American Welding Society AWS-AWS D11.2-1989-R2006 Guide for Welding Iron Castings-AWS
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American Welding Society AWS-AWS D11.2-1989-R2006 Guide for Welding Iron Castings-AWS PDF...
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ANSI/AWS D11.2-89 (R2006) An American National Standard
Guide for Welding Iron Castings
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ANSI/AWS D11.2-89 (R2006) An American National Standard
Guide for Welding Iron Castings Prepared by the American Welding Society (AWS) D11 Committee on Welding Iron Castings Under the Direction of the AWS Technical Activities Committee Approved by the AWS Board of Directors, March 3, 1988
Abstract This standard presents briefly the history and metallurgy of cast iron and the welding processes applicable to it. A newly developed weldability test is described in detail and instructions given for its application in specific cases. Provision is made for qualification of welding procedures and welders when necessary; quality control practice is also included.
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Approved by the American National Standards Institute July 14, 1988
ANSI/AWS D11.2-89 (R2006)
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International Standard Book Number: 0-87171-295-4 American Welding Society 550 N.W. LeJeune Road, Miami, FL 33126 © 1989 by American Welding Society All rights reserved Printed in the United States of America Reaffirmed: April 27, 2006 Photocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in any form, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyright owner. Authorization to photocopy items for internal, personal, or educational classroom use only or the internal, personal, or educational classroom use only of specific clients is granted by the American Welding Society provided that the appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet: .
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Statement on the Use of American Welding Society Standards All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the American National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by agreement between the contracting parties. AWS American National Standards are developed through a consensus standards development process that brings together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the process and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the accuracy of any information or the soundness of any judgments contained in its standards. AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this standard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. In issuing and making this standard available, AWS is not undertaking to render professional or other services for or on behalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity to someone else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given circumstances. This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.
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Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard accept any and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement of any patent or product trade name resulting from the use of this standard. Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so. On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are posted on the AWS web page (www.aws.org). Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the Managing Director, Technical Services Division, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. However, such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation. This standard is subject to revision at any time by the AWS D11 Committee on Welding Iron Castings. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS D11 Committee on Welding Iron Castings and the author of the comments will be informed of the Committee’s response to the comments. Guests are invited to attend all meetings of the AWS D11 Committee on Welding Iron Castings to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.
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Personnel (Reaffirmation) AWS Committee on Welding Iron Castings E. G. Yevick, Chair S. Charlip, Vice Chair J. L. Gayler, Secretary *J. G. Bielenberg *R. A. Bishel R. A. Bushey J. L. Cooley D. W. Davis *R. O. Drossman R. H. Frost S. D. Kiser E. R. Kuch *R. L. Montana *L. W. Myers N. Prager M. D. Rosensteel J. D. Simko J. Turriff
Weld-Met International Group Nassau Research Corporation American Welding Society Retired Consultant ESAB Welding & Cutting Products J C & Associates, Incorporated Beaver Valley Alloy Foundry Wear Management Services, Incorporated Colorado School of Mines Special Metals Consultant Mid-Florida Technical Institute Consultant Anchor Research Corporation Beyond the Bend Hodge Foundry, Incorporated Wisconsin Wire Works
*Advisor
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Personnel (Original) AWS Committee on Welding Iron Castings L. W. Myers, Chair R. J. Dybas, 1st Vice Chair J. E. Jones, 2nd Vice Chair E. J. Seel, Secretary K. E. Banks R. G. Bartifay *J. G. Bielenberg R. A. Bishel R. A. Bushey R. O. Drossman E. R. Kuch *J. C. Margerie *J. V. Matush *A. H. Miller W. F. Ridgway *L. E. Shoemaker *R. A. Strahl *C. F. Walton E. G. Yevick W. M. Zimmer
Dresser-Rand General Electric Company American Welding Institute American Welding Society Teledyne McKay Aluminum Company of America Consultant Inco Alloys International Alloy Rods Wear Management Services Cooper Industries Centre Technique Combustion Engineering DISC Eutectic Corporation Inco Alloys International California Polytechnic State University Consultant Weld-Met International AMPCO Metal
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Foreword This foreword is not a part of ANSI/AWS D11.2-89 (R2006), Guide for Welding Iron Castings, but is included for informational purposes only. This publication is a reaffirmation of the first edition published in 1989. The content of the standard is identical to the 1989 publication except that the safety and health facts sheets in Appendix F have been updated. Reaffirmation of this standard by the Committee on the Welding of Iron Castings indicates that this standard’s content is still current with today’s technology and practices. This guide was prepared by the American Welding Society Committee on the Welding of Iron Castings as a service to the industry. Sufficient data have been gathered and organized to yield an authoritative source of sound technical practices for joining iron castings. The description of iron castings, together with factors to be considered in joining them, is presented here as clearly and concisely as possible. It is the Committee’s hope that this guide will lead to better quality and performance. These recommendations represent the best of current practice in the opinion of the Committee. At the present state of the art, all recommendations may not be applicable to all products and situations. Selection of pertinent requirements should be the result of rational decisions and not lack of knowledge on the part of those who are welding iron castings.
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Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary, AWS D11 Committee on Welding of Iron Castings, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.
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Table of Contents Page No. Personnel (Reaffirmation) ............................................................................................................................................v Personnel (Original) ..................................................................................................................................................vii Foreword .....................................................................................................................................................................ix List of Tables ............................................................................................................................................................ xiii List of Figures............................................................................................................................................................xiv 1. Scope and History................................................................................................................................................1 1.1 Scope............................................................................................................................................................1 1.2 History .........................................................................................................................................................1 2. Cast Iron — Its Metallurgy and Weldability....................................................................................................1 2.1 Metallurgy....................................................................................................................................................1 2.2 Difficulties in Welding Iron Castings..........................................................................................................4 2.3 AWS Weldability Test Program..................................................................................................................6 2.4 Preweld Testing for Weldability................................................................................................................11 3. General Considerations When Welding Iron Castings .................................................................................14 3.1 Base Metal Preparation..............................................................................................................................14 3.2 Joint Design ...............................................................................................................................................15 3.3 Heat Input ..................................................................................................................................................17 3.4 Preheat .......................................................................................................................................................17 3.5 Electrode Manipulation .............................................................................................................................20 3.6 Peening ......................................................................................................................................................21 3.7 Cooling ......................................................................................................................................................21 3.8 Postweld Heat Treatment...........................................................................................................................21 4. Gas Processes .....................................................................................................................................................23 4.1 Oxyfuel Welding (OFW)...........................................................................................................................23 4.2 Flame Spraying of Gray Iron (FLSP) ........................................................................................................27 4.3 Braze Welding ...........................................................................................................................................27 5. Arc Welding Processes......................................................................................................................................30 5.1 General.......................................................................................................................................................30 5.2 Shielded Metal Arc Welding (SMAW) .....................................................................................................30 5.3 Gas Metal Arc Welding (GMAW) ............................................................................................................35 5.4 Flux Cored Arc Welding (FCAW) ............................................................................................................37 5.5 Gas Tungsten Arc Welding (GTAW)........................................................................................................41 5.6 Submerged Arc Welding (SAW)...............................................................................................................44 6. Surfacing and Overlaying.................................................................................................................................45 6.1 Processes....................................................................................................................................................45 6.2 Thermal Spraying ......................................................................................................................................45 6.3 Other Processes..........................................................................................................................................47 6.4 Surfacing Materials....................................................................................................................................48 6.5 Technique ..................................................................................................................................................50 7. Applications .......................................................................................................................................................50 7.1 Casting Defect Repair................................................................................................................................50 7.2 Repair of Machining Defects.....................................................................................................................51
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Page No. 7.3 7.4
Repair of Castings After Service ...............................................................................................................51 Fabrication .................................................................................................................................................51
8. Welding Procedure and Performance Qualification......................................................................................51 8.1 General.......................................................................................................................................................51 8.2 Welding Procedure Qualification ..............................................................................................................52 8.3 Welding and Welding Operator Performance Qualification .....................................................................52 9. Quality Control..................................................................................................................................................52 9.1 General.......................................................................................................................................................52 9.2 Quality Control Practices and Procedures .................................................................................................52 9.3 Acceptance Criteria ...................................................................................................................................54 10. Safety and Health ..............................................................................................................................................54 10.1 Fumes and Gases .......................................................................................................................................54 10.2 Radiation....................................................................................................................................................55 10.3 Electric Shock............................................................................................................................................55 10.4 Fire Prevention...........................................................................................................................................55 10.5 Explosion ...................................................................................................................................................55 10.6 Burns..........................................................................................................................................................55 10.7 Further Information ...................................................................................................................................55 Appendix A — Weldability Test .............................................................................................................................51 A1. Introduction................................................................................................................................................57 A2. Equipment Required ..................................................................................................................................57 A3. Welding Conditions ...................................................................................................................................58 A4. Test Procedure ...........................................................................................................................................59 Appendix B — Applications ....................................................................................................................................63 Appendix C — Welding Procedure and Performance Qualification ..................................................................83 C1. General.......................................................................................................................................................83 C2. Welding Procedure Qualification ..............................................................................................................83 C3. Inspection Results Required ......................................................................................................................95 C4. Welding and Welding Operator Performance Qualification .....................................................................97 Appendix D — Recommended System for Classification of Welds in Iron Castings, Appendix D — and Associated Quality Levels ....................................................................................................105 D1. Classification of Welds in Iron Castings .................................................................................................105 D2. Test Requirements ...................................................................................................................................105
Appendix F — Safety and Health .........................................................................................................................111
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Appendix E — ASME Code Cases........................................................................................................................109 E1. Case 1867.................................................................................................................................................109 E2. Case 1939.................................................................................................................................................109
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List of Tables Table
Page No.
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List of Figures Figure
Page No.
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Page No.
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Figure
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Guide for Welding Iron Castings
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28 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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29 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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30 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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31 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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32
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33 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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34 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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35 Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
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36 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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37
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38 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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39 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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40 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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ANSI/AWS D11.2-89 (R2006)
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41 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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ANSI/AWS D11.2-89 (R2006)
42 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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43 Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
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44 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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45 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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46 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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47 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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48 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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49 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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ANSI/AWS D11.2-89 (R2006)
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50 Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
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51 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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52 Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
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53
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54 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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55 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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56 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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ANSI/AWS D11.2-89 (R2006)
Appendix A Weldability Test This appendix is not a part of ANSI/AWS D11.2-89 (R2006), Guide for Welding Iron Castings, but is included for informational purposes only.
