Welding is a fabrication process that joins two or more materials using heat, pressure, or a combination of the two, to form a strong, permanent bond.

When workpieces are joined together at high temperatures, the heat causes a weld pool of molten material. After cooling and solidifying, this forms an incredibly strong weld.

Although welding is relied on by countless industries that need to join metal, plastic or wood parts, it brings a higher degree of risk than other processes.

In this blog, Surface Finishing Equipment outlines some of the most common dangers associated with welding operations and what you can do to mitigate these risks – including acquiring the appropriate personal protective equipment (PPE).

Welding safety hazards and precautions

Welding operations present numerous risks to workers, and it’s important to be aware of them so you can eradicate them.

· Exposure to fumes

When completing welding activities, workers will be exposed to invisible fumes like ozone, nitrogen oxide, chromium, nickel oxide, and carbon monoxide – all of which can easily penetrate the lungs.

When exposed to a high concentration of fumes or gases for prolonged periods, the consequences can be detrimental to health. For instance, it could cause occupational asthma, pneumonia, cancer, or throat and lung irritation, to name just a few.

Employers are legally responsible for making sure that risks are assessed, controlled and monitored effectively. However, the best way to prevent excessive exposure to dangerous fumes is to provide respiratory protective equipment (RPE).

· Electric shocks

Live electrical circuits are used during the arc welding process to create a pool of molten metal, which can put welders at risk of experiencing an electric shock.

This is one of the most severe hazards posed by the process, resulting in serious injuries and fatalities.

Secondary electric shocks are common, too. These occur when workers touch a part of the welding or electrode circuit whilst touching the metal being welded.

The risk of electric shocks is typically greater for those who work in damp conditions, wear wet clothing, or work on metal flooring or structures.

Wearing insulated, flame-resistant gloves and steel toe-capped safety footwear with rubber soles will protect welders from electric shocks, as well as heat, fire, burns, and falling objects.

· Loud noises

Workers carrying out welding activities can expect to be exposed to loud noises – usually above 85dB – which can damage their ears and result in hearing loss.

Those who are exposed to such sounds regularly may suffer from ringing in their ears (also known as tinnitus), dizzy spells, higher blood pressure, and an increased heart rate.

To minimise such hazards when welding, hearing protection must be worn at all times. In environments where there is a risk of sparks and splatter flying through the air and entering the ear, fire-resistant ear muffs are favourable.

· Burns

With high temperatures, UV rays, and molten metal, welders are susceptible to severe burns which can affect both the skin and eyes.

To prevent severe burns when welding, fire-resistant clothing should be worn on the arms and legs. Boots and gloves will also protect the hands and feet, whilst welding helmets shield the face and eyes from chemical burns and sparks.

Welding PPE

Although accidents happen – usually when you least expect them – making sure that you’re equipped with appropriate PPE will ensure that you’re fully prepared for when they do.

Welders who work without suitable protective personal equipment will be exposed to carcinogenic welding fumes, aggressive airborne particles, and extremely high temperatures. As a result, vital organs, such as the lungs, skin, and eyes, could be damaged.

Fortunately, here at SFEG, we have an extensive range of PPE available for welding activities – offering adequate protection for the eyes, face, lungs, and ears.

We supply welding visors (including tinted shields) which can protect the face and eyes from flying particles, sparks, bright lights, irritation, burns, and radiation. For maximum protection, these can be worn in addition to fire-resistant coverings.

Fume extraction is the responsibility of employers, ensuring that workers’ lungs are protected from fumes and oxides associated with the welding process. If welders are not protected from welding fumes, it can have an adverse impact on their health, causing cancer and, in some cases, asphyxiation. Therefore, all individuals undertaking welding activities must have a respirator (either a supplied air respirator with a breathing hose or a battery-powered unit).

When it comes to hearing protection, you’ll discover ear defenders from RPB Safety on our website. These are not only designed to protect the ears against loud noises in welding environments, but they easily clip into the respirators we supply, with no modifications needed.

Want to know more?

If you have any questions about the welding PPE we supply at SFEG, please don’t hesitate to get in touch with our specialists.

We’re always on hand to help and will gladly share our expertise, providing you with the information you need to make an informed decision.

To speak to a member of our team directly, call 0161 480 8087. Or, if you prefer, send an email to sales@sfeg.co.uk, and we’ll get back to you as soon as possible.