CHAPTER 41 WELDING AND CUTTING

41 WELDING AND CUTTING

Welding is a method of joining metal parts together

by heating them until they melt and pressing them
together.
Arc welding is the most common type of welding Wire Drive
process used in construction. Arc welding uses
intense heat to melt metal, causing the molten
metal to intermix, usually with a filler metal from
an electrode. Once the liquid metal cools, a bond is
formed, joining two pieces of metal together.
Flame cutting (i.e., oxyacetylene or oxyfuel cutting)
is an allied process that requires the use of a torch, Power
Controls
fuel gas, and oxygen to cut metals—primarily steel. Source
For some of the information in this chapter, IHSA Contactor
gratefully acknowledges its use of the Canadian
Figure 41-2: Gas Metal Arc Welding
Standards Association standard CAN/CSA W117.2-12:
Safety in Welding, Cutting and Allied Processes, © CSA.
Flux Cored Arc Welding (FCAW) is a variation
of MIG welding. It uses a hollow consumable wire
Welding Methods whose core contains various chemicals that generate
shielding gases to strengthen the weld (Figure 41-3).
Shielded Metal Arc Welding (SMAW) is the most
common arc welding process in construction
(Figure 41-1).
Gas Nozzle

Current-Carrying
Contact Tube
Electrode Coating Electrode Wire
Flux-Cored
Electrode Gas Shielding
Protective Gas from
Arc Electrode Coating Molten
Weld Metal
Slag Solidified
Weld Metal
Solidified Metal
Molten Metal
Base Metal

Figure 41-3: Flux Cored Arc Welding

Figure 41-1: Shielded Metal Arc Welding
Gas Tungsten Arc Welding (GTAW) or Tungsten
SMAW uses a short length of consumable Inert Gas Welding (TIG) uses a non-consumable
electrode, which melts as it maintains the arc. tungsten electrode that maintains the arc and
Melted metal from the electrode is carried across provides enough heat to join metals (Figure 41-4).
the arc to become the filler metal of the weld. Filler metal is added in the form of a rod held close
to the arc. The rod melts and deposits filler metal
The electrode is coated with a complex mix of
at the weld. Shielding gases may or may not be
chemicals that release a shielding gas such as
used, depending on the metal being welded.
carbon dioxide to keep air out of the arc zone and
protect the weld from oxidation. The composition Gas Shielding
of the coating varies with the metal being welded.
Gas Metal Arc (GMAW) or Metal Inert Gas Welding
(MIG) uses an uncoated consumable wire that is
fed continuously down the middle of the welding Power
torch. A ring-like tube around the wire transports Source
Tungsten
an inert gas such as argon, helium, or carbon Electrode
dioxide from an outside source to the arc zone to
prevent oxidation of the weld (Figure 41-2).

Workpiece

Figure 41-4: Gas Tungsten Arc Welding

Tools and Techniques 41-1

WELDING AND CUTTING

Oxyacetylene Welding and Cutting burns a Welding Hazards

mixture of gases—oxygen and acetylene—to
generate heat for welding metals (Figure 41-5). It’s Physical - Ionizing radiation (x-rays, gamma rays)
the most common fuel gas cutting and welding -N on-ionizing radiation (ultraviolet,
used in construction. The process may also employ infrared)
the use of a filler metal. - Visible light
- Temperature extremes
Mixer - Fire
Gas - Noise
Supplies - Electrical energy
Chemical - Flammable/combustible products
Nozzle - Welding fumes
- Toxic gases
- Dust
Workpiece Biological - Bacteria
- Fungi
Figure 41-5: Oxyacetylene Welding - Viruses