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57 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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58 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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59 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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60 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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ANSI/AWS D11.2-89 (R2006)
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Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
61 Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
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62 Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
ANSI/AWS D11.2-89 (R2006)
Appendix B Examples of Applications
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This appendix is not a part of ANSI/AWS D11.2-89 (R2006), Guide for Welding Iron Castings, but is included for informational purposes only.
63 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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64 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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65 Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
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66 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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67 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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68 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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69 Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
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70 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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71 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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72 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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73 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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74
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75 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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76 Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
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77 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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78 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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79 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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80 Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
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81 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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82 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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ANSI/AWS D11.2-89 (R2006)
Appendix C Welding Procedure and Performance Qualification This appendix is not a part of ANSI/AWS D11.2-89 (R2006), Guide for Welding Iron Castings, but is included for informational purposes only.
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84 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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ANSI/AWS D11.2-89 (R2006)
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85 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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86 Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
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87 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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88 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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89
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90 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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91
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92 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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93 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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94 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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95 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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96 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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97 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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98 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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102 --`,```,```,,```
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Appendix D Recommended System for Classification of Welds in Iron Castings, and Associated Quality Levels This appendix is not a part of ANSI/AWS D11.2-89 (R2006), Guide for Welding Iron Castings, but is included for informational purposes only.
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Appendix E ASME Code Cases* This appendix is not a part of ANSI/AWS D11.2-89 (R2006), Guide for Welding Iron Castings, but is included for informational purposes only.
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Appendix F Safety and Health Fact Sheets This appendix is not a part of AWS D11.2-89(R2006), Guide for Welding Iron Castings, but is included for informational purposes only. --`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
The following pages present copies of short articles (Fact Sheets) on Safety and Health topics published by the American Welding Society. Each article is available free of charge from the American Welding Society website, www.aws.org.
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Safety and Health Fact Sheet No. 1
October 2003
© 2003 American Welding Society
Fumes and Gases
x
Depending on material involved ranges from irritation of eyes, skin, and respiratory system to more severe complications.
x
Effects may occur immediately or at some later time.
x
Fumes can cause symptoms such as nausea, headaches, dizziness, and metal fume fever.
x
The possibility of more serious health effects exists when highly toxic materials are involved. For example, manganese overexposure can affect the central nervous system resulting in impaired speech and movement.
x
In confined spaces the gases might displace breathing air and cause asphyxiation.
INTRODUCTION Many welding, cutting, and allied processes produce fumes and gases, which may be harmful to your health. DEFINITION Fumes are solid particles which originate from welding consumables, the base metal, and any coatings present on the base metal.
x
In addition to shielding gases that may be used, gases are produced during the welding process or may be produced by the effects of process radiation on the surrounding environment.
x
Acquaint yourself with the effects of these fumes and gases by reading the Material Safety Data Sheets (MSDSs) for all materials used (consumables, base metals, coatings, and cleaners).
x
x
HOW TO AVOID OVEREXPOSURE
For help, consult a recognized specialist in Industrial Hygiene or Environmental Services. The amount and composition of these fumes and gases depend upon the composition of the filler metal and base material, welding process, current level, arc length, and other factors.
POSSIBLE EXPOSURE
EFFECTS
OF
OVER-
x
Keep your head out of the fumes.
x
Do not breathe the fumes.
x
Use enough ventilation or exhaust at the arc, or both, to keep fumes and gases from your breathing zone and general area.
x
In some cases, natural air movement provides enough ventilation and fresh air.
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. Fact Sheet No. 1 — 10/03
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x
ANSI/AWS D11.2-89 (R2006)
x
Where ventilation is questionable, use air sampling to determine the need for corrective measures.
x
Use mechanical ventilation to improve air quality.
x
If engineering controls are not feasible, use an approved respirator.
x
Work in a confined space only if it is well ventilated, or while wearing an airsupplied respirator. Fumes from welding or cutting and oxygen depletion can alter air quality causing injury or death. Be sure the breathing air is safe.
x
Follow OSHA guidelines for permissible exposure limits (PELs) for various fumes.
x
Follow the American Conference of Governmental Industrial Hygienists recommendations for threshold limit values (TLVs) for fumes and gases.
x
Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding or cutting situation.
American Conference of Governmental Industrial Hygienists (ACGIH). Threshold Limit Values for Chemical Substances and Physical Agents and Biological Exposure Indices, available from ACGIH, 1330 Kemper Meadow Drive, Cincinnati, OH 45240-1634 (telephone: 513-742-2020; web site: www.acgih.org). American Welding Society (AWS). Fumes and Gases in the Welding Environment and other welding related safety and health publications, available from Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112-5776 (telephone: 800-854-7179; web site: www.global.ihs.com). Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Title 30 Mineral Resources, Parts 1 to 199, available from the U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (telephone: 202-693-9400; web site: www.msha.gov). For specific information, refer to the applicable Material Safety Data Sheet (MSDS) available from the manufacturer, distributor, or supplier. TLV is a registered trademark of the ACGIH.
INFORMATION SOURCES Occupational Safety and Health Administration (OSHA). Code of Federal Regulations, Title 29 Labor, Parts 1910.1 to 1910.1450, available from the U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (telephone: 800-321-6742; web site: www.osha.gov).
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. Fact Sheet No. 1 — 10/03
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Safety and Health Fact Sheet No. 2
October 2003
© 2003 American Welding Society
Radiation INTRODUCTION Most arc welding and cutting processes, laser welding, and torch welding, cutting, and brazing, or soldering produce quantities of radiation requiring precautionary measures. Some processes, such as resistance welding and cold pressure welding, ordinarily produce negligible quantities of radiant energy.
x
Ionizing (such as X-rays).
x
Nonionizing (such as ultraviolet, visible light, or infrared).
IONIZING RADIATION
DEFINITION Radiation is electromagnetic energy given off by the arc or flame that can injure eyes and burn skin. An operator sees visible light radiation. However, he does not see ultraviolet or infrared radiation. Radiation is often silent and undetected, yet injury occurs. Have all users learn about the effects of radiation.
x
Produced by the electron beam welding process.
x
Controlled within acceptable limits by using suitable shielding around the electron beam welding area.
x
Produced during grinding (pointing) of thoriated tungsten electrodes for Gas Tungsten Arc Welding (GTAW) process -- the grinding dust is radioactive.
x
Controlled by using local exhaust and, if necessary, an approved respirator.
EFFECTS OF RADIATION
NONIONIZING RADIATION
The effects of radiation depend on the wavelength, intensity, and length of time one is exposed to the radiant energy. Although a variety of effects is possible, the following two injuries are most common: x
Skin burns.
x
Eye damage.
x
Intensity and wavelength of energy produced depend on the process, welding parameters, electrode and base metal composition, fluxes, and any coatings or plating on the base material.
x
Ultraviolet radiation increases approximately as the square of the welding current.
x
Visible brightness (luminance) of the arc increases at a much lower rate.
TYPES OF RADIATION There are two types of radiation associated with welding operations:
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. Fact Sheet No. 2 — 10/03
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ANSI/AWS D11.2-89 (R2006)
x
Processes using argon produce larger amounts of ultraviolet radiation than those using most other shielding gases.
x
Locate welding operations so that other workers are not exposed to either direct or reflected radiation. Use screens, curtains, or adequate distances from other work stations, aisles, or walkways to avoid exposure.
x
Wear safety glasses with UV protective side shields in addition to a proper welding helmet with filter plate. The side shields provide needed protection from reflected radiation.
x
Have all persons wear safety glasses with UV protective side shields anytime near welding or cutting areas.
x
Choose safety glasses according to ANSI Z87.1.
HOW TO PROTECT AGAINST IONIZING RADIATION x
Required protection varies with time of exposure, distance from source, and shielding used.
x
Follow recommended procedures in AWS F2.1.
x
When grinding (pointing) thoriated tungsten electrodes, always use local exhaust and, if necessary, respiratory protection to prevent inhalation of dust.
x
External radiation from thoriated tungsten electrodes during storage, welding, or disposal of residues is negligible under normal conditions.
INFORMATION SOURCES NONIONIZING RADIATION
American Welding Society (AWS). Recommended Practices for Electron Beam Welding (AWS C7.1), available from Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112-5776 (telephone: 800-854-7179; web site: www.global.ihs.com).
HOW TO PROTECT AGAINST NONIONIZING RADIATION x
Use welding helmet with correct shade of filter plate according to ANSI Z87.1. Note: Transparent welding curtains are not intended as welding filter plates, but rather are intended to protect passersby from incidental exposure.
x
x
ON
International Institute of Welding (IIW). Statement from Commission VIII, Health and Safety 2000. Welding with NonConsumable Thoriated Tungsten Electrodes. Document IIW-VIII-1901-00. np: np.
Protect exposed skin with adequate gloves and clothing according to ANSI Z49.1.
Manufacturers’ Literature
Be aware of reflections from welding arcs, and protect all persons from intense reflections.
Product
Information
INFORMATION SOURCES NONIONIZING RADIATION
Note: Paints using titanium dioxide or zinc oxide as major pigmentation media have a low reflectance for ultraviolet radiation.
ON
American National Standards Institute (ANSI). Practice for Occupational and Educational Eye and Face Protection
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. Fact Sheet No. 2 — 10/03
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(ANSI Z87.1), available from ANSI, 25 West 43rd Street, New York, NY 10036 (telephone: 212-642-4900; web site: www.ansi.org).
Arcs, Nonionizing Radiation Protection Special Study No. 42-0053-77, NTIS, Springfield, VA (telephone: 703-605-6000; web site: www.ntis.gov).
American National Standards Institute (ANSI). Safety in Welding, Cutting, and Allied Processes (ANSI Z49.1), available from Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112-5776 (telephone: 800-854-7179; web site: www.global.ihs.com).
National Technical Information Service (NTIS). Evaluation of the Potential Retinal Hazards from Optical Radiation Generated by Electric Welding and Cutting Arcs, Nonionizing Radiation Protection Special Study No. 42-0312-77, NTIS, Springfield, VA (telephone: 703-605-6000; web site: www.ntis.gov).
American National Standards Institute (ANSI). Safe Use of Lasers (ANSI Z136.1), available from ANSI, 25 West 43rd Street, New York, NY 10036 (telephone: 212-642-4900; web site: www.ansi.org).
Sliney, D. H. and Freasier, B. C. Evaluation of Optical Radiation Hazards, Applied Optics, Vol 12, pp. 1-24, January 1973. Naidoff, M. A. and Sliney, D. H. Retinal Injury from a Welding Arc, American Journal of Ophthalmology, Vol. 77, No. 5, pp. 663-668, May 1974.
