Topic

Welding

LEARNING OUTCOMES
By the end of this topic, you should be able to:
1.

Define the different types of welding and their applications;

2.

Explain common hazards related to the welding activity; and

3.

Discuss the control measures to minimise welding hazard.

INTRODUCTION
Welding is a common work activity that we can see in manufacturing,
automotive, construction, metallurgical and petrochemical industries. Basically,
welding is an industrial process for joining metal parts by applying heat or
pressure. It is a potentially hazardous activity due to the nature of work where
there are risks of electric shock, explosion, toxic fumes, noise, fire and
electrocution. Therefore, work activities involving welding requires careful
precautions to reduce those hazards. In this topic, we will learn about different
types of welding activities, potential welding hazards and effective control
measures.

5.1

TYPE OF WELDING ACTIVITY

There are various types of welding such as fusion welding, braze welding,
friction welding, forge welding and explosion welding. Various energy sources
such as electric arc, electric resistance, electron beams, friction and ultrasound are
used according to each welding type. Detailed explanations on each of the
welding type and their applications are discussed below in the following
subtopics (Sacks, et al., 2005).
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5.1.1

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Fusion Welding

Fusion welding is achieved by introducing heat to melt metals with similar

properties. There are different types of fusion welding and these are further
explained below:
(a)

Manual Metal Arc Welding (MMAW) or Shielded Metal Arc Welding

(SMAW) or Stick Welding
This is the most basic welding type where it involves stick welding which is
when it uses a consumable flux-coated electrode to lay the weld and join
metals together. Electric arc is produced between the metals and electrode
to form a joint. The advantages include low cost, versatile and simple
procedures.
Application: It is used in manufacturing industry, construction sites and for
repairing activities.

(b)

Gas Metal Arc Welding (GMAW) or Metal Inert Gas Welding (MIG)
GMAW uses the same principle as MMAW except that gas is used to shield
the arc from surrounding contaminants. The advantages of using this type
of welding are it is clean because there is no slag formation, highlyproductive and very easy to use.
Application: Used in automotive industry, repair and robotic welding.

5.1.2

Explosion Welding

Explosion welding, a relatively new type of welding is done by detonating one of

the components using chemical explosives to bond two different metals. The
advantages of explosion welding are there will be no heat-affected zone formed,
minor melting and the final product is not affected by the large differences in
material melting temperatures.
Application: Explosion welding is normally used in hydrometallurgy industry,
shipbuilding, power generation and petroleum refining.

5.1.3

Braze Welding

Braze welding involves the use of bronze or brass filler rod with flux coating to
join metals together. The advantages of braze welding are that lower amount of
heat is required and the work pieces retain their shape.
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Application: It is ideal for production of joining application, repair tools and

equipment.

5.1.4

Friction Welding

Heat is produced by the friction between component surfaces in relative motion

to another to join the materials together. Its advantages are less preparation
required, produce strong bond and allow dissimilar metals to fuse together.
Application: Used in automotive industry, aviation and nuclear industry.

5.1.5

Forge Welding

Basically, this type of welding has been around for centuries involving two metal
components that are heated and then hammered together to form a joint. The
advantages are its versatility to weld similar metals and dissimilar metals and
require simple method.
Application: It is used for production of pattern-welded blade and shotgun barrel
manufacturing.

5.2

WELDING HAZARDS

The first step in managing risks of welding activity is to identify the related
hazards. Basically, different types of welding possess similar hazards. Work
activity that involves welding is potentially hazardous to both safety and health.
The effects can be short-term or have long-term effects. Electric shock is one
example of short-term effect whereas deteriorating lungs function due to
inhalation of toxic fumes is an example of long-term effect. Potential hazards
related to welding activity are discussed in the following paragraph.

5.2.1

Common Hazards Related to Welding Activity

Welders face an array of hazards which can be potentially dangerous this

includes electric shock, fumes and gases, burns and exposure to heat, fire and
explosions, noise and vibration as well as radiation. Detailed explanation on
these hazards which are contained in Health and Safety in Welding (Department
of Labour, 2006) and Welding Process: Code of Practice (SafeWork Australia,
2012) are as follows:

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(a)

Improper Grounding
Any equipment or tool that uses electrical current to operate poses electric
shock hazard. If the welding tools or parts are not grounded properly,
touching the live electrical parts or electrode may results in burn or even
fatal electrocution.

