Here is a risk assessment for welding:

Hazards:

• Arc Flash and Radiation: Welding produces intense UV and infrared radiation that can cause burns to the skin and eyes 3, 9. Control measures include using appropriate welding helmets with correct filter lenses [1], wearing protective clothing, and using noncombustible screens or shields to protect nearby workers 3, 9. Ensure workers adjacent to welding areas are protected by screens/shields or wear appropriate goggles [1].
• Fumes and Gases: Welding can release hazardous fumes and gases, especially when welding materials with coatings or in confined spaces 2, 6. These fumes can cause respiratory irritation, metal fume fever, or long-term health issues. Control measures include providing adequate ventilation, using local exhaust systems, and providing respiratory protection when necessary 2, 6, 20. Monitor exposure levels to ensure they do not exceed occupational exposure limits 2, 7. When welding or cutting stainless steel, ensure mechanical ventilation is used to remove fumes [2].
• Fire and Explosions: Welding can create sparks and molten metal that can ignite flammable materials in the vicinity 10, 14. Control measures include removing flammable materials from the work area, using fire-resistant shields, and having a fire watch present 10, 14, 18. Ensure cutting and welding are scheduled so that plant operations that might expose combustibles to ignition are not started during cutting or welding [3]. Also, ensure that cutting or welding is permitted only in areas that are or have been made fire safe [3].
• Electric Shock: Welding equipment can pose a risk of electric shock, especially in wet conditions 4, 17. Control measures include ensuring equipment is properly grounded, using insulated electrode holders, and avoiding welding in wet environments 1, 5, 17. Provide special protection against electric shock when arc welding is performed in wet conditions or under conditions of high humidity [2].
• Physical Hazards: Welding can involve physical hazards such as burns from hot materials, cuts from sharp edges, and strains from lifting heavy objects. Control measures include wearing appropriate PPE such as gloves and aprons [1], using proper lifting techniques, and ensuring the work area is free from obstructions [1].
• Confined Spaces: Welding in confined spaces introduces additional hazards such as limited ventilation and difficulty in rescue 6, 8, 20. Control measures include providing forced ventilation, using supplied-air respirators, stationing an attendant outside the space, and ensuring a preplanned rescue procedure is in place 8, 20. You must adequately vent all welding and cutting operations carried on in confined spaces to prevent the accumulation of toxic materials or possible oxygen deficiency [4].

Risk Assessment:

• Assess the likelihood and severity of each hazard based on the specific welding task, environment, and equipment being used.
• Consider factors such as the type of materials being welded, the duration of the task, and the proximity of other workers.
• Use a risk matrix to prioritize hazards and determine appropriate control measures.

Control Measures (Hierarchy of Controls):

1. Elimination: If possible, eliminate the hazard by using alternative methods or materials.
2. Substitution: Substitute hazardous materials with less hazardous alternatives.
3. Engineering Controls: Use engineering controls such as ventilation systems, machine guards, and welding booths to isolate the hazard 1, 3, 5, 20. Flash welding machines must be equipped with a hood to control flying flash [5].
4. Administrative Controls: Implement administrative controls such as safe work procedures, training programs, and permit systems to minimize exposure to hazards 2, 10. Ensure that a job hazard analysis is made, by qualified personnel, of the operations to be performed on each welding machine to determine the safeguards and personal protective equipment that must be used for each job [5].
5. Personal Protective Equipment (PPE): Provide and ensure the use of appropriate PPE such as welding helmets, gloves, aprons, and respirators as a last line of defense 3, 8, 9. Except when engaged in light work, all welders should wear flameproof gauntlet gloves [1].

Monitoring and Review:

• Regularly inspect welding equipment and PPE to ensure they are in good working condition.
• Conduct air monitoring to assess the effectiveness of ventilation systems.
• Review and update the risk assessment as needed based on changes in the work environment or new information about hazards.
• Ensure workers are trained on the identified hazards and control measures 2, 14.

Specific Recommendations:

• Develop a written welding safety program that includes hazard identification, risk assessment, and control measures.
• Provide regular training to welders on safe welding practices and the use of PPE.
• Ensure that all welding equipment is properly maintained and inspected.
• Establish a permit system for hot work to ensure that fire prevention measures are in place.
• Provide first-aid equipment and ensure that employees are trained in first aid [2].
• When arc welding is to be suspended for any substantial period of time, such as during lunch or overnight, you must remove all electrodes from the holders and carefully locate the holders so that accidental contact cannot occur and the machine disconnected from the power source 8, 10.
• In order to eliminate the possibility of gas escaping through leaks or improperly closed valves, when gas welding or cutting, you must close the torch valves and positively shut off the fuel-gas and oxygen supply to the torch at some point outside the confined area whenever the torch is not to be used for a substantial period of time, such as during lunch hour or overnight 8, 10.

By implementing these control measures and following safe work practices, the risks associated with welding can be significantly reduced.