Hinrichs, J. F. Project Committee on Radiation - Summary Report, Welding Journal 57(62): 1978 (telephone 800-4439353; web site: www.aws.org).
Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Title 30 Mineral Resources, Parts 1 to 199, available from the U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (telephone: 202-693-9400; web site: www.msha.gov).
Moss, C. E. Optical Radiation Transmission Levels Through Transparent Welding Curtains, Welding Journal 58(6975s): 1979 (telephone 800-443-9353; web site: www.aws.org). Moss, C. E., et al. Optical Radiation Levels Produced by Air-Carbon Arc Cutting Processes, Welding Journal 59(43-46): 1980 (telephone 800-443-9353; web site: www.aws.org).
American Welding Society (AWS). Ultraviolet Reflectance of Paint, available from Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112-5776 (telephone: 800-854-7179; web site: www.global.ihs.com).
Moss, C. E. and Murray, W. E. Optical Radiation Levels Produced in Gas Welding, Torch Brazing and Oxygen Cutting, Welding Journal 89(37-46): 1979 (telephone 800-443-9353; web site: www.aws.org). --`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
National Technical Information Service (NTIS). Evaluation of the Potential Hazards from Actinic Ultraviolet Radiation Generated by Electric Welding and Cutting AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. Fact Sheet No. 2 — 10/03
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Safety and Health Fact Sheet No. 3
October 2003
© 2003 American Welding Society
individual susceptibility, noise level, and exposure duration.
INTRODUCTION In welding, cutting, and allied operations, noise may result from the process, the power source, or other equipment. Air carbon arc cutting and plasma arc cutting are examples of processes which are frequently noisy. Engine-driven generators may also be quite noisy. Excessive noise is a known health hazard.
x
There is evidence that excessive noise affects other bodily functions and behavior as well.
HOW TO PROTECT AGAINST NOISE x
Reduce the intensity of the source.
DEFINITION
x
Shield the source where practical.
Scientifically, noise is composed of several frequencies and involves random changes in frequency or amplitude. Sound waves are produced when the air is mechanically disturbed. Sound is measured by its frequency (pitch-high or low) and intensity (loudness). Practically, noise is unwanted or unpleasant sound. It can get in the way of the sounds we would rather hear and often need to hear for safety reasons.
x
Use engineering control methods, such as room acoustics, to control noise.
x
If engineering methods fail to reduce noise to acceptable levels, wear approved personal protective devices such as ear muffs or ear plugs appropriate for the situation.
x
Follow OSHA regulations which require a Hearing Conservation Program if noise levels reach 85 dB on an 8-hour, Time Weighted Average (TWA) basis.
x
If noise level is questionable, have a certified safety specialist or Industrial Hygienist take measurements and make recommendations.
EFFECTS NOISE
OF
OVEREXPOSURE
TO
x
Loss of hearing that may be either full or partial and either temporary or permanent.
x
Hearing loss may be a temporary threshold shift from which the ears may recover if removed from the noise source.
x
INFORMATION SOURCES Occupational Safety and Health Administration (OSHA). Code of Federal Regulations, Title 29 Labor, Parts 1910.1 to 1910.1450, available from the U.S.
The time required to develop permanent hearing loss depends on
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. Fact Sheet No. 3 — 10/03
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Noise
ANSI/AWS D11.2-89 (R2006)
Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (telephone: 800-321-6742; web site: www.osha.gov).
Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Title 30 Mineral Resources, Parts 1 to 199, available from the U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (telephone: 202-693-9400; web site: www.msha.gov).
American Conference of Governmental Industrial Hygienists (ACGIH). Threshold Limit Values for Chemical Substances and Physical Agents and Biological Exposure Indices, available from ACGIH, 1330 Kemper Meadow Drive, Cincinnati, OH 45240-1634 (telephone: 513-742-2020; web site: www.acgih.org).
TLV is a registered trademark of the ACGIH.
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AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. Fact Sheet No. 3 — 10/03
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Safety and Health Fact Sheet No. 4
October 2003
© 2003 American Welding Society
Chromium and Nickel in Welding Fume
The fume from welding processes may contain compounds of chromium, including hexavalent chromium, and of nickel. The composition of the base metals, the welding materials used, and the welding processes affect the specific compounds and concentrations found in the welding fume.
x
NIOSH Criteria Documents 76–129 and 77–164 (listed below) contain these conclusions based on data from the chromate producing industry and from nickel ore-refining processes.
x
Conclusions from the International Agency for Research on Cancer (IARC): (1) there is limited evidence in humans for the carcinogenicity of welding fumes and gases, and (2) there is inadequate evidence in experimental animals for the carcinogenicity of welding fumes.
IMMEDIATE EFFECTS OF OVEREXPOSURE TO FUMES CONTAINING CHROMIUM AND NICKEL x
Similar to the effects produced by fumes from other metals.
x
Cause symptoms such as nausea, headaches, dizziness, and respiratory irritation.
x
Some persons may develop a sensitivity to chromium or nickel which can result in dermatitis or skin rash.
OVERALL EVALUATION
CHRONIC (LONG TERM) EFFECTS OF EXPOSURE TO FUMES CONTAINING CHROMIUM AND NICKEL x
Definite effects are not yet determined
x
Conclusions from the National Institute for Occupational Safety and Health (NIOSH): some forms of hexavalent chromium and nickel and their inorganic compounds should be considered occupational carcinogens (cancercausing agents).
x
Welding fumes are possibly carcinogenic to humans (Group 2B).
x
No determination has yet been made concerning the health effects on welders or users of chromium- or nickel-containing alloys.
x
Nevertheless, give consideration to the NIOSH and IARC conclusions.
HOW TO PROTECT AGAINST OVEREXPOSURE x
Do not breathe fumes and gases. Keep your head out of the fumes.
x
Use enough ventilation or exhaust at the arc or both to keep fumes and gases from your breathing zone and general area.
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. Fact Sheet No. 4 — 10/03
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INTRODUCTION
ANSI/AWS D11.2-89 (R2006)
If ventilation is questionable, use air sampling to determine the need for corrective measures.
x
Keep exposure as low as possible.
(telephone: 800-321-6742; www.osha.gov).
web
site:
American Conference of Governmental Industrial Hygienists (ACGIH). Documentation of the Threshold Limit Values and Biological Exposure Indices, available from ACGIH, 1330 Kemper Meadow Drive, Cincinnati, OH 45240-1634 (telephone: 513-742-2020; web site: www.acgih.org).
INFORMATION SOURCES National Institute for Occupational Safety and Health (NIOSH). Criteria for a Recommended Standard: Occupational Exposure to Chromium (VI), NIOSH Publication No. 76-129. Cincinnati, OH (telephone: 800-356-4674; web site: http://www.cdc.gov/niosh/homepage.html).
IARC Monographs on the Evaluation of Carcinogenic Risks to Humans, Chromium, Nickel, and Welding, Vol. 49 (1990), Oxford University Press, New York, NY 10016 (telephone: 212-726-6000; web site: www.oup-usa.org).
National Institute for Occupational Safety and Health (NIOSH). Criteria for a Recommended Standard: Occupational Exposure to Inorganic Nickel, NIOSH Publication No. 77-164. Cincinnati, OH (telephone: 800-356-4674; web site: http://www.cdc.gov/niosh/homepage.html).
The following references include the specific precautionary methods used to protect against exposure to fumes and gases:
American Welding Society (AWS). Fumes and Gases in the Welding Environment, available from Global Engineering Docments, 15 Inverness Way East, Englewood, CO 80112-5776 (telephone: 800854-7179; web site: www.global.ihs.com).
American National Standards Institute (ANSI). Safety in Welding, Cutting, and Allied Processes (ANSI Z49.1), available from Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112-5776 (telephone: 800-854-7179; web site: www.global.ihs.com).
American Conference of Governmental Industrial Hygienists (ACGIH). Threshold Limit Values for Chemical Substances and Physical Agents and Biological Exposure Indices, available from ACGIH, 1330 Kemper Meadow Drive, Cincinnati, OH 45240-1634 (telephone: 513-742-2020; web site: www.acgih.org).
National Institute for Occupational Safety and Health (NIOSH). Safety and Health in Arc Welding and Gas Welding and Cutting, NIOSH Publication No. 78-138. Cincinnati,OH (telephone: 800-356-4674; web site: http://www.cdc.gov/niosh). Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Title 30 Mineral Resources, Parts 1 to 199, available from the U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (telephone: 202-693-9400; web site: www.msha.gov).
Occupational Safety and Health Administration (OSHA). Code of Federal Regulations, Title 29 Labor, Parts 1910.1 to 1910.1450, available from the U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. Fact Sheet No. 4 — 10/03
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x
ANSI/AWS D11.2-89 (R2006)
Safety and Health Fact Sheet No. 5
October 2003
© 2003 American Welding Society
Electrical Hazards
INTRODUCTION Electric shock from welding and cutting equipment can result in death or severe burns. Additionally, serious injury can occur if the welder falls as a result of the shock. All of the following are electrically energized when the power is “on”: electrode and welding circuit, input power circuit and machine internal circuits, the wire, reel of wire, drive rolls, and all other metal parts touching the energized electrode.
x
Properly install and ground the equipment in accordance with the instruction manual and national, state, and local codes.
x
Do not work alone where there are electrically hazardous conditions.
x
Wear dry, insulating gloves in good condition and protective clothing.
x
Insulate yourself from the workpiece and ground by wearing rubber soled shoes or standing on a dry insulated mat or platform.
x
Use fully insulated electrode holders. Never dip the holder into water to cool it or lay it on conductive surfaces or the work surface.
x
Do not touch holders connected to two welding machines a the same time.
x
Do not allow the holder or electrode to come in contact with any other person.
x
Do not use worn, damaged, undersized, or poorly spliced cables, welding gun cables, or torch cables. Make sure all connections are tight, clean, and dry. Do not wrap cables carrying electric current around any part of your body.
HOW TO AVOID ELECTRIC SHOCKS
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Use proper precautionary measures and recommended safe practices at all times. Train all personnel using welding and cutting equipment to reduce the risk of injuries, fatalities, and electrical accidents, by following these instructions: x
Read all instructions, labels, and installation manuals before installing, operating, or servicing the equipment.
x
Train all personnel involved in welding operations to observe safe electrical work practices according to OSHA 1910.332.
x
Do not touch live electrical parts.
x
x
Have all installation, operation, maintenance, and repair work performed only by qualified people.
.