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(b) Expose to Fumes and Gas

Inhalation of toxic fumes and gases such as aluminium, chromium, copper
and iron oxide from welding activity has short-term and long-term effects
(Goetsch, 2015). Short-term effects include metal fume fever, dermatitis,
suffocation and irritation to respiratory system. These short-term effects
normally lasted within one to three days. On the other hand, long-term
effects refer to carcinogenic effects of those metal fumes and gases.
Prolonged exposure to hazardous fumes and gases may result in
deteriorating respiratory system, nervous system and cardiovascular
system. However, these effects only show up after several years and
difficult to be connected to welding activity because of many other factors.
(c)

Expose to Intense Heat

The temperature of welding arc can reach up to 6,000Celcius. As a result,
there are risk of burns to skin and other exposed body parts when come in
contact with those hot surfaces and flying sparks.

(d)

Expose to Flying Sparks and Compressed Gas

Welding activity used flammable gas (hydrogen, acetylene and methanenatural gas) as fuel. Welding also produces flying sparks and heat which
can result in fires and explosions if mixed with sufficient oxygen and fuel.
Explosion hazard is presents when welding on containers such as vessels,
tanks, pipes or drum. Loose connections of cables that come in contact with
faulty welding equipment may cause fire. In addition, compressed gas in
cylinder, which is also a component of welding activity poses explosion
hazard.

(e)

Noise and Vibration

Excessive exposure to high level of noises from welding can cause damage
to hearing. In addition, vibration from welding activity may affect nervous
system.

(f)

Radiation
The plasma arc emits intense ultraviolet, visible light and infrared
radiation. Laser beam and electron beam welding and cutting processes
also produce visible and/or invisible radiation. In addition, whenever the

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high voltage is on, an electron beam system is capable of generating X-rays

(Human Resources and Social Development Canada, 2013).
(g)

Expose to Sharp Edge and Awkward Posture

Flying parts or contact with electrode or sharp edge metals can cause
injury. If a welder works in an awkward position, he is exposed to
strenuous and other musculoskeletal injuries.

SELF-CHECK 5.1
1.

List five types of welding activity.

2.

Briefly describe hazards related to welding.

5.3

CONTROL OF WELDING HAZARDS

Risk assessment for welding is not necessary unless welding is undertaken in

specific situation, for example confined space. According to the Welding Process:
Code of Practice (SafeWork Australia, 2012), risk of welding hazards depends on
various factors which are listed as follows:
(a)

Type of welding;

(b)

Material of the electrode;

(c)

Surface coating of the parts or components being welded;

(d)

Properties of the materials being welded;

(e)

Voltage and current use in the process; and

(f)

Type of ventilation.

5.3.1

Control Measures of Specific Hazards

Necessary precautions should be taken to control the identified welding hazards

effectively. In this section, you will learn about control measures in accordance to
the hierarchy of control measures. According to the Welding Process: Code of
Practice (SafeWork Australia, 2012), control measures include, but are not limited
to the following:

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(a)

Elimination
You must always target to eliminate any hazard sources and their related risk
as the very first step if practicable. For example, eliminate any welding
activity that can expose to hazardous fumes or gases if it is reasonably
practicable. In addition, eliminate the need of welding work if other
alternative such as fabrications can be designed to include pre-cast
components or extruded shapes.

(b)

Substitution
If elimination is not possible, apply substitution in which a less-hazardous
process or chemical replaced the use of hazardous substances, practices or
processes. For example, opt for electric welding where less fumes are
generated compared to gas welding.

(c)

Isolation
Isolation can be done by screening or isolating hazard from the welder and
other workers. The following are examples of isolation methods to control
specific hazards:

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(i)

Welding activity that has potential exposure of fumes and gas can be
carried out in specified areas away from general fabrication.

(ii)

Place fire-resistant barriers to isolate potential combustible materials to

mix with welding sparks.

(iii) Ensure there is no trace of flammable substances in closed containers

such as vessels, tanks or drums to be welded prior to welding. Fill
those containers with inert substances such as water or nitrogen if
necessary.

(d)

(iv)

Isolate welding work from others by using barriers, welding bay or

sound absorbing surfaces to reduce exposure to high-level of noise.

(v)

Place barriers or protective screens to prevent radiation exposure to

others who are not directly involved with the welding work.

