-05-2 10* 10*

Zirconium alloys and compounds (as Zr) 12004-83-0 5 5

Supplemental Information:
(*) Not listed. Nuisance value maximum is 10 milligrams per cubic meter. PEL value for
iron oxide is 10 milligrams per cubic meter. TLV value for iron oxide is 5 milligrams
per cubic meter.

(**) As respirable dust.

(*****) Subject to the reporting requirements of Sections 311, 312, and 313 of the
Emergency Planning and Community Right-to-Know Act of 1986 and of 40CFR 370
and 372.

(b) The PEL for chromium (VI) is 0.005 milligrams per cubic meter as an 8 hour time weighted
average. The TLV for water-soluble chromium (VI) is 0.05 milligrams per cubic meter. The
TLV for insoluble chromium (VI) is 0.01 milligrams per cubic meter.

(c) Values are for manganese fume. STEL (Short Term Exposure Limit) is 3.0
milligrams per cubic meter. PEL of 1.0 milligrams per cubic meter proposed by OSHA
in 1989. Present PEL is 5.0 milligrams per cubic meter (ceiling value).

(****) There is no listed value for insoluble barium compounds. The TLV for soluble barium
compounds is 0.5 mg/m3.

TLV and PEL values are as of February 2016. Always check Safety Data Sheet (SDS) with product or on
the Lincoln Electric website at http://www.lincolnelectric.com

17
Supplement 4

SECTION A: 1.d. Keep all equipment safety guards, covers and

devices in position and in good repair. Keep

WARNINGS
hands, hair, clothing and tools away from
V-belts, gears, fans and all other moving
parts when starting, operating or repairing
CALIFORNIA PROPOSITION 65 WARNINGS equipment.

Diesel Engines 1.e. In some cases it may be necessary to remove safety guards
to perform required maintenance. Remove guards only when
Diesel engine exhaust and some of its constituents are known necessary and replace them when the maintenance requiring
to the State of California to cause cancer, birth defects, and other their removal is complete. Always use the greatest care when
reproductive harm. working near moving parts.
Gasoline Engines 1.f. Do not put your hands near the engine fan. Do not attempt to
The engine exhaust from this product contains chemicals known override the governor or idler by pushing on the throttle control
to the State of California to cause cancer, birth defects, or other rods while the engine is running.
reproductive harm.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap ormagneto wire
ARC WELDING CAN BE HAZARDOUS. PROTECT as appropriate.
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
1.h. To avoid scalding, do not remove the radiator
INJURY OR DEATH. KEEP CHILDREN AWAY.
pressure cap when the engine is hot.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional
safety information, it is strongly recommended that you purchase a
copy of Safety in Welding & Cutting - ANSI Standard Z49.1 from the
American Welding Society, P.O. Box 351040, Miami, Florida 33135
or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety
ELECTRIC AND
booklet E205 is available from the Lincoln Electric Company, 22801 MAGNETIC FIELDS MAY
St. Clair Avenue, Cleveland, Ohio 44117-1199. BE DANGEROUS.
BE SURE THAT ALL INSTALLATION, OPERATION,
2.a. Electric current flowing through any conductor
MAINTENANCE AND REPAIR PROCEDURES ARE causes localized Electric and Magnetic Fields
PERFORMED ONLY BY QUALIFIED INDIVIDUALS. (EMF). Welding current creates EMF fields around welding cables
and welding machines.

2.b. EMF fields may interfere with some pacemakers, and welders
having a pacemaker should consult their physician before
welding.
FOR ENGINE POWERED
EQUIPMENT. 2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the 2.d. All welders should use the following procedures in order to
maintenance work requires it to be running. minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
1.b. Operate engines in open, well-ventilated them with tape when possible.
areas or vent the engine exhaust fumes outdoors.
2.d.2. Never coil the electrode lead around your body.
1.c. Do not add the fuel near an open flame 2.d.3. Do not place your body between the electrode and work
welding arc or when the engine is running. cables. If the electrode cable is on your right side, the
Stop the engine and allow it to cool before work cable should also be on your right side.
refueling to prevent spilled fuel from 2.d.4. Connect the work cable to the workpiece as close as
vaporizing on contact with hot engine parts possible to the area being welded.
and igniting. Do not spill fuel when filling tank.
2.d.5. Do not work next to welding power source.
If fuel is spilled, wipe it up and do not start engine until fumes
have been eliminated.

18
 Supplement 4

ELECTRIC SHOCK ARC RAYS CAN BURN.

CAN KILL.
3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover
electrically hot when the welder is on. Do plates to protect your eyes from sparks and the rays of the arc
not touch these hot parts with your bare skin when welding or observing open arc welding. Headshield and
or wet clothing. Wear dry, hole-free gloves to insulate hands. filter lens should conform to ANSI Z87. I standards.