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. Fact Sheet No. 5 — 10/03
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ANSI/AWS D11.2-89 (R2006)
x
Ground codes.
x
When required, ground the workpiece to a good electrical earth ground. The work lead is not a ground lead. Do not use the work lead as a ground lead. Use a separate connection to ground the workpiece to earth.
x
Do not touch an energized electrode while you are in contact with the work circuit.
x
When using auxiliary power from welding generators, it is recommended that you use a circuit protected by a ground fault circuit interrupter (GFCI) such as receptacles in boxes, extension cords, and the like. Use of an assured grounding system is also acceptable and is equivalent to use of a GFCI protected circuit.
x
x
workpiece
as
required
semiautomatic DC constant voltage metal electrode (wire) welder, 2) a DC manual covered electrode (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!
by
In confined spaces or in locations that are electrically hazardous due to water or perspiration, do not use welding equipment with AC output unless it is also equipped with a voltage reducer and remote output control. Use equipment with DC output and do not work alone. Additional safety precautions are required when welding is performed under any of the following electrically hazardous conditions: in damp locations or while wearing wet clothing; on metal floors, gratings, scaffolds, or other metal structures; in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. Where these conditions are present, use one of the following types of equipment presented in order of preference: 1) a
x
Wear a safety harness to prevent falling if working above floor level where there are no other protective structures such as railings, walls, guard fences, or the like.
x
Turn off all equipment when not in use. Disconnect the power to equipment that will be left unattended or out of service.
x
Disconnect the input power or stop the engine before installing or servicing the equipment. Lock the input disconnect switch in the “open” position, or remove the fuses, so that power cannot be turned on accidentally.
x
Use only well maintained equipment. Routinely inspect welding equipment and repair or replace all damaged parts before further use.
x
Keep all covers and panels securely in place.
Follow lockout/tagout procedures (see AWS Safety and Health Fact Sheet No. 18, Lockout/Tagout). WEARERS OF PACEMAKERS x
The technology of heart pacemakers changes frequently and this may change the way these devices are affected by other electrical devices including welding equipment. Wearers of pacemakers or other electronic
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. Fact Sheet No. 5 — 10/03
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to 1910.1450, available from the U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (telephone: 800-321-6742; web site: www.osha.gov).
equipment vital to life should be instructed to check with their doctor and with the device manufacturer to determine if any hazard exits when near welding or cutting operations. See AWS Fact Sheet No. 16 for additional information about pacemakers and welding.
National Fire Protection Association (NFPA). National Electric Code (NFPA 70), available from National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269-9101 (telephone: 800-3443555; website: www.nfpa.org).
PROCEDURES FOR ELECTRIC SHOCK x
Turn off the electric power.
x
Use nonconducting material, such as wood, to free the victim from contact with live parts or wires.
x
National Fire Protection Association (NFPA). Standard for Fire Prevention During Welding, Cutting and Other Hot Work (NFPA 51B), available from National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 022699101 (telephone: 800-344-3555; website: www.nfpa.org).
If the victim is not breathing, call for emergency services. Administer cardiopulmonary resuscitation (CPR) immediately after breaking contact with the electrical source. Continue CPR until breathing starts or until help arrives.
x
Where an automatic electronic defibrillator (AED) is available use according to instructions.
x
Treat an electrical burn as a thermal burn by applying clean, cold (iced) compresses. Prevent contamination, and cover with a clean, dry dressing.
National Fire Protection Association (NFPA). Standard for Electrical Safety Requirements for Employee Workplaces (NFPA 70E), available from National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269-9101 (telephone: 800-344-3555; website: www.nfpa.org). Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Title 30 Mineral Resources, Parts 1 to 199, available from the U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (telephone: 202-693-9400; web site: www.msha.gov).
INFORMATION SOUCES American National Standards Institute (ANSI). Safety in Welding, Cutting, and Allied Processes (ANSI Z49.1), available from Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112-5776 (telephone: 800-854-7179; web site: www.global.ihs.com).
American Welding Society (AWS). Safety and Health Fact Sheets, available from Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112-5776 (telephone: 800-854-7179; web site: www.global.ihs.com).
Occupational Safety and Health Administration (OSHA). Code of Federal Regulations, Title 29 Labor, Parts 1910.1
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein. Fact Sheet No. 5 — 10/03
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123 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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ANSI/AWS D11.2-89 (R2006)
Safety and Health Fact Sheet No. 6 September 1995
© 1998 American Welding Society
FIRE AND EXPLOSION PREVENTION
INTRODUCTION Welding, cutting, and allied processes produce molten metal, sparks, slag, and hot work surfaces. These can cause fire or explosion if precautionary measures are not followed. MAIN CAUSES OF FIRES IN WELDING AND CUTTING—FLYING SPARKS •
Sparks can travel up to 35 feet (10 meters) on a horizontal direction from the work area.
Note: Sparks and molten metal can travel greater distances when falling. Sparks can pass through or become lodged in cracks, clothing, pipe holes, and other small openings in floors or partitions.
TYPICAL COMBUSTIBLE MATERIALS AND CONDITIONS •
Parts of buildings such as floors, partitions, and roofs.
•
Contents of buildings such as wood, paper, clothing, plastics, chemicals, and flammable liquids and gases.
•
Outdoor combustible materials include dry leaves, grass, and brush.
•
Welding and cutting have caused explosions when performed in spaces containing flammable gases, vapors, liquids, or dusts.
HOW TO PREVENT FIRES •
Remove any combustible material from the work area.
•
Where possible, move the work to a location well away from combustible materials.
•
If relocation is not possible, protect combustibles with a cover made of fire-resistant material.
Fact Sheet No. 6—9/95
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•
•
Remove or make safe all combustible materials for a radius of 35 feet (10 meters) around the work area.
•
Using fire-resistant material, cover or block all open doorways, windows, cracks, and other openings.
•
If possible, enclose the work area with portable fire-resistant screens.
•
Protect combustible walls, ceilings, floors, etc., from sparks and heat with fire-resistant covers.
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If working on a metal wall, ceiling, etc., prevent ignition of combustibles on the other side by moving the combustibles to a safe location.
•
If relocation of combustibles cannot be done, designate someone to serve as a fire watch, equipped with a fire extinguisher, during the welding operation and for at least one half-hour after welding is completed.
•
Do not weld or cut on material having a combustible coating or combustible internal structure, as in walls or ceilings, without an approved method for eliminating the hazard.
•
Do not dispose of hot slag in containers holding combustible material.
•
Keep a charged fire extinguisher nearby, and know how to use it.
•
After welding or cutting, make a thorough examination for evidence of fire. Remember that easily visible smoke or flame may not be present for some time after the fire has started.
•
Be aware that overloading and improper sizing can cause overheating of electrical equipment and possible fire hazard.
•
Be sure all electrical equipment and wiring are installed properly and have recommended circuit protection.
•
Be sure the work cable is connected to the work as close to the welding area as practical. Work cables connected to the building framework or other locations some distance from the welding area increase the possibility of the welding current passing through lifting chains, crane cables, or other alternate circuits. This can create fire and shock hazards or overheat lifting chains or cables until they fail.
•
Do not weld or cut in atmospheres containing dangerously reactive or flammable gases, vapors, liquids, or dust.
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ANSI/AWS D11.2-89 (R2006)
ANSI/AWS D11.2-89 (R2006)
•
Do not apply heat to a container that has held an unknown substance or a combustible material whose contents, when heated, can produce flammable or explosive vapors.
•
Do not apply heat to a workpiece covered by an unknown substance or whose coating can produce flammable, toxic, or reactive vapors when heated.
•
Develop adequate procedures, and use proper equipment to do the job safely.
•
Provide adequate ventilation in work areas to prevent accumulation of flammable gases, vapors, or dusts.
•
Clean and purge containers before applying heat.
•
Vent closed containers, including castings, before preheating, welding, or cutting. Venting prevents the buildup of pressure and possible explosion due to the heating and expansion of gases.
INFORMATION SOURCES American National Standards Institute (ANSI). Safety in Welding, Cutting, and Allied Processes, Z49.1, available from American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. Occupational Safety and Health Administration (OSHA). Code of Federal Regulations, Title 29 Labor, Chapter XVII, Parts 1901.1 to 1910.1450, Order No. 869-019-00111-5, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 02402. National Fire Protection Association. Cutting and Welding Processes, NFPA Standard 51B, available from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. American Welding Society (AWS). Recommended Safe Practices for the Preparation for Welding and Cutting Containers That Have Held Hazardous Substances, AWS F4.1, available from American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. American Welding Society (AWS). Fire Safety in Welding and Cutting, Pamphlet, available from American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. --`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Title 30 Mineral Resources, Parts 1-199, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402.
Fact Sheet No. 6—9/95
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Safety and Health Fact Sheet No. 7 September 1995
© 1998 American Welding Society
BURN PROTECTION
INTRODUCTION Sparks and spatter fly off from the welding process. Hot metal and sparks blow out from the cutting process. The workpiece and equipment get hot. The flying sparks and hot metal, spatter, hot workpiece, and hot equipment can cause burns. Additionally, arc rays can cause radiation burns (see Fact Sheet No. 2).
•
Wear dry, hole-free insulating gloves.
•
Touching hot equipment such as electrode holders, gun tips, and nozzles can cause burns—always wear insulated gloves or allow a cooling period when touching these and any associated parts of equipment that are near the actual welding or cutting operation.
•
Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless pants, high shoes, and a cap.
•
Do not wear pants with cuffs or shirts with open pockets or any clothing that can catch and hold molten metal or sparks.
•
Wear high top shoes or leather leggings and fire-resistant boots.
•
Use approved helmets or hand shields that provide protection for the face, neck, and ears, and wear a head covering to protect the head.
•
Wear approved safety goggles with side shields.
•
When welding or cutting overhead or in confined spaces, wear flame-resistant ear plugs or ear muffs to keep sparks out of ears.
•
Keep clothing free of grease, oil, solvents, or any flammable substances.
•
Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding or cutting.
Fact Sheet No. 7—9/95
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HOW TO PREVENT BURNS
•
If combustible substances spill on clothing, change to clean fire-resistant clothing before doing any welding or cutting.
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Use aprons, cape-sleeves, leggings, shoulder covers, and bibs designed and approved for welding and cutting service.
•
Where unusually heavy welding or cutting is involved, use sheet metal shields for extra protection.
•
For highly hazardous processes or jobs, give serious consideration to automation.
•
Do not attempt to repair or disconnect electrical equipment under load. Disconnecting under load produces arcing of the contacts and may cause burns or shocks.