Engineering control
Engineering control normally involves high level of expertise. Examples of
how engineering control is applied to minimise risk of welding activity are:

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Local Exhaust Ventilation (LEV)

LEV is one example of engineering control where hazardous air
contaminant is effectively controlled at the source. It requires a highly
skilled area of expertise and therefore must only be designed or
installed by competent person. LEV (see Figure 5.1) system consists of:

Hood to capture air contaminant (hazardous fumes and gases) at

their point of operation;

Air cleaning system to control the surrounding air;

Duct system;

Stack to disperse decontaminated air into the surrounding; and

Exhaust fan.

Figure 5.1: Components of local exhaust ventilation

Source: https://www.osha.gov/dts/osta/otm/otm_iii/otm_iii_3.html

Examples of LEV that are appropriate for welding activity include:

(ii)

Portable installation;

Fixed installation; and

Fume extractor

Safety Devices

Install shut down mechanism such as fuses or safety switches on

equipment if practicable;

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(e)

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Fully insulate electrode holder; and

Use Alternate Current (AC) only if required for the welding

process.

Administrative Control
If risks are still present, you have to implement effective administrative
control. Following are some examples of administrative controls to minimise
risk related to welding:
(i)

Place sign that informs about the presence of electrical hazard.

(ii)

Provide clear instructions and safe procedures for welding activity

involving hazardous substances.

(iii) Comply with the minimum exposure standard by reducing working

time that exposes worker to hazardous substances.
(iv)

Allow short break in between work to minimise perspiration and

change to dry welding gloves if necessary.

(v)

Provide workers with adequate training and information about related

hazards and precautions necessary for protection.

(vi)

Inspect all equipment including welding tools, PPE, cables and

insulation prior to work.

(vii) When considered necessary, health assessment should be conducted on

employees who are exposed to hazardous substances.
(viii) Provide fire fighting equipment(s) near welding area.
(f)

Personal Protective Equipment (PPE)

This is the final resort to minimise the remaining risks. This method however
heavily relies on human behaviour and adequate supervision. Thus, periodic
inspection on the PPE shall be conducted to check whether they are properly
worn and in good conditions. Table 5.1 summarises the recommended PPE
for protection of specific hazards.

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Table 5.1: Recommended PPE for Different Form of Welding Hazards

PPE Type

Welding Hazards

Recommendations

Eye, face and head

protection

Radiation, welding
sparks, flying objects,
heat and light

Wear eye, face and head

protection such as goggles,
helmets and protective filters.

Hand protection

Electrical hazard, heat,

hot parts or objects

Wear dry and thermal resistant

welding gloves to protect
exposed skin.

Foot protection

Electrical hazard, heat

and wet/oily floor

Wear foot protection such as

boots or shoes that are non-slip,
heat and fire resistant.

Clothing and safety

harness (if welding is
undertaken above
floor level)

Electrical hazard, heat,

fire, and ultraviolet light
radiation

Wear dry, fire-proof, insulated

and heat resistant clothing.

Hearing protection

Noise

Wear ear plugs or ear muff to

reduce noise exposure level.

Respiratory protection

Gas, fumes and dusts

and hazardous air
contaminant

Wear sound, proper, and

disinfected
respirators
if
required in some situations such
as welding to be undertaken in
confined space.

Screen

Ultraviolet radiation

Place opaque or translucent

screen to protect the people
within the vicinity of welding
from potential radiation.

Source: Safe Work Australia (2012)

ACTIVITY 5.1
From the understanding that you have got from subtopic 5.3.1, draw a
simple mind map that summarises the main ideas of this topic. Your
mind map must include type of welding, welding hazards and control
measures of welding hazard. This mind map should be adequate for
revision in future.

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5.3.2

WELDING

Maintenance of Welding Equipment

You have to ensure that any equipment used in welding including welding
machines, ventilation system, and PPE are adequately and regularly maintained.
Any maintenance, testing or installation of electrical equipment such as
generators, power sources, welding machine and ventilation system shall only be
conducted by competent person. All PPE used for welding must be maintained
to be in sound, clean and hygienic. Periodic inspection on PPE is necessary to
check any ineffective or damaged PPE.

SELF-CHECK 5.2
Explain how to minimise fumes and gas hazard from welding activity
by applying hierarchy of control measures.

ACTIVITY 5.2
Refer to the following Health and Safety in Welding by New Zealands
Department of Labour (2006) for further reading on welding.

ACTIVITY 5.3
Fill in the missing word(s) on your own. Then compare your answers
with your coursemate.
(a)

A new type of welding where chemical explosives is detonated to

form bond between different metals is known as _____________.

