F&AE 8Safety&Health PDF

4.
8 Safety and Health

4.8 Safety and Health
4.8.1 Protection from heat, light, flying objects, and fumes

4.8.2 Protection from fumes and harmful gasses
4.8.3 Electric shock
4.8.4 Explosion and fire
4.8.5 General safety and health
4.8.1 Protection from heat, light, flying objects,
and fume
Welding arcs and gas flames radiate a great amount of heat
(infrared rays) and light (visible as well as ultraviolet rays).
High voltage electron beam welding radiates X-rays. Arc welding

scatters hot spatter, and gas cutting scatters hot slag.
Accordingly, operators must protect their eyes and skin from heat,
light, flying spatter, and slag.
(1) Eye and face protection
Very strong visible light due to welding can cause temporarily
blindness and ophthalmia. Ultraviolet rays can cause temporary but
serious and painful ophthalmia and burns on the skin. Infrared
radiation for a short time does little harm, but long time can cause
an incurable reduction in eyesight.
When welding or cutting using an arc, welding helmets or hand-

shields (prescribed in JIS T 8142:2003) containing appropriate filter
plates and cover plates must be used. When welding or cutting
using a gas flame, safety goggles with a filter lens (as prescribed in
JIS T 8141:2003) must be worn by operators. *JIS T 8142:2003
Personal face protectors for welding *JIS T 8141:2003 Personal eye
protections for optical radiations
Suitable filter plates and lenses must be selected and used depending
on the work conditions as shown in Table 4.22.
If a suitable shade number is more than 10, two plates of smaller

shade numbers can be combined. When two filter plates (shade
number n1 and n2) are combined, the total shade number will be
n1+n2 -1. For example, if two filter plates with shade numbers 7 and 4
are used, the total shade number used will be 10.] Welding arc lights
may be strong and potentially dangerous over a wide area. The use of
protective screens around a welding space may be necessary.
(2) Body protection

For protection from radiation and heat burns (due to spatter and
slag), leather gloves (JIS T 8113), sleeves, leggings, shoes, etc., of
durable material must be worn. These protective articles are also
effective against electric shock. *JIS T 8113:1976 Protective leather
gloves for welders
4.8.2 Protection from fumes and harmful gasses
Welding fumes and gasses are generated in varying degrees from different
welding operations and arc with a product of vaporization, oxidization, and
condensation of components in the consumables and, to a degree, the base
metal. The amount of welding fumes can be measured by methods prescribed in
JIS Z 3930:2001. Table 4.23 shows an example of data from various arc welding
methods. *JIS Z 3930:2001 Determination of emission rate of particulate fume in
arc welding.
The effects of welding fumes on the human body differ depending upon
their composition. JIS Z 3920:1991 (Methods for chemical analysis of
elements in welding fumes) prescribes procedures of chemical analysis.
When welding is performed with a zinc or cadmium-coated material or

with heavy metals such as a copper alloy, harmful fumes caused by the
vaporization of these heavy metals are produced.
Therefore, welding or cutting should be performed after removal of any

heavy metal coating or plating.
Also, preparation of a rest space and cleaning of the work space are
necessary. Every welder and related worker must also have a periodic
pneumoconiosis check.
Fumes from low hydrogen-type electrodes contain fluorides which
sometimes cause toxic symptoms such as fever.
When a welder or other workers are exposed to welding fumes over a

period of many years, there is a danger of pneumoconiosis even if acute
toxic symptoms do not appear.
Accordingly, regulations to prevent pneumoconiosis specify that arc

welding, cutting, or gouging in a narrow space such as workshop, pit, tank,
ship, pipe, rolling stock, etc. should be performed with total or local
ventilation systems or with an air-ventilated helmet.
Also, preparation of a rest space and cleaning of the work space are
necessary. Every welder and related worker must also have a periodic
pneumoconiosis check.
Fume density can be reduced by ventilation. The effects of ventilation
are confirmed and evaluated by JIS Z 3950:2005(Methods of
measurement for airborne dust concentration in welding environment).
Filter type respirators are widely used for protection from fumes. JIS T
8151:1991 (Dust respirators) prescribes requirements as shown in Table
4.24.
After using a respirator for a few hours, respiration resistance increases

and the filter should be changed.
When certain fume generating machines are used, such as a thermal
sprayer, a fume collecting system should be established. As a volume of
treated air decreases with time, filters should be changed regularly. The
notice from the Ministry of Labor prescribes guidelines as shown in Table
4.25
(1)Electric shock caused during welding
Shock severity will depend on the amount of current, the duration of
flow, the path of flow, and the physical condition of the victim.
The amount of current depends upon the applied voltage and the
resistance of the body path. When AC current and DC current of same
voltage are compared, DC current is more dangerous when considering
electric shock.
Even a very light electric shock can cause a person to fall from a high
location with fatal results.
(1)Electric shock caused during welding
In the case of arc welding, the no-load voltage of the welding power
source must be maintained at a certain level to maintain arc stability.
Although JIS C 9300:1999 (Arc welding power source) prescribes the
upper limit of a no-load voltage as 85-95 V, these voltages can still
cause a serious electric shock.
Electric resistance is usually reduced in the presence of water or