HOW TO PROTECT OTHERS FROM BURNS •
Use noncombustible screens or barriers to protect nearby persons or watchers.
•
Mark hot work pieces to alert others of the burn and fire hazards.
•
If job requires several persons, have all wear proper protective gear and follow all required procedures.
INFORMATION SOURCES American National Standards Institute (ANSI). Safety in Welding, Cutting, and Allied Processes, Z49.1, available from American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. Occupational Safety and Health Administration (OSHA). Code of Federal Regulations, Title 29 Labor, Chapter XVII, Parts 1901.1 to 1910.1450, Order No. 869-019-00111-5, available from Superintendent of Documents, U.S. Government Printing office, Washington, DC 20402. American National Standards Institute (ANSI). Practice for Occupational and Educational Eye and Face Protection, Z87.1, available from American National Standards Institute, 11 West 42nd Street, New York, NY 10036. ________. Standard for Men’s Safety-Toe Footwear, ANSI Z41.1, available from American National Standards Institute, 11 West 42nd Street, New York, NY 10036. Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Title 30 Mineral Resources, Parts 1-199, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402.
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ANSI/AWS D11.2-89 (R2006)
ANSI/AWS D11.2-89 (R2006)
Safety and Health Fact Sheet No. 8 September 1995
© 1998 American Welding Society
INTRODUCTION Like other industries that work with metals, welding and cutting are seldom done in isolation. Other equipment and tools are normally used and kept nearby. The use of, or the closeness to, mechanical equipment can present hazards to the welder. A knowledge of the proper use of power tools, such as grinders, chippers, drills, and various hand tools, is important to welder safety. Know and understand the safe limits and proper use of cranes, positioners, and other material handling equipment, and use the appropriate guards and personal protective equipment. Recommendations concerning frequently encountered mechanical hazards in welding follow. GRINDING WHEEL SAFETY •
Follow grinding wheel speed limitations according to manufacturer’s instructions.
•
Do not grind on the side of a wheel not designed for such service.
•
When starting a new wheel, stand to the side until it reaches speed, and correct any abnormalities noted.
•
Be sure guards are in place and properly used.
PERSONAL PROTECTIVE EQUIPMENT •
Wear proper eye and hand protection.
•
Use face shields, safety glasses, and goggles as appropriate.
•
Wear dry, hole-free insulating gloves when welding or cutting.
•
Avoid wearing loose items such as rings, necklaces, bracelets, long hair, loose clothing, neckties, scarves, earrings, and beards.
•
Watch out for sharp objects, pinch points, and moving objects.
Fact Sheet No. 8—9/95
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MECHANICAL HAZARDS
ANSI/AWS D11.2-89 (R2006)
•
Use tools safely.
•
Use the right tool for the job. Be sure it is the right size.
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Use good quality tools, and use them for the job they were intended to perform. For example, it is often tempting to use a screwdriver for a chisel or a pair of pliers for a wrench—avoid such practices. The right tool will do the job faster and safer.
•
Keep a firm grip on tools to prevent them from slipping away.
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Do not overload or force a tool beyond its capabilities.
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Never force a tool.
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Foresee results of unexpected occurrences such as tools getting away, binding, or coming loose from their handles.
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Check any tool that has become jammed or otherwise overstressed for damage before reuse.
•
Anticipate the reactive force from tools.
•
Anticipate what might happen to a component that is to be loosened or unbolted from its working position.
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When using tools that involve weights and spring tension, be certain that all pressures are applied and released in a safe manner.
•
Follow lockout procedures for equipment and tools specifying such a procedure.
•
Do not bypass interlocks on equipment. Bypassing defeats the safety device and creates a possibly serious hazard.
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Inspect tools before use.
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Never use a tool that is in poor or faulty condition.
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Keep all hand tools in good working condition.
•
Store hand tools in a safe place. Many accidents are caused by tools falling off ladders, shelves, or scaffolds that are being moved. Each tool should have a designated place in the tool box or electrician’s pouch.
•
For additional information of the safe operation and guarding of mechanical equipment, refer to the manufacturers’ safe operating procedures for the equipment being used.
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HAND TOOL SAFETY
ANSI/AWS D11.2-89 (R2006)
INFORMATION SOURCES American National Standards Institute (ANSI). Safety in Welding, Cutting, and Allied Processes, Z49.1, available from American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. ________. Safety Requirements for The Lockout/Tagout of Energy Sources, ANSI Z244.1, available from American National Standards Institute, 11 West 42 Street, New York, NY 10036. ________. Practice for Occupational and Educational Eye and Face Protection, ANSI Z87.1, available from American National Standards Institute, 11 West 42nd Street, New York, NY 10036. Occupational Safety and Health Administration (OSHA). Code of Federal Regulations, Title 29 Labor, Chapter XVII, Parts 1901.1 to 1910.1450, Order No. 869-019-00111-5, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 02402. National Institute for Occupational Safety and Health. Safety and Health in Arc Welding and Gas Welding and Cutting, NIOSH Publication No. 78-138. Cincinnati, Ohio: National Institute for Occupational Safety and Health. Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Title 30 Mineral Resources, Parts 1-199, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402.
Fact Sheet No. 8—9/95
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ANSI/AWS D11.2-89 (R2006)
Safety and Health Fact Sheet No. 9 September 1995
© 1998 American Welding Society
TRIPPING AND FALLING
INTRODUCTION Welding, cutting and associated processes take place in a wide variety of locations under many different conditions. Welding and cutting occur in shops and factories on the floor level, on high steel in skyscraper construction, in pits, vats, mines, tanks, ship compartments, and literally everywhere that metals are joined or cut. CAUSES OF TRIPPING AND FALLING
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•
Poor housekeeping of materials, equipment, hoses, and tools.
•
Scattered parts and pieces either left over or waiting for use.
•
Failure to use approved safety belts and harnesses or incorrect use of them when working above floor level.
•
Electric shock from faulty equipment.
•
Sudden loud noises or shouts.
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Incorrect or improperly used or installed safety equipment such as ladders, guardrails, scaffolds, and nets.
•
Failure to wear proper personal protective wear such as skid-resistant soles on shoes to meet the needs of the job.
•
Horseplay or unsafe actions, such as tossing tools to each other or bumping someone in a precarious position.
•
Restricted vision caused by needed safety gear such as welding helmets and safety goggles.
•
Failure to fully understand the hazards, such as toxic fumes, when entering a pit, tank, or compartment.
Fact Sheet No. 9—9/95
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HOW TO PREVENT TRIPPING AND FALLING •
Be alert, awake, and concentrated about the job and the work area; notice any changing conditions; stay focused—do not let yourself or others be preoccupied or woozy on the job.
•
Wear and use only the correct, approved equipment for the specific job; be sure it is properly installed and used.
•
Do not carry things that obstruct your view or that upset your balance.
•
Prohibit horseplay on the job.
•
Follow all standard safe practices required by your employer.
•
Keep the work area clean and neat—ask your supervisor for help if this is a problem.
•
Do not take chances or unnecessary risks—such actions can cause accidents.
INFORMATION SOURCES American National Standards Institute (ANSI). Safety in Welding, Cutting, and Allied Processes, Z49.1, available from American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. Occupational Safety and Health Administration (OSHA). Code of Federal Regulations, Title 29 Labor, Chapter XVII, Parts 1901.1 to 1910.1450, Order No. 869-019-00111-5, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402. National Institute for Occupational Safety and Health. Safety and Health in Arc Welding and Gas Welding and Cutting, NIOSH Publication No. 78-138. Cincinnati, Ohio: National Institute for Occupational Safety and Health. Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Title 30 Mineral Resources, Parts 1-199, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402.
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ANSI/AWS D11.2-89 (R2006)
Safety and Health Fact Sheet No. 10 September 1995
© 1998 American Welding Society
FALLING OBJECTS
INTRODUCTION Welding, cutting, and associated processes often take place in areas where failing objects may be present. Failing objects may seriously injure or kill. Failing objects are common problems on construction and demolition sites of all kinds, from buildings to bridges, and are also often a problem during maintenance work. HOW TO PROTECT AGAINST FALLING OBJECTS •
Wear approved head and foot protection.
•
Be alert and aware of your total work environment and any possible overhead objects before you start working.
•
Place a safety net or equivalent below overhead work.
•
Follow safe work practices when working below overhead activities.
•
Notify others of overhead work and any changing job conditions.
•
Remember, a welding helmet or goggles restricts vision and may prevent taking the action necessary to avoid falling objects.
•
Post areas where failing objects are a hazard.
HOW TO PREVENT FALLING OBJECTS •
Be certain that material being welded or cut is secured from failing.
•
Do not permit loose objects near the edge 19 of overhead structures.
•
Cover floor and wall openings.
•
Use toe boards with guardrails.
Fact Sheet No. 10—9/95
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•
Do not kick, throw, or push anything off overhead structures this includes electrode stubs and scrap metal.
•
Do not create failing objects for others—be alert to all your actions.
INFORMATION SOURCES American National Standards Institute (ANSI). Safety in Welding, Cutting, and Allied Processes, Z49.1, available from American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. National Institute for Occupational Safety and Health. Safety and Health in Arc Welding and Gas Welding and Cutting, NIOSH Publication No. 78-138. Cincinnati, Ohio: National Institute For Occupational Safety And Health. Occupational Safety and Health Administration (OSHA). Code of Federal Regulations, Title 29 Labor, Chapter XVII, Parts 1901.1 to 1910.1450, Order No. 869-019-00111-5, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402. Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Title 30 Mineral Resources, Parts 1-199, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402.
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Safety and Health Fact Sheet No. 11 September 1995
© 1998 American Welding Society
CONFINED SPACES
INTRODUCTION/DEFINITION Many different places require welding, cutting, and heating work. Some of these places lack room and become “confined spaces.” Confined spaces have the following characteristics: •
Limited space, entry, or exit.
•
Poor ventilation—lack of safe breathing air and possible buildup of hazardous gases, fumes, and particles.
EXAMPLES OF CONFINED SPACES • • • • • • • • •
Small rooms. Process vessels. Pits Tunnels. Vats. Reactor vessels. Underground utility vaults. Unventilated corners of a room. Furnaces.
• • • • • • • •
Storage tanks. Pipelines. Sewers. Silos. Degreasers Boilers Compartments of ships. Ventilation and exhaust ducts.
REASONS FOR DEATHS AND SERIOUS INJURIES FROM WELDING IN CONFINED SPACES Fire. • Electric shock. • Exposure to hazardous air contaminants.