(b)

The best option of welding type to be carried out in construction

site and require less cost is ______________.

(c)

Watch for _____________ as they can come in contact with

flammable and combustible materials to ignite flame.

(d)

____________hazard is present when welding is done on closed

containers such as tank, vessels, pipes or drum that contain
flammable substances.

(e)

__________________ is installed to remove hazardous gas and

fumes from the working area.

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(f)

During all welding activity, avoid ___________ by working on dry

floor with rubber shoes and wear ___________ to protect from
touching live electrical parts.

(g)

Place translucent ___________ to protect other people within the

vicinity of welding from potential radiation.

(h)

Hazardous fumes and gas can cause irritation to ________,

_________ and __________.

(i)

Inhalation of fumes and gas from welding activity can have both
___________ and ________ that can affect health in the long run.

(j)

Fire __________ must be provided for any type of potential fire

that might be encountered.

79

Welding is an industrial process used for joining metal parts by applying heat
or pressure or both.

Some examples of welding types are Manual Metal Arc Welding (MMAW),
Gas Metal Arc Welding (GMAW), forge welding, explosion welding, friction,
welding and braze welding.

Major hazards related to welding activity are improper grounding, heat,

fume and gas, flying sparks, compressed gas, radiation, noise and vibration.

Touching live electrical parts or improper cable connection can cause electric
shock.

Inhaling hazardous fumes and gas such as aluminium, chromium, copper

and iron oxide have both short-term effects and long-term effects to health.

Flying sparks or hot metals from welding activity come in contact with
flammable materials may result in fire or explosion. Welding on containers
such as vessel, drum, pipe and tank also might result in explosion.

Exposure to intense UV light and infrared rays from welding activity can
produce temporarily light blinding, affect iris of the eyes and cause cataract
in some people.
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Flying parts or contact with sharp edge during welding may cause injury.

Excessive exposure to high noise level can result in hearing damage.

Risks associated with welding hazards depend on the following factors; type
of welding, material of the electrode, surface coating of the parts or
components being welded, properties of the materials being welded, voltage
and current use in the process and type of ventilation.

Control measures to minimise risk of welding hazard in this topic is

presented by applying hierarchy of control measures:

Elimination: Eliminate any welding activity hazards.

Substitution: Opted for electric welding rather than gas welding as less
fumes are produced by electric welding.

Isolation: Use opaque or translucent screen to protect others within

vicinity from radiation hazard. It is a normal practice to carry out welding
in a place away from others.

Engineering control: LEV is the most effective method of engineering

control to minimise risk associated with hazardous gas and fumes from
welding activity. Shutdown mechanism such as fuses or safety switches is
used to avoid electrical hazard.

Administrative control: Provide workers with adequate training and

information about related hazards and precautions necessary for
protection. Besides, fire extinguisher equipment must be provided in the
working area. Employers shall comply with the minimum exposure
standard by reducing working time that exposes worker to hazardous
substances.

PPE: Wear appropriate PPE all the time when carrying out welding work.
Examples of PPE are dry hand gloves, insulated rubber shoes, goggles,
fire resistant clothes, ear plugs or ear muffs and respirators.

You must ensure that any equipment used in welding including welding
machines, ventilation system, and PPE are adequately and regularly
maintained.

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Braze welding

Gas Metal Arc Welding (GMAW)

Explosion welding

Manual Metal Arc Welding (MMAW)

Forge welding

Personal Protective Equipment (PPE)

Friction welding

Welding

Fusion welding

Welding hazard

Human Resources and Social Development Canada, HRDC. (2013). Guide to

health hazards and hazard control measures with respect to welding and
allied
processes.
Retrieved
from
http://www.labour.gc.ca/eng/
health_safety/pubs_hs/hhhcmrwap.shtml
Goetsch, D. L. (2015). Occupational safety and health for technologists, engineers,
and managers (8th ed.). England: Pearson.
Department of Labour. (2006). Health and safety in welding. Retrieved from
http://www.business.govt.nz/worksafe/information-guidance/allguidance-items/welding-health-and-safety-in/welding-dol10157.pdf
Sacks, R. J., Ciaramitaro, J. A. & Carney, J. (2005). Welding principles and
practices (3rd ed.). New York, NY: McGraw Hill.
Safe Work Australia. (2012).Welding process: Code of practice. Retrieved from
http://www.safeworkaustralia.gov.au/sites/SWA/about/Publications/Doc
uments/703/Welding%20Processes.pdf

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