3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant material
Make certain the insulation is large enough to cover your full area to protect your skin and that of your helpers from the arc rays.
of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if screening and/or warn them not to watch the arc nor expose
welding must be performed under electrically themselves to the arc rays or to hot spatter or metal.
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such
as floors, gratings or scaffolds; when in cramped FUMES AND GASES
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
CAN BE DANGEROUS.
with the workpiece or ground) use the following 5.a. Welding may produce fumes and gases
equipment: hazardous to health. Avoid breathing these
Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep your head out of the
DC Manual (Stick) Welder. fume. Use enough ventilation and/or exhaust at the arc to
keep fumes and gases away from the breathing zone. When
AC Welder with Reduced Voltage Control.
welding hardfacing (see instructions on container
3.c. In semiautomatic or automatic wire welding, the electrode, or SDS) or on lead or cadmium plated steel and
electrode reel, welding head, nozzle or semiautomatic welding other metals or coatings which produce highly
gun are also electrically hot. toxic fumes, keep exposure as low as possible
and within applicable OSHA PEL and ACGIH TLV
3.d. Always be sure the work cable makes a good electrical limits using local exhaust or mechanical ventilation
connection with the metal being welded. The connection should unless exposure assessments indicate otherwise.
be as close as possible to the area being welded. In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
3.e. Ground the work or metal to be welded to a good electrical (earth)
Additional precautions are also required when
ground.
welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
5. b. The operation of welding fume control equipment is affected
welding machine in good, safe operating condition. Replace
by various factors including proper use and positioning of the
damaged insulation.
equipment, maintenance of the equipment and the specific
3.g. Never dip the electrode in water for cooling. welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
3.h. Never simultaneously touch electrically hot parts of electrode thereafter to be certain it is within applicable OSHA PEL and
holders connected to two welders because voltage between the ACGIH TLV limits.
two can be the total of the open circuit voltage of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
3.i. When working above floor level, use a safety belt to protect coming from degreasing, cleaning or spraying operations. The
yourself from a fall should you get a shock. heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and cause
injury or death. Always use enough ventilation, especially in confined
areas, to insure breathing air is safe.

5.e. Read and understand the manufacturers instructions for this

equipment and the consumables to be used, including the Safety
Data Sheet (SDS) and follow your employers safety practices.
SDS forms are available from your welding distributor or from the
manufacturer.

5.f. Also see item 1.b.

19
Supplement 4

WELDING AND CUTTING CYLINDER MAY EXPLODE IF

SPARKS CAN CAUSE DAMAGED.
FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing
6.a. Remove fire hazards from the welding area. the correct shielding gas for the process used
If this is not possible, cover them to prevent and properly operating regulators designed for
the welding sparks from starting a fire. Remember that welding the gas and pressure used. All hoses, fittings,
sparks and hot materials from welding can easily go through etc. should be suitable for the application and
small cracks and openings to adjacent areas. Avoid welding near maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely chained to
6.b. Where compressed gases are to be used at the job site, special an undercarriage or fixed support.
precautions should be used to prevent hazardous situations. Refer 7.c. Cylinders should be located:
to Safety in Welding and Cutting (ANSI Standard Z49.1) and the
operating information for the equipment being used. Away from areas where they may be struck or subjected
to physical damage.
6.c. When not welding, make certain no part of the electrode circuit
is touching the work or ground. Accidental contact can cause A safe distance from arc welding or cutting operations
overheating and create a fire hazard. and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the electrically hot parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances 7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have when opening the cylinder valve.
been cleaned. For information, purchase Recommended
Safe Practices for the Preparation for Welding and Cutting of 7.f. Valve protection caps should always be in place and hand tight
Containers and Piping That Have Held Hazardous Substances, except when the cylinder is in use or connected for use.
AWS F4.1 from the American Welding Society (see address
7.g. Read and follow the instructions on compressed gas cylinders,
above).
associated equipment, and CGA publication P-l, Precautions for
6.e. Vent hollow castings or containers before heating, cutting or Safe Handling of Compressed Gases in Cylinders, available from
welding. They may explode. the Compressed Gas Association 1235 Jefferson Davis Highway,
Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
FOR ELECTRICALLY
6.g. Connect the work cable to the work as close to the welding area POWERED EQUIPMENT.
as practical. Work cables connected to the building framework
or other locations away from the welding area increase the 8.a. Turn off input power using the disconnect
possibility of the welding current passing through lifting chains, switch at the fuse box before working on the
crane cables or other alternate circuits. This can create fire equipment.
hazards or overheat lifting chains or cables until they fail.
8.b. Install equipment in accordance with the U.S. National Electrical
6.h. Also see item 1.c. Code, all local codes and the manufacturers recommendations.

