Welding involves several hazards that require strict safety procedures to prevent injury, illness, fire, and explosions. These procedures encompass various aspects, including hot work management, ventilation, electrical safety, ergonomics, and the use of personal protective equipment (PPE).

A hot work management program is essential for controlling or eliminating hot work hazards. This includes policies, procedures, and assigned responsibilities for all aspects of hot work. The program should define where and when hot work is permitted, who is authorized to perform it, and what assessments are required before starting. Training is crucial for employees, supervisors, and fire watch personnel. [10] [16]

Adequate ventilation is crucial to remove air contaminants from the worker's breathing zone, prevent accumulation of flammable gases, and avoid oxygen-deficient atmospheres. Local exhaust ventilation (LEV) is the preferred method for removing welding fumes and gases, capturing contaminants before they mix with room air. Options include downdraft benches, movable hoods, and fume extraction welding guns. [2] [5]

Electrical safety is paramount due to the risk of electric shock. Precautions include ensuring cables are in good condition, avoiding contact with live parts, grounding the workpiece, and using proper protective equipment like rubber boots and gloves. In case of electric shock, immediate medical help should be called, and the victim should be safely removed from the electrical source before administering first aid. [9] [6] [11]

Ergonomic considerations are important to prevent musculoskeletal disorders. Tips for good working posture include positioning the welding item at a comfortable height, avoiding awkward body positions, and using tools to aid posture. When lifting heavy loads like cylinders, use lifting aids or get help, and ensure cylinders are moved safely with secured caps and appropriate trolleys. [1] [3] [8]

PPE is crucial for protecting against various welding hazards. This includes eye and face protection (welding helmets and shields with appropriate filter shades), skin protection (fire-resistant clothing), and respiratory protection (respirators) when ventilation is insufficient. The selection and use of PPE should follow established guidelines and regulations. [17] [2]

Welding fumes and gases pose significant health risks. Welding fumes are complex mixtures of metals, metallic oxides, silicates, and fluorides, with composition varying based on the materials being welded and the electrode type. Gases like carbon monoxide, nitrogen oxides, and ozone can also be produced. Exposure can be minimized by removing coatings from the weld area, using proper ventilation, and wearing appropriate respiratory protection. [4] [7] [12]

Coatings on metals can release toxic vapors or fumes during welding. It is important to remove these coatings from the weld area using stripping products or wet slurry vacuum techniques. Avoid grinding coatings, as the dust may be toxic. Always follow safety procedures and use appropriate PPE during coating removal. [14] [14] [14]

Several types of compressed gases are used in welding, each with specific hazards. Gases like oxygen, propane, propylene, hydrogen, and acetylene are commonly used for heating and shielding. These gases can be flammable, pose explosion risks, and may displace oxygen, causing asphyxiation. Proper handling and storage are essential. [13] [15]