Explosion. Asphyxiation.
ACTIONS REQUIRED BEFORE APPROVING START OF WORK IN A CONFINED SPACE •
Open all covers and secure them from closing.
Fact Sheet No. 11—9/95
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• • •
ANSI/AWS D11.2-89 (R2006)
•
Test confined space atmosphere for (1) suitable oxygen content, (2) no combustibles or reactives, (3) no toxics.
Note: The testing requires special equipment and training. •
Isolate lines by capping or double valving and venting, if feasible—keep vents open and valves leak-free.
•
Lock out all systems not required during welding, cutting, or heating.
•
Provide means for readily turning off power, gas, and other supplies from outside the confined space.
•
Protect or remove any hazardous materials or materials which may become a physical or health risk when heated or exposed to an arc.
REQUIRED ACTIONS DURING WORK IN A CONFINED SPACE •
Continuously ventilate and monitor confined space to ensure that fumes and gases do not exceed safe exposure limits as found in OSHA (Occupational Safety and Health Administration) regulations Title 29, CFR Part 1910, 1000.
•
Use NIOSH/MSHA (National Institute for Occupational Safety and Health/Mine Safety and Health Administration) approved breathing device when required by code, instruction, or good practice.
•
Keep unnecessary persons and equipment out of and away from the confined space.
•
Do not allow equipment to block exit or possible rescue efforts.
•
Place as much equipment as possible outside the confined space.
•
Do not go into a confined space unless a watchperson, properly equipped and trained for rescue, is outside and maintaining continuous communications with worker inside.
•
Provide means for turning off power, gases, and fuel from inside the confined space, if feasible, especially if outside turn-off means are not provided, feasible, or certain.
INFORMATION SOURCES National Institute for Occupational Safety and Health. Criteria for a Recommended Standard—Working in Confined Spaces, NIOSH Publication No. 80-106. Cincinnati, Ohio: National Institute for Occupational Safety and Health.
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Occupational Safety and Health Administration (OSHA). Code of Federal Regulations, Title 29 Labor, Chapter XVII, Parts 1901.1 to 1910.1450, Order No. 869-019-00111-5, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402. De Reamer, R. Modern Safety and Health Technology, New York, New York: John Wiley & Sons. American National Standards Institute (ANSI). Safety Requirements for Working in Tanks and Other Confined Spaces, ANSI Z117.1, available from American National Standards Institute, 11 West 42nd Street, New York, NY 10036. Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Title 30 Mineral Resources, Parts 1-199, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402.
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Safety and Health Fact Sheet No. 12 September 1995
© 1998 American Welding Society
CONTACT LENS WEAR
INTRODUCTION Since 1967, the American Welding Society has received reports concerning welders who have claimed to have had contact lenses fused to their eyes, either by the heat of the arc or by microwave radiation. Not one of these reports has been substantiated, and safety bulletins issued by the Occupational Safety and Health Administration (OSHA), the Food and Drug Administration (FDA), and the National Safety Council (NSC) have all refuted that such incidents could possibly have occurred. The American Optometric Association (AOA) has stated that improvements in lens materials, and in design, fitting, and care procedures, have eliminated many of the problems formerly associated with contact lenses. The Association noted that contact lenses do not make the eye more susceptible to injury nor will they make matters worse if an eye injury accidentally happens. •
The sum of all the research is this—wearing contact lenses poses no problem for welders in most normal situations.
GUIDELINES FOR USE OF CONTACT LENSES Use the following guidelines, adapted from the Contact Lens Ophthalmologists Association (CLAO), and endorsed by the AWS, where contact lenses are worn in welding situations: •
Wear contact lenses in industrial environments, in combination with appropriate industrial safety eyewear, except where there is likelihood of injury from intense heat, massive chemical splash, highly particulate atmosphere, or where specific regulations prohibit such use.
•
Have all employees wearing contact lenses notify their immediate supervisors and the plant safety medical personnel about their use of contacts—let people know you wear them.
•
Train all first aid personnel in the proper removal of contact lenses.
•
Encourage the wearing of contact lenses in industry for those employees whose central and peripheral vision can be increased by contact lenses, as contrasted to
Fact Sheet No. 12—9/95
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spectacle lenses. Examples of such employees are those who have had a cataract removed from one or both eyes, those with irregular astigmatism from corneal scars, or keratoconus, and those who are extremely nearsighted. •
Have employees keep a spare pair of contacts or prescription spectacles, or both, in their possession on the job to avoid an inability to function if they should damage or lose a contact lens while working.
•
Do not permit safety and medical personnel to discriminate against an employee who can achieve visual rehabilitation by contact lenses, either in job placement or on return to a job category.
•
Have safety and medical personnel determine on an individual basis the need for wearing spectacles or contact lenses in jobs which require unique visual performance. Carefully consider also the recommendations of the Occupational Safety and Health Administration and the National Institute for Occupational Safety and Health.
INFORMATION SOURCES American Optometric Association. AOA News Release: It’s Safe to Wear Contacts in School Shops and Labs.” St. Louis, Missouri: American Optometric Association, November 1984. Contact Lens Association of Ophthalmologists. CLAO position paper. New Orleans, Louisiana: Contact Lens Association of Ophthalmologists. National Safety Council, “Let’s End the Contact Lens Rumor.” National Safety News. Chicago, Illinois: National Safety Council, June 1983.
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Occupational Safety and Health Administration. OSHA New Release: OSHA Eye Experts Dispel Contact Lens Rumors.” Washington, DC: U.S. Department of Labor Office of Information, August 9, 1983.
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Safety and Health Fact Sheet No. 13 September 1995
© 1998 American Welding Society
ERGONOMICS IN THE WELDING ENVIRONMENT
INTRODUCTION The welding environment introduces many challenges to the field of ergonomics, many of which are now just being understood, not only by the manufacturing/processing sector, but by the medical profession as well. DEFINITION --`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
Ergonomics, also called human factors engineering, involves designing the workplace to fit the needs of the workers, rather than trying to make workers adjust to the workplace. When a workplace is designed properly, the worker performing the task feels comfortable with the job both physically and psychologically. Quality and production increase, and all parties benefit from the improved conditions. PROBLEMS RESULTING FROM POOR ERGONOMICS •
Repetitive Motion Disorder (RMD).
•
Cumulative Trauma Injury (CTI).
•
Lower productivity.
•
Lower quality.
•
Worker dissatisfaction.
POSSIBLE SOLUTIONS TO ERGONOMIC PROBLEMS •
Recognize that both RMD and CTI are often felt to be a type of short term weakness or fatigue, when actually they are the start of potentially larger injuries.
•
Address all initial complaints in a timely manner.
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•
Interact with the worker and discuss possible solutions to give the employee ownership of any new plans and to gain acceptance for any redesign solutions.
•
Redesign the workstation in conjunction with the employee so he feels part of the process, uses the new design, and helps develop other ideas for future improvements.
WORKSTATION DESIGN FACTORS Some of the many factors that require consideration when analyzing and designing the welding environment include the following: •
The physical ability of the worker (history).
•
The weight of the gun.
•
The design of tools.
•
The position of the work.
•
The body mechanics of the individual welding operation.
•
The type of protective equipment the welder is using.
•
The work space (size, lighting, temperature, noise, vibration, etc.)
•
Physical requirements of the job (lifting, turning, reaching).
•
Mental requirements of the job (motivation, alertness, concentration).
INFORMATION SOURCES McKormick and Sanders. Human Factors in Engineering and Design. New York: McGraw-Hill Book Co., 1982. AIHA Report, Ergonomic System Analysis Checklist, published by the American Industrial Hygiene Association, 475 Wolf Ledges Parkway, Akron, OH 44311.
Ergonomics Program Management Guidelines, OSHA 1990. Washington, DC: U.S. Government Printing Office
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Safety and Health Fact Sheet No. 14 September 1995
© 1998 American Welding Society
GRAPHIC SYMBOLS FOR PRECAUTIONARY LABELS
INTRODUCTION Existing standards, such as American National Standards Institute (ANSI) Z49.1, ANSI Z535.4, and National Electrical Manufacturer’s Association (NEMA) EW6, thoroughly present guidelines for the minimum required information, method of presentation, signal words, color use, and label format. DEFINITION
RATIONALE FOR GRAPHIC SYMBOLS Pictures may convey information better than words. Therefore, the next logical evolution of precautionary labeling adds graphic symbols to show the major welding or cutting hazards. The use of symbols on precautionary labels is optional and is recommended for the following reasons: •
Symbols may show and help to explain the hazards quickly—fast concept transfer— and use visual (not verbal) recognition.
•
Symbols address nonreaders as well as readers.
•
Symbols may be multilingual and usually translate directly into all languages.
RATIONALE FOR STANDARDIZED SYMBOLS The welding and cutting industry needs standardized symbols and uniform methods of use to avoid user confusion and to supplement and reinforce the written message. NEMA EW6 standard provides a list of symbols and minimum symbol size for labels along with complete information regarding their use and application.
Fact Sheet No. 14—9/95
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Graphic symbols are pictures sometimes called pictographs, pictograms, or pictorials used in place of, or as a supplement to, written words. These symbols provide non-verbal communication about the possible hazard. They represent or symbolize the hazard.
ANSI/AWS D11.2-89 (R2006)
•
Use the symbols to show the associated hazard.
•
Take standard symbols from NEMA EW6.
•
Follow a building block approach.
•
Select a base symbol—often it is used alone such as the fire symbol.
•
Choose additional symbol element(s) to fully show the hazard.
•
Combine the chosen symbol element(s), such as the stick electrode symbol, with the base symbol, such as fumes and gases.
•
Carefully review all symbols on this Fact Sheet and in NEMA EW6.
•
Follow the design methods and standard way of incorporating symbols onto the safety label according to EW6.
INFORMATION SOURCES National Electrical Manufacturer’s Association. Guidelines for Precautionary Labeling for Arc Welding and Cutting Products, Arc Welding Section, NEMA EW6. Washington, DC: National Electrical Manufacturer’s Association. American National Standards Institute (ANSI). Safety in Welding, Cutting, and Allied Processes, Z49.1, available from American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. ________. Criteria for Safety Symbols, available from American National Standards Institute, 11 West 42nd Street, New York, NY 10036. ________. Product Safety Signs and Labels, ANSI Z535.4, available from American National Standards Institute, 11 West 42nd Street, New York, NY 10036. American Welding Society. Labeling and Safe Practices Committee SH4. FMC Corporation. Product Safety Sign and Label System. Santa Clara, California. Westinghouse Electric Corp. MB 3662. Product Safety Label Handbook. Pittsburgh, Pennsylvania.