other moisture. When arc welding or cutting is to be done under
damp or wet conditions (including heavy perspiration), the welder
must wear dry gloves and clothing in good condition to prevent
electric shock.
(2) Protection from electric shock
1) Use of an insulated electrode holder Electrode holders shall be insulated
with heat resistant materials according to JIS C 9302:1999 (Welding electrode
holders for arc welding), and Safety and Health Regulations prescribe the use
of insulated electric holders as well. The use of a broken electrode holder
with the conducting part exposed is strictly prohibited.
2) Use of a voltage reducing device Even when an insulated electrode holder is
used, use of a voltage reducing device is necessary, as both ends of a covered
electrode cannot be insulated. Safety and Health Regulations require the use
of a voltage reducing device for AC arc welding power source in a narrow
space enclosed by electric conductive walls, or at a location more than two
meters high.
3) Grounding The frame or chassis of welding power sources must be
connected to a good electrical ground. 14mm2 cables are used for grounding
the chassis of welding power sources. An output terminal connected to the
base metal must be grounded as well, or it will be dangerous as the voltage
at base metal and worktable rises.
4) Cables and connections JIS C 3404:2000
(Welding cables) prescribes welding cables for leads and electrode holders. For both
oil-resistance and durability, chloroprene is superior to natural rubber for insulation of
welding cables. Cables and cable connectors must be used within their current rating
and duty cycle limitations. Use of an excessive current rating or duty cycle will result in
overheating and rapid deterioration of the insulation and connectors. Excess length of
welding cables also results in heat energy loss. Cable connectors should be totally
insulated.
5) Protective leather gloves for welders

Welders must wear dry leather gloves to prevent electric shock and bums. Silicon
treated gloves have excellent waterproof properties and prevent the deterioration of
electrical insulation.
6) First aid
If someone has suffered an electrical shock, cut off the electricity source immediately.
Seek medical attention at once. If there is no time to cut off the power source,
separate the person from the electrifying object using dry gloves, a piece of wood, or
any other well-insulating material. While waiting for medical help, loosen clothes, give
treatment to any burns, and give artificial respiration if the person is not breathing.
4.8.4 Explosion and fire
When welding or cutting is performed, combustible and explosive materials
(oils, paints, solvents, insulation materials, wood, textiles, flammable gasses,
powder dust, etc.), must be removed from the work area to prevent ignition
or explosion from open flame, electric arcs, hot metal, sparks, or spatters.
Prior to welding or cutting work, the absence of such dangerous items must
be confirmed.
Fire-screens and fire extinguishers must also be readily available. When

welding work is suspended, electrical switches must be turned off to prevent
fire which may be caused by a short circuit between the electrode and the
base metal. Gas welding and cutting use fuel gas and oxygen. All gasses for
these purposes are explosive as shown in Table 4.26.
Accordingly, special attention must be paid to their storage, transportation,

and usage. Gas flames must be carefully watched and should something be
observed amiss (see Table 4.27), necessary countermeasures must be taken
immediately.
4.8.5 General safety and health
(1) Work at high locations
Preparations and precautions for work at high locations are

shown in Table 4.28. In addition, non- flammable seats or
screens should be prepared to prevent scattering and falling
of spatter and slag. Remaining electrodes and cut pieces
should be collected in boxes or bags to prevent them from
falling
(2) Welding in a confined space
When welding or cutting is performed in a confined space, special attention
must be paid to prevent electric shock, explosion, and fire. In addition,
existing fumes in a confined space can easily build up, as can the
concentration of any gasses evolved or used in the welding process.
Concentration of gasses can cause asphyxiation.
Adequate ventilation is the key controlling fumes and gasses in a welding

environment. Also, a watch for accidents should be always assigned.
Regulations for the prevention of asphyxiation require ventilation to assure
adequate oxygen for life support (at least 18 % by volume), or alternately
the use of an air line mask, when gas shielded arc welding is performed in a
closed container or an enclosed area.
JIS T 8151 prescribes air line masks. With this device, a welder has access to
fresh air regardless of the condition of the work location. Air line masks are
effective for both fumes and gasses without impairing respiration
(3) Wet and high temperature environments
The possibility of electric shock not only increases due to
perspiration, but work efficiency and concentration decreases due
to fatigue.
Ventilation is essential, however, excessive ventilation may cause

weld defects such as blowholes. Use of oxygen for ventilation is
strictly prohibited due to the danger of fire or explosion.
When radiated heat from welding is too strong, use of insulated

sheets or aprons are recommended. Air ventilated clothing is also
effective.
(4) Noise
Arc air gouging and plasma arc cutting are process that tends to
have high noise levels. Excessive noise, particularly continuous
noise at high levels, causes stress, headaches, etc. and may cause
temporary or permanent hearing loss.
Ear plugs or other head gear must be worn to prevent hearing loss.
JIS T 8 161 (Ear protection equipment) prescribes class 1 ear
protection (for protection from all frequency noise), and class 2 (for
protection from high frequency noise).
High frequency noise is generally more harmful than middle or low

frequency noise; therefore, use of class 2 ear plugs (which cut off
harmful high frequency noise yet still permit normal conversation)
is recommended.

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4.

8 Safety and Health

4.8.1 Protection from heat, light, flying objects, and fumes

High voltage electron beam welding radiates X-rays. Arc welding

When welding or cutting using an arc, welding helmets or hand-

If a suitable shade number is more than 10, two plates of smaller

(2) Body protection

When welding is performed with a zinc or cadmium-coated material or

Therefore, welding or cutting should be performed after removal of any

When a welder or other workers are exposed to welding fumes over a

Accordingly, regulations to prevent pneumoconiosis specify that arc

After using a respirator for a few hours, respiration resistance increases

Electric resistance is usually reduced in the presence of water or

5) Protective leather gloves for welders

Fire-screens and fire extinguishers must also be readily available. When

Accordingly, special attention must be paid to their storage, transportation,

Preparations and precautions for work at high locations are

Adequate ventilation is the key controlling fumes and gasses in a welding

Ventilation is essential, however, excessive ventilation may cause

When radiated heat from welding is too strong, use of insulated

High frequency noise is generally more harmful than middle or low

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