6.I. Read and follow NFPA 51B Standard for Fire Prevention During 8.c. Ground the equipment in accordance with the U.S. National
Welding, Cutting and Other Hot Work, available from NFPA, 1 Electrical Code and the manufacturers recommendations.
Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/
safety for additional safety information.

20
 Supplement 4

PRCAUTIONS DE SRET pantalons sans revers, et chaussures montantes.

Pour votre propre protection lire et observer toutes les

instructions et les prcautions de sret specifiques qui 5. Toujours porter des lunettes de scurit dans la zone de
parraissent dans ce manuel aussi bien que les prcautions de soudage. Utiliser des lunettes avec crans lateraux dans
sret gnrales suivantes: les zones o lon pique le laitier.

Sret Pour Soudage A LArc 6. Eloigner les matriaux inflammables ou les recouvrir afin de
1. Protegez-vous contre la secousse lectrique: prvenir tout risque dincendie d aux tincelles.

a. Les circuits llectrode et la pice sont sous tension 7. Quand on ne soude pas, poser la pince une endroit isol
quand la machine souder est en marche. Eviter de la masse. Un court-circuit accidental peut provoquer un
toujours tout contact entre les parties sous tension et la chauffement et un risque dincendie.
peau nue ou les vtements mouills. Porter des gants
secs et sans trous pour isoler les mains. 8. Sassurer que la masse est connecte le plus prs
b. Faire trs attention de bien sisoler de la masse possible de la zone de travail quil est pratique de le faire.
quand on soude dans des endroits humides, ou sur Si on place la masse sur la charpente de la construction
un plancher metallique ou des grilles metalliques, ou dautres endroits loigns de la zone de travail, on
principalement dans les positions assis ou couch augmente le risque de voir passer le courant de soudage
pour lesquelles une grande partie du corps peut tre en par les chaines de levage, cbles de grue, ou autres
contact avec la masse. circuits. Cela peut provoquer des risques dincendie ou
c. Maintenir le porte-lectrode, la pince de masse, le cble dechauffement des chaines et des cbles jusqu ce quils
de soudage et la machine souder en bon et sr tat se rompent.
defonctionnement.
d.Ne jamais plonger le porte-lectrode dans leau pour le 9. Assurer une ventilation suffisante dans la zone de soudage.
refroidir. Ceci est particulirement important pour le soudage de
e. Ne jamais toucher simultanment les parties sous tles galvanises plombes, ou cadmies ou tout autre
tension des porte-lectrodes connects deux mtal qui produit des fumes toxiques.
machines souder parce que la tension entre les deux
pinces peut tre le total de la tension vide des deux 10. Ne pas souder en prsence de vapeurs de chlore provenant
machines. doprations de dgraissage, nettoyage ou pistolage.
f. Si on utilise la machine souder comme une source La chaleur ou les rayons de larc peuvent ragir avec
de courant pour soudage semi-automatique, ces les vapeurs du solvant pour produire du phosgne (gas
precautions pour le porte-lectrode sapplicuent aussi fortement toxique) ou autres produits irritants.
au pistolet de soudage.
11. Pour obtenir de plus amples renseignements sur la sret,
2. Dans le cas de travail au dessus du niveau du sol, se voir le code Code for safety in welding and cutting CSA
protger contre les chutes dans le cas ou on recoit un Standard W 117.2-1974.
choc. Ne jamais enrouler le cble-lectrode autour de
nimporte quelle partie du corps.

3. Un coup darc peut tre plus svre quun coup de PRCAUTIONS DE SRET POUR
soliel, donc:
LES MACHINES SOUDER
a. Utiliser un bon masque avec un verre filtrant appropri TRANSFORMATEUR ET
ainsi quun verre blanc afin de se protger les yeux
du rayonnement de larc et des projections quand on REDRESSEUR
soude ou quand on regarde larc.
b. Porter des vtements convenables afin de protger la
peau de soudeur et des aides contre le rayonnement de 1. Relier la terre le chassis du poste conformement au
larc. code de llectricit et aux recommendations du fabricant.
c. Protger lautre personnel travaillant proximit Le dispositif de montage ou la piece souder doit tre
au soudage laide dcrans appropris et non- branch une bonne mise la terre.
inflammables.
2. Autant que possible, Iinstallation et lentretien du poste
4. Des gouttes de laitier en fusion sont mises de larc de seront effectus par un lectricien qualifi.
soudage. Se protger avec des vtements de protection
libres de lhuile, tels que les gants en cuir, chemise paisse, 3. Avant de faires des travaux linterieur de poste, la
debrancher linterrupteur la boite de fusibles.