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HOW TO USE THE SYMBOLS
ANSI/AWS D11.2-89 (R2006)
International Organization for Standardization. Graphic Symbols for Use on Equipment, ISO 7000, available from International Organization for Standardization, 1, rue de Varembé, 1211 Geneva 20, Switzerland. EXAMPLES FROM NEMA EW6 These symbols with hazards are recommended and endorsed by the American Welding Society Labeling and Safe Practices Committee anytime optional symbols are used on a precautionary label.
HAZARD
SOURCE OF HAZARD
SYMBOL
SOURCE
Electric Shock
Welding Electrode
ISO, FMC, NEMA
Electric Shock
Wiring
ISO, FMC
Electric Shock
Welding Electrode and Wiring
ISO, FMC, NEMA
Fumes and Gases
Any Source
FMC, NEMA
Fumes and Gases
Welding Fumes and Gases
ISO, FMC, NEMA
Arc Rays
Welding Arc
ISO, FMC, NEMA
Fire
Engine Fuel
FMC, NEMA
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HAZARD
SOURCE OF HAZARD
SYMBOL
SOURCE
Fumes and Gases
Engine Exhaust
ISO, FMC, NEMA
Fumes and Gases
Engine Exhaust and Welding Arc
ISO, FMC, NEMA
Moving Parts Causing Bodily Injury
Moving Parts Such as Fans and Rotors
FMC, NEMA
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Safety and Health Fact Sheet No. 15 September 1995
© 1998 American Welding Society
STYLE GUIDELINES FOR SAFETY AND HEALTH DOCUMENTS
INTRODUCTION Style for welding and cutting documents means two things: matter and manner; form and content; style and format. Style refers not only to what is said, but also how it is stated and presented to the reader. --`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
EARLY STYLE METHODS AND FEATURES The style and format for welding and cutting documents have evolved with time. Ten or fifteen years ago documents contained the following features: •
Commands or directives telling what to do without explaining the consequences of not doing it.
•
Frequent use of the passive voice rather than active voice.
•
Use of underlining for emphasis.
EARLY STYLE EXAMPLES •
“A check off list should be used by the welding operator.”
•
“Proper quality control procedures should be used.”
REASONS FOR NOT USING EARLY STYLE The AWS Safety and Health Committee recommends the early method not be used for the following reasons: •
The older style of writing does not give or imply the consequences of the failure to act as directed.
•
The older style does not tell how to avoid the consequences when it is possible to do so.
Fact Sheet No. 15—9/95
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CURRENT STYLE METHODS AND FEATURES Currently, it is recommended that documents state the hazards and include the consequences as well as how to avoid them. The stylistic features are as follows: •
Use the active voice.
•
Use strong, clear, action verbs in the imperative mood.
•
Use short, direct sentences.
USE OF PRECAUTIONARY LABELING SIGNAL WORDS There are three signal words used to identify the levels of hazard in ANSI Z535.4— DANGER, WARNING, and CAUTION. Wherever possible, reserve these words for use on labels only. Avoid the use of signal words in prose. Use the word “precautionary” instead of signal words for text.
CURRENT STYLE EXAMPLES •
“Use a checklist. Do not skip any items. Omitting steps can cause personal injury or equipment damage.”
•
“Use proper quality control procedures to meet intended performance requirements and to minimize costs.”
BACKGROUND OF CURRENT STYLE The current writing style evolves from precautionary labeling practices and arises from the obligation to users found in standards and codes, as well as from an industry-wide concern for the well-being of its customers. The writing method needs to warn and instruct the reader about the normal use and reasonably foreseeable misuse and abuse of a product or process as is used in current precautionary labeling practices. The instruction literature which accompanies a product, or process, is considered as part of that practice. •
The warn part of the requirement is met by a statement of the hazard and consequences of the failure to act as specified.
•
The instruct part of the requirement is met by explaining how to avoid the hazard and consequences.
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•
It is not mandatory to have a particular order to the statements. It can be warn and instruct or instruct and warn. Either sequence is satisfactory, though warn and instruct is preferred.
•
This order preference is based on current precautionary labeling practices which warn first and instruct second.
•
For all safety and health information published by the American Welding Society, try to follow the warn and instruct requirements for the normal use as well as for the foreseeable misuse and abuse of the product or process.
FORMAT SUGGESTIONS •
Several formats satisfy these requirements. The two most popular are the following:
•
Put all information in one or two sentences.
•
Use an entry statement containing the warning (statement of hazard and its consequences) followed by a list of simple instructions telling how to avoid the hazard like the following typical example from NEMA EW6:
WARNING: ELECTRIC SHOCK can kill: FUMES AND GASES can be hazardous; ARC RAYS can injure eyes and burn skin. •
Do not touch live electrical parts.
•
Keep your head out of the fumes.
•
Wear dry insulating gloves and clothing.
•
Use enough ventilation or exhaust at the arc to keep fumes and gases from your breathing zone, and the general area.
•
Wear correct eye, ear, and body protection.
•
Read and follow the manufacturer’s instructions, employer’s safety practices, and Material Safety Data Sheets (MSDSs).
Fact Sheet No. 15—9/95
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ANSI/AWS D11.2-89 (R2006)
ANSI/AWS D11.2-89 (R2006)
FEATURES OF THE CURRENT METHOD •
Use simple, clear, precise words.
•
Use the active voice instead of the passive voice in sentence structure.
•
Use the imperative mood of the verbs to give commands or directives.
SUMMARY Remember the primary purpose of any instructions, but especially those containing safety or health information; •
Quickly get to the point to keep the reader’s attention and save time.
•
Be clear, direct, and simple in communicating all the reader needs to know.
•
Use easy-to-read short lists to follow the preferred method.
INFORMATION SOURCES National Electrical Manufacturer’s Association, Guidelines for Precautionary Labeling for Arc Welding and Cutting Products, EW6. Washington, DC: National Electrical Manufacturer’s Association. ________. Manual for NEMA Standards Publications, NEMA NS 1-1983. Washington, DC: National Electrical Manufacturer’s Association. American National Standards Institute (ANSI). Style Manual for Preparation of Proposed American National Standards, ANSI X3/90-1887 X,S,M,T, available from American National Standards Institute, 11 West 42nd Street, New York, NY 10036. ________. Product Safety Signs and Labels, ANSI Z535.4, available from American National Standards Institute, 11 West 42nd Street, New York, NY 10036.
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Safety and Health Fact Sheet No. 16 March 1997
© 1998 American Welding Society
PACEMAKERS AND WELDING
DEFINITION Pacemakers are devices which are implanted in cardiac patients to ensure proper heart rhythm. Since these devices are electrical in operation, their ability to function can be affected by strong electromagnetic fields.
WELDING AND ELECTROMAGNETIC FIELDS Electric arc welding and cutting processes produce intense electric and magnetic (electromagnetic) fields. Persons with a pacemaker should not go near welding or cutting operations until they have consulted their doctor and obtained information from the manufacturer of the device.
STEPS TO REDUCE EXPOSURE Pacemaker wearers should observe the following precautions: •
Do not use current settings higher than necessary.
•
Keep the weld cables as close together as possible by twisting or taping them.
•
Connect work clamp to workpiece as close to the weld as possible.
•
Arrange cables to one side and away from the operator.
•
Keep welding power source and cables as far away as practical.
•
Do not weld with rapidly repeated short spurts—wait about 10 seconds between each weld.
•
If you feel sick, stop welding immediately and get medical attention.
•
Do not work alone.
Fact Sheet No. 16—3/97
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TALK TO THE DOCTOR If you are getting a pacemaker and will be working with or around welding, talk with your doctor. Inform him of your occupation. Discuss your work clearly with him. Pacemakers differ, and your doctor can select one that is less likely to be affected by interference. INFORMATION SOURCES Guidant Corporation, 4100 Hamline Avenue North, St. Paul, MN 55112-5798, Phone: 800-505-4636.
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Medtronic, Inc., 7000 Central Avenue, N.E., Minneapolis, MN 55432-3576, Phone: 800505-4636.
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Safety and Health Fact Sheet No. 17 January 1996
© 1998 American Welding Society
ELECTRIC AND MAGNETIC FIELDS (EMF)
INTRODUCTION Electric and magnetic fields are often referred to as “electromagnetic fields,” or EMF. There is concern that EMF may affect your health.
HOW IS EMF PRODUCED? Voltage is the difference in electric potential between two points. This voltage creates and electric field between those points. Now suppose that an electric connection is made between those two points, so that there is an electric current. This current produces a magnetic field. Magnetic fields occur whenever there is current flow.
IS EMF HARMFUL? Many scientific tests have been and are still being conducted by governmental and private agencies to determine if EMF is harmful to our health. Most studies to date indicate that there is no evidence of significant health problems from EMF.
HOW DO I MINIMIZE EXPOSURE? •
Do not place your body between the torch and work cables. Route cables on the same side of your body.
•
Route the welding cables close together. Secure them with tape when possible.
•
Connect the work cable to the workpiece as close to the weld as possible.
•
Keep the welding power source and cables as far away from your body as possible.
•
Never coil the torch or work cable around your body.
Fact Sheet No. 17—1/96 --`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`--
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INFORMATION SOURCES Occupational Safety and Health Administration (OSHA). Code of Federal Regulations, Title 29 Labor, Chapter XVII, Parts 1900 to 1910, Order No. 869-019-00111-5, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402. Environmental Protection Agency (EPA). Questions and Answers about Electric and Magnetic Fields, National Institute of Environmental Health Sciences (of Dept. of Health and Human Services) and Dept. of Energy, available from Miles Kahn, P.O. Box 37133, Washington, DC 20013-7133. --`,```,```,,```,,`,````,`,,``-`-`,,`,,`,`,,`---
United States Congress, Office of Technology Assessment. Biological Effects of Power Frequency Electric & Magnetic Fields—Background Paper, OTA-BP-AE-63, May, 1989, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402. American Conference of Governmental Industrial Hygienists (ACGIH). Threshold Limit Values for Chemical Substances and Physical Agents and Biological Exposure Indices, available from ACGIH, Inc., 6500 Glenway Ave., Cincinnati, OH 45211. National Electrical Manufacturers Association (NEMA). Q & A: Biological Effects of Electric & Magnetic Fields, available from NEMA, 2101 L Street, N.W., Washington, DC 20037.
