Subpart JSubpart JWelding and CuttingWelding and Cutting

These handouts and documents with attachments are not final, complete, or definitive instruments. This information is for guidance These handouts and documents with attachments are not final, complete, or definitive instruments. This information is for guidance purposes only. You should independently verify and satisfy yourself as to its accuracy. The AHBSIF does not assume any purposes only. You should independently verify and satisfy yourself as to its accuracy. The AHBSIF does not assume any

liability for damages arising from the use of this information or exhibits and attachments thereto and renders no opinion that liability for damages arising from the use of this information or exhibits and attachments thereto and renders no opinion that any of the terms, conditions, and/or cited federal standards in this document and the exhibits and attachments should be any of the terms, conditions, and/or cited federal standards in this document and the exhibits and attachments should be

explicitly followed by the fund member. Seek specific guidance from the appropriate regulator (OSHA) or professional advisor.explicitly followed by the fund member. Seek specific guidance from the appropriate regulator (OSHA) or professional advisor.

Potentially Hazardous Fumes Potentially Hazardous Fumes and Gasesand Gases

FumesFumes – Solid particles – Solid particles that originate from the that originate from the welding media, base welding media, base metal, or coatingmetal, or coating

GasGas – Generated by – Generated by the shielding gas or the shielding gas or process radiationprocess radiation NickelNickel ZincZinc Iron OxideIron Oxide CopperCopper CadmiumCadmium FluoridesFluorides ManganeseManganese Chrome & GasesChrome & Gases

Effects of OverexposureEffects of Overexposure Acute EffectsAcute Effects

Irritation of eyes, skin, Irritation of eyes, skin, respiratory systemrespiratory system

nausea, headaches, nausea, headaches, dizzinessdizziness

Metal Fume Fever Metal Fume Fever Asphyxiation (confined Asphyxiation (confined

space)space) Chronic EffectsChronic Effects

Central nervous system Central nervous system impairmentimpairment

Respiratory illnessRespiratory illness Reproductive disordersReproductive disorders Possible links to Possible links to

Parkinson’sParkinson’s

RadiationRadiation VisibleVisible – intense light – intense light

emitted during emitted during welding operationswelding operations

InfraredInfrared - produced by - produced by electric arc and other electric arc and other flame cutting flame cutting equipment equipment

UltravioletUltraviolet - generated - generated by all arc processesby all arc processes

Radiation Effects - Influencing Radiation Effects - Influencing Factors Factors

WavelengthWavelength IntensityIntensity Duration of Duration of

exposureexposure Exposure may Exposure may

result in skin burns result in skin burns or eye damageor eye damage

Common Welding Common Welding TechniquesTechniques

MIG WeldingMIG Welding TIG WeldingTIG Welding MAPP GasMAPP Gas Oxy-fuel Oxy-fuel

WeldingWelding

MIG WeldingMIG Welding ““Metal Inert Gas”Metal Inert Gas” Semi-automatic or automatic arc welding Semi-automatic or automatic arc welding

process in which a continuous and process in which a continuous and consumable wire electrode and a shielding consumable wire electrode and a shielding gas are fed through a welding gun. gas are fed through a welding gun.

Can use alternating or direct current, DC is Can use alternating or direct current, DC is most common most common

Typically used with steelTypically used with steel Fast welding techniqueFast welding technique

TIG WeldingTIG Welding ““Tungsten Inert Gas”Tungsten Inert Gas” Uses a nonconsumable tungsten electrode Uses a nonconsumable tungsten electrode

and filler metal to produce the weld. and filler metal to produce the weld. A shielding gas such as argon protects the A shielding gas such as argon protects the

process from atmospheric contamination process from atmospheric contamination Commonly used with Aluminum, Magnesium, Commonly used with Aluminum, Magnesium,

Copper, light gauge Stainless SteelCopper, light gauge Stainless Steel Slower than other welding techniquesSlower than other welding techniques Harder to master than other forms of welding Harder to master than other forms of welding

but produces higher quality and stronger but produces higher quality and stronger weldswelds

MAPP GasMAPP Gas ““Methyl Acetylene Propodiene”Methyl Acetylene Propodiene” Consists of LPG mixed with MAPPConsists of LPG mixed with MAPP Does not require dilution or special container Does not require dilution or special container

fillers during transport which allows a fillers during transport which allows a greater volume of gas to be transported at greater volume of gas to be transported at the same given weightthe same given weight

Most commonly used for brazing and Most commonly used for brazing and solderingsoldering

Ideal for aluminum and copperIdeal for aluminum and copper

Oxy-fuel WeldingOxy-fuel Welding ““Oxyacetylene Welding” aka Gas Oxyacetylene Welding” aka Gas

WeldingWelding Two pieces are heated to a Two pieces are heated to a

temperature that produces a shared temperature that produces a shared pool of molten metal. pool of molten metal.

The molten pool is supplied with The molten pool is supplied with additional metal called filler.additional metal called filler.