21
Supplement 5

WARNING LABEL/OPERATING MANUAL

REQUEST FORM

NOTE: M16196 WARNING LABELS, FOR LINCOLN

ELECTRIC WELDERS, ARE AVAILABLE FREE OF
CHARGE to update your welding equipment.
Operating manuals are also available upon
request. PLEASE contact The Lincoln Electric
Company at www.lincolnelectric.com and
make the request online.

Supplement 6 Fan Shroud

Attached to Radiator

ENGINE WELDER FAN GUARDS

In order to determine whether your engine
welder has the proper fan guards, compare your
welder with the photo. If your welder lacks
the guards shown, contact your nearest Lincoln
Field Service Shop or Distributor for assistance.

Keep all equipment safety guards, covers and

devices in position and in good repair. Keep hands,
hair, clothing and tools away from V-belts, gears,
fans and all other moving parts when starting,
operating or repairing equipment.

In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them
when the maintenance requiring their removal
is complete. Always use the greatest care when
working near moving parts.

Do not put your hands near the engine fan. Do

not attempt to override the governor or idler by
pushing on the throttle control rods while the
engine is running. Doors One Each Side Typical Fan Guard One Mounted
On Each Side of Radiator

22
Supplement 7

WELDING SAFETY CHECKLIST

HAZARD FACTORS TO CONSIDER PRECAUTION SUMMARY

Electric shock can kill Wetness Insulate welder from workpiece and ground using dry insulation. Rubber
Welder in or on workpiece mat or dry wood.
Confined space Wear dry, hole-free gloves. (Change as necessary to keep dry.)
Electrode holder and cable insulation Do not touch electrically hot parts or electrode with bare skin or
wet clothing.
If wet area and welder cannot be insulated from workpiece with dry
insulation, use a semiautomatic, constant voltage welder or stick welder
with voltage reducing device.
Keep electrode holder and cable insulation in good condition. Do not use if insula-
tion is damaged or missing.

Fumes and gases can be dangerous Confined area Use ventilation or exhaust to keep air breathing zone clear, comfortable.
Positioning of welders head Use helmet and positioning of head to minimize fume in breathing zone.
Lack of general ventilation Read warnings on electrode container and Safety Data Sheet (SDS)
Electrode types, i.e., manganese, for electrode.
chromium, etc. See SDS Provide additional ventilation/exhaust where necessary to maintain exposures
Base metal coatings, galvanize, paint below applicable limits.
Use special care when welding in a confined area.
Do not weld unless ventilation is adequate.

Welding sparks can cause fire or explosion Containers which have held Do not weld on containers which have held combustible materials (unless strict
combustibles AWS F4.1 procedures are followed). Check before welding.
Flammable materials Remove flammable materials from welding area or shield from sparks, heat.
Keep a fire watch in area during and after welding.
Keep a fire extinguisher in the welding area.
Wear fire retardant clothing and hat. Use earplugs when welding ovehead.

Arc rays can burn eyes and skin Process: gas-shielded arc most Select a filter lens which is comfortable for you while welding.
severe Always use helmet when welding.
Provide non-flammable shielding to protect others.
Wear clothing which protects skin while welding.

Confined space Metal enclosure Carefully evaluate adequacy of ventilation especially where gas may displace
Wetness breathing air.
Restricted entry If basic electric shock precautions cannot be followed to insulate welder from work
Heavier than air gas and electrode, use semiautomatic, constant voltage equipment with cold electrode
Welder inside or on workpiece or stick welder with voltage reducing device.
Provide welder helper and method of welder retrieval from outside enclosure.

General work area hazards Cluttered area Keep cables, materials, tools neatly organized.

Indirect work (welding ground) Connect work cable as close as possible to area where welding is being
connection performed. Do not allow alternate circuits through scaffold cables, hoist chains,
ground leads.

Electrical equipment Use only double insulated or properly grounded equipment.

Always disconnect power to equipment before servicing.

Engine-driven equipment Use in only open, well ventilated areas.

Keep enclosure complete and guards in place.
See Lincoln Electric Service Shop if guards are missing.
Refuel with engine off.
Is using auxiliary power, OSHA may require GFI protection or assured
grounding program (or isolated windings if less than 5kW).

Gas cylinders Never touch cylinder with the electrode.

Never lift a machine with cylinder attached.
Keep cylinder upright and chained to support.

23
 THE LINCOLN ELECTRIC COMPANY
Publication E205 | Issue Date 02/16 22801 Saint Clair Avenue Cleveland, OH 44117 U.S.A.
Lincoln Global Inc. All Rights Reserved Phone: +1 216.481.8100 www.lincolnelectric.com