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Fact Sheet No. 17—1/96
154 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
ANSI/AWS D11.2-89 (R2006)
Safety and Health Fact Sheet No. 18 March 1997
© 1998 American Welding Society
LOCKOUT/TAGOUT
INTRODUCTION Sometimes work must be performed on equipment, pipelines, and machinery that may contain moving parts, pressurized gases or liquids, electrical energy, or other hazards. Contact with any of these may result in injury or death.
DEFINITIONS “Lockout” means to install a locking device that keeps the switch, valve, or other mechanism from being turned on or opened. “Tagout” means to put a tag on the locking device. The tag indicates DANGER or WARNING, along with a brief message. It has a place to put the date and person’s name who lockedout the equipment so that he or she may be easily found or notified.
STEPS TO FOLLOW •
Train employees in the purpose and methods of lockout/tagout.
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Inform the job supervisor about the proposed work, and obtain permission to lockout and tagout the equipment.
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Shut down the equipment.
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Place locks and tags on the switches and valves to prevent their use.
Note: If more than one person is performing work on the equipment, it is recommended that they have their own locks and tags on the lockout point. •
Have the operator try to start the equipment or open the valves. If the equipment and valves are not operable, proceed to the next step. If they are operable, check where the locks should be placed or, if needed, place additional locks to ensure that equipment or valves are not operable. Check the equipment or valves for operation again.
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Fact Sheet No. 18—3/97
Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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ANSI/AWS D11.2-89 (R2006)
•
Start the work. If the employees’ shift ends before the work is completed, they must remove their locks and the next shift’s employees must install their locks before continuing the work and before the previous shift’s locks are removed.
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When the work is completed, ensure that all employees are clear before removing the locks and tags, energizing equipment, or opening valves.
INFORMATION SOURCES Occupational Safety and Health Administration (OSHA). Code of Federal Regulations, Title 29 Labor, Chapter XVII, Parts 1901.1 to 1910.1450, Order No. 869-019-00111-5, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402. Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Parts 1-199, available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402. For specific information on recommended lockout points for equipment, machinery, and valves, contact the manufacturer.
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Page 2 of 2
Fact Sheet No. 18—3/97
156 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
ANSI/AWS D11.2-89 (R2006)
Safety and Health Fact Sheet No. 19 March 1998
© 1998 American Welding Society
LASER WELDING AND CUTTING SAFETY
INTRODUCTION A laser is a device which produces an intense, coherent, directional beam of light. The term LASER is an acronym for Light Amplification by Stimulated Emission of Radiation. Lasers can be designed to deliver a large amount of energy to a very small area. In welding and cutting operations, this energy can heat metals quickly to very high temperatures. Much of the radiation that strikes the workpiece is reflected into the environment, creating hazards. Some laser light used in laser welding equipment is invisible, so the hazard may not be readily apparent. HOW LASERS WORK Typical lasers use electricity to create the unique coherent light that is very different from ordinary non-coherent light, such as that from a light bulb. Coherent light can be tightly focused and is not diffused or scattered like ordinary light. This coherent light beam is parallel and can be focused to cut or weld metals. Laser light can be different colors of the visible light spectrum, or can be invisible when the light is ultraviolet or infrared. Lasers used for welding and cutting may be infrared, and therefore the beam may be invisible. It is very difficult to take precautions against things one cannot see. It is even more difficult to convince others to take precautions against hazards they cannot see and may not understand. POTENTIAL HAZARDS •
RADIATION—Both visible and invisible light radiation are produced when welding or cutting. Due to the interaction with the workpiece, high levels of hazardous blue light and ultraviolet radiation (secondary radiation) are produced. This light radiation is often reflected from the workpiece into the work area. Radiation from these processes can seriously burn eyes an skin quickly and permanently. These hazards are addressed in the American National Standards Institute Z136.1 standard.
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FIRE—Since the laser system produces a very small spot size with high energy, the hazard of fire is present if the beam hits flammable material. Keep flammables away from the welding or cutting area. Be sure to cover and protect anything flammable in the area, since reflected radiation could start fires in unexpected places. Protect the work area.
Fact Sheet No. 19—3/98
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Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
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•
FUMES AND MISTS—Lasers easily vaporize metals. In doing so, fumes and mists are created which can present a respiratory hazard. Often the fumes and mists cannot be seen, yet they can pose a serious health hazard. Always use adequate ventilation.
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MECHANICAL—The optical device on the robotic arm or other beam manipulator can malfunction and send the laser beam in unintended directions. Therefore, it is essential that the work cell be shielded in conformance with standards for the laser type and class.
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ELECTRIC SHOCK—Since lasers require a large amount of electrical power to accomplish specific tasks, electrical hazards are present. Conventional hazards associated with any electrical industrial power source are present. These require standard and common electrical safe practices as found in ANSI Z49.1 and in AWS Safety and Health Fact Sheet No. 5. Additionally, there are the unique electrical hazards common to lasers in general and the hazard of the individual application. Usually, the best source of safety information is provided in the instruction manual from the manufacturer of the laser system. Always read, understand, and follow the manufacturer’s recommended safety procedures.
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EYE AND SKIN DAMAGE—Laser system eye and skin hazards are addressed in the ANSI Z136.1 standard. In many use situations, special laser eye protective devices are required. According to the ANSI Z136.1 standard, this eyewear must be labeled with both the optical density (protective factor) and wavelength(s) for which the protection is afforded. The protective eyewear must be compatible with the manufacturer’s specifications for the laser system in use, to ensure that the eyewear is suitable. In addition to the primary hazard of the laser beam, there may be a considerable eye hazard from high levels of secondary radiation. The ANSI Z136.1 standard requires that the eyes be protected from this secondary radiation in addition to the primary laser beam. A precaution must be added here—standard safety glasses alone do not provide protection. Any laser eyewear, plain or prescription, must be labeled with the wavelength(s) of protection and the optical density at that wavelength(s). In some laser systems, ultraviolet light may be leaked into the workplace. Thus the eyewear should provide primary beam protection, secondary radiation protection, and also ultraviolet protection.
SAFETY NEEDS All laser welding and cutting installations are required to have a laser safety officer (LSO). The LSO is responsible for personnel protection, laser cell class conformance, and enforcement of all laser safety regulations. Be certain to follow recommendations from the laser system manufacturer. In addition, provide certified laser protective eyewear, clothing, and shields where required.
Page 2 of 3
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Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
Fact Sheet No. 19—3/98
158 Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
ANSI/AWS D11.2-89 (R2006)
INFORMATION SOURCES American National Standards Institute (ANSI). Safe Use of Lasers, Z136.1, available from American National Standards Institute, 11 West 42nd Street, New York, NY 10036. Kokosa, J. Hazardous Chemicals Produced By Laser Materials Processing, Journal of Laser Applications, 6 (1994) pp. 195–201. Laser Institute of America (LIA). Guide for the Selection of Laser Eye Protection, available from Laser Institute of America, 12424 Research Parkway, Orlando, FL 32826. ________. OSHA Instruction Publication 8-1.7, Guidelines for Laser Safety and Hazard Assessment, available from Laser Institute of America, 12424 Research Parkway, Orlando, FL 32826. ________. Industrial Laser Safety Reference Guide, available from Laser Institute of America, 12424 Research Parkway, Orlando, FL 32826. ________. Laser Safety Guide, available from Laser Institute of America, 12424 Research Parkway, Orlando, FL 32826. Shannon, G., et al. Investigation Into the Underwater Laser Welding of Steel, Journal of Laser Applications, 6 (1994), pp 112-229. Sliney, D. and Wolbarsht, M. Safety with Lasers and Other Optical Sources, Plenum Press, New York, available from Laser Institute of America, 12424 Research Parkway, Orlando, FL 32826. Varanelli, A. Electrical Hazards Associated with Lasers, Journal of Laser Applications, 7 (1995) pp. 62–64.
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Fact Sheet No. 19—3/98
Page 3 of 3
159 Copyright American Welding Society Provided by IHS under license with AWS No reproduction or networking permitted without license from IHS
Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
ANSI/AWS D11.2-89 (R2006)
Safety and Health Fact Sheet No. 20 February 1997
© 1998 American Welding Society
THERMAL SPRAYING SAFETY
INTRODUCTION Thermal spraying processes use modifications of arc, plasma, and oxyfuel energy sources to produce the resulting heat, atmosphere, and particle velocity needed to properly coat an object (a substrate) with the desired thickness and properties of a surfacing material. The high temperatures, velocity, and projectile distance of the spraying processes create a unique set of safety hazards for the operator and those nearby. DEFINITIONS/PROCESS DESCRIPTIONS According to ANSI/AWS A3.0, Standard Welding Terms and Definitions, Thermal Spraying (THSP) is a group of processes that deposit molten metallic or non-metallic surfacing materials onto a prepared substrate. All thermal spraying processes introduce a feedstock (usually a powder or wire) into a heating device (combustion or electrical). There the material is heated, blended into the heat plume, and sprayed onto a prepared substrate. The molten particles strike the surface, flatten, and form thin platelets that conform and adhere to the substrate and to one another. As they cool, they build up a lamellar structure to form the desired coating. Combustion processes include Low-Velocity Oxyfuel (LVOF) and High-Velocity Oxyfuel (HVOF) systems. Electrical processes are Arc (two-wire), Plasma Arc (powder), and Plasma Induction (powder) systems. Typical operating conditions for the various processes are shown in the table below.
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Dust—Finely divided airborne solid particulate should be treated as an explosive and inhalation hazard. Adequate ventilation and wet collection of the overspray should be provided to minimize these hazards.
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Fumes, Vapors, and Gases—Ventilate and use safe practices according to ANSI Z49.1, the MSDSs, and AWS Safety and Health Fact Sheet No. 1. In addition, most spray and abrasive blasting operations require the use of an approved respirator that complies with requirements of ANSI Z88.2. Also, precautions should be exercised to avoid the presence of chlorinated hydrocarbon solvent vapor in the area of the arc or plasma spraying. Hazardous phosgene gas can be produced when hydrocarbon vapors are exposed to ultra-violet radiation from these processes.
Fact Sheet No. 20—2/97
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Licensee=ISATIS Group in iran Revised Sub Account/5620002316 Not for Resale, 08/27/2013 04:05:15 MDT
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POTENTIAL HAZARDS AND HAZARDOUS EFFECTS
ANSI/AWS D11.2-89 (R2006)
LVOF
HVOF
Arc
Plasma Arc
Plasma Induction (Atmosphere)
Temperature
to 5000°F
to 6000°F
4000–15,000°F
4000–15,000°F
to 30,000°F
Velocity
200–700 ft/sec (
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