Safe Work PracticesSafe Work Practices The surrounding work area should be clean and The surrounding work area should be clean and

free of potentially combustible materialfree of potentially combustible material A fire extinguisher should be kept on hand at all A fire extinguisher should be kept on hand at all

timestimes Good ventilation is a must for all welding Good ventilation is a must for all welding

operationsoperations Personal protective equipment (PPE) should Personal protective equipment (PPE) should

include eye and face protection as well as include eye and face protection as well as protective clothingprotective clothing

Less toxic materials should be substituted when Less toxic materials should be substituted when possiblepossible Cadmium-free silver soldersCadmium-free silver solders Asbestos-free electrodesAsbestos-free electrodes

Pre-Shift InspectionPre-Shift Inspection Leads – insulation breech, kinksLeads – insulation breech, kinks Torch – tip, valves, tool bodyTorch – tip, valves, tool body Hoses & Fittings Hoses & Fittings Bottles & ValvesBottles & Valves Cart or other CG Bottle SupportCart or other CG Bottle Support Surrounding Area Surrounding Area Fire ProtectionFire Protection Any defective equipment must be replaced, Any defective equipment must be replaced,

repaired, or removed from servicerepaired, or removed from service

PersonalPersonal Protective Protective EquipmentEquipment

HelmetHelmet Must Comply with Must Comply with

ANSI Z87.1ANSI Z87.1 Most equipped Most equipped

with auto-darken with auto-darken features, 1/10,000 features, 1/10,000 of a secondof a second

OSHA 1926.102 OSHA 1926.102 Tables E-1 and E-2 Tables E-1 and E-2 specify minimum specify minimum protection levelsprotection levels

Personal Protective Personal Protective EquipmentEquipment

GlovesGloves ANSI Z49.1ANSI Z49.1 Must be flame Must be flame

resistantresistant Gloves should be in Gloves should be in

good shapegood shape Must resist potential Must resist potential

electric shock from electric shock from welding unitwelding unit

Personal Protective Personal Protective EquipmentEquipment

ApronApron ANSI Z49.1ANSI Z49.1 Produced in Produced in

variety of fire variety of fire retardant retardant materialsmaterials LeatherLeather NomexNomex Chemically Chemically

treated textilestreated textiles

Compressed Gas CylindersCompressed Gas Cylinders Typical Oxygen cylinder Typical Oxygen cylinder

pressures are around pressures are around 2600 lbs/in²2600 lbs/in²

Oxy fittings should be Oxy fittings should be kept clean and free of oil kept clean and free of oil and greaseand grease

Hose colors determine Hose colors determine use:use: RedRed – fuel gas hose – fuel gas hose GreenGreen – Oxygen – Oxygen Black – Inert gasBlack – Inert gas

Compressed Gas CylindersCompressed Gas Cylinders Cylinder valves must be Cylinder valves must be

protected at all timesprotected at all times Cylinders should be stored in an Cylinders should be stored in an

upright and secure positionupright and secure position The tilt and roll method is The tilt and roll method is

accepted practice for accepted practice for movement, never attempt to movement, never attempt to hoist with chokershoist with chokers

Valve caps must be secure any Valve caps must be secure any time the cylinder is not in usetime the cylinder is not in use

When stored, oxygen cylinders When stored, oxygen cylinders should be separated from other should be separated from other gas cylinders. gas cylinders. The required separation is 20’ The required separation is 20’

oror A five foot high fire wall with an A five foot high fire wall with an

approved fire-resistance ratingapproved fire-resistance rating

Welding Torch - Cutting Torch Welding Torch - Cutting Torch ComparisonComparison

Cutting Torch SafetyCutting Torch Safety Take appropriate Take appropriate

precautions for flooring precautions for flooring surfacesurface

Work benches made of Work benches made of steel or other fire steel or other fire retardant material is retardant material is acceptableacceptable

Adequate ventilationAdequate ventilation Confined SpacesConfined Spaces Toxic FumesToxic Fumes

Cutting Torch SafetyCutting Torch Safety

Appropriate personal protective Appropriate personal protective equipmentequipment

Control potentially combustible Control potentially combustible materials around work areamaterials around work area

Fire extinguisher handy at all timesFire extinguisher handy at all times Equipment maintenanceEquipment maintenance

Safe Welding ChecklistSafe Welding ChecklistFamiliarization with all applicable Familiarization with all applicable Material Safety Data Sheets (MSDS)Material Safety Data Sheets (MSDS)

Surrounding area free of potentially Surrounding area free of potentially combustible materialscombustible materials

Leeds should be fully insulated, no Leeds should be fully insulated, no kinks or deformationkinks or deformation

Fire extinguisher readily available, Fire extinguisher readily available, fully charged and functionalfully charged and functional

Torch tip, valves, and tool body in Torch tip, valves, and tool body in good working ordergood working order

Proper face, hand, and body Proper face, hand, and body protection in useprotection in use

Hoses and fittings tight and free of Hoses and fittings tight and free of wear, dry rotwear, dry rot

Surrounding work areas protected Surrounding work areas protected by welding curtainsby welding curtains

Bottles secured and upright whether Bottles secured and upright whether stored or in use, cap securedstored or in use, cap secured

Adequate ventilation for all Adequate ventilation for all processes at all locationsprocesses at all locations

Bottles free of excessive corrosion, Bottles free of excessive corrosion, no dents, collar threads intact, clean no dents, collar threads intact, clean fittingfitting

Insure proper grounding of welding Insure proper grounding of welding machinemachine

Valves and gauges secured and Valves and gauges secured and operationaloperational

Any defective equipment replaced Any defective equipment replaced or repaired prior to the start of workor repaired prior to the start of work