Once a chemical from welding has entered the

Welding Gases body it may have a toxic effect. Effects can range
from mild irritation to death and are influenced by
Fuel gases for welding are used alone or with oxygen.
a number of factors. Different organs may also be
Examples include propane, propylene, and natural gas.
affected, such as the lungs, kidneys, and brain.
Acetylene is a mixture of carbon and hydrogen. Its
The two major types of effects are acute and
stored energy is released as heat when it burns.
chronic, as described in the Occupational Health
When burned with oxygen, acetylene can produce
chapter in this manual.
a higher flame temperature (3,300°C) than any
other gas used commercially. The wide flammable
range of acetylene (2.5% to 81% in air) is greater Physical Hazards
than that of other commonly used gases, with
consequently greater hazard. Radiation
Both ionizing and non-ionizing radiation may be
Base Metals encountered by welders and their helpers. Ionizing
is more hazardous because it can contribute
Because each metal and metal alloy responds to
directly to cancer.
heat in a distinct way, different base metals are
used for specific purposes and applications. Below Ionizing — A common source is the emission of
are the common base metals used for welding. x-rays and gamma rays from equipment used to
gauge the density and thickness of pipes and to
• Mild Steel – an alloy of iron, carbon, silicon, and
check welds.
occasionally molybdenum or manganese
• Stainless and High Alloy Steels – containing Non-ionizing — A major source is ultraviolet,
iron, nickel, chromium, and occasionally cobalt, infrared, and visible light radiation from sunlight or
vanadium, manganese, and molybdenum welding.
• Aluminum – either pure or as an alloy containing Radiation produced by the welding process
magnesium, silicon, and occasionally chromium is mainly non-ionizing, which includes
• Galvanized steel – steel that has been coated electromagnetic fields, infrared radiation, visible
with a layer of zinc to prevent corrosion. light, and ultraviolet radiation.
Exposure to ultraviolet (UV) radiation can result
Welding Hazards directly from the arc or from a reflection off bright
Welders in construction are exposed to a wide objects such as shiny metal or white clothing. It
range of hazards such as inhalation of toxic fumes can cause “arc eye” when sight is not adequately
and gases, serious burns from hot metal, and protected. Eyes become watery and painful
electric shocks from welding cable. Eye protection anywhere from 2 to 24 hours after exposure. The
is a must for welders and others who may be condition may last 1–5 days but is usually reversible
exposed to the welding process. with no lasting effects. However, repeated exposure
may result in scar tissue that can impair vision.
UV exposure may also cause a temporary loss
of visual sharpness called “fluorescence.” It may
eventually lead to the development of cataracts in
the eye if eye protection is not worn.

41-2 Construction Health and Safety Manual

 WELDING AND CUTTING

Skin reddening, commonly known as sunburn, is Electrical Energy

another hazard of UV exposure. Blistering may
Electrical shock is the effect produced by current
occur in extreme cases. Although excessive
on the nervous system as it passes through the
exposure to UV radiation from the sun has been
body. Electrical shock may cause violent muscular
linked to skin cancer, there are no reports of
contractions, leading to falls and injuries. It may
increased skin cancer rates from welding exposure.
also have fatal effects on the heart and lungs.
The intensity of UV radiation varies with the type of
Electrical shock may occur as a result of improper
welding. Generally, the higher the temperature of
grounding and/or contact with current through damp
the welding process the higher the UV radiation.
clothing, wet floors, and other humid conditions. Even
Infrared radiation is hazardous for its thermal or if the shock itself is not fatal, the jolt may still cause
heating effects. Excessive exposure to the eye may welders to fall from their work positions.
cause damage.
Electrical burns are an additional hazard. The burns
Visible light is released at high intensity by welding. often occur below the skin surface and can damage
Short-term exposure can produce “flash blindness” muscle and nerve tissue. In severe cases, the results
in which vision is affected by after-images and can be fatal.
temporary blind spots. Repeated exposure to
high-intensity visible light can produce chronic The extent of injury due to electrical shock depends
conjunctivitis, characterized by red, tearful eyes. on voltage and the body’s resistance to the current
passing through it (see the Electrical Hazards
X-rays and gamma rays are invisible forms of chapter in this manual). Even low voltages used
ionizing radiation used to inspect welds during in arc welding can be dangerous under damp or
radiographic testing. Exposure to these rays can humid conditions. Welders should keep clothing,
be extremely damaging to unprotected parts of gloves, and boots dry and stay well insulated from
the body. Keep all personnel away from any area work surfaces, the electrode, the electrode holder,
where this type of testing is being done. X-rays are and grounded surfaces.
also produced during electron beam welding. The
welding chamber must be completely shielded to Stray welding current may cause extensive
confine the x-rays and protect the operator. damage to equipment, buildings, and electrical
circuits under certain conditions.
Extreme Temperatures
Very high temperatures are caused by the welding Chemical Hazards
process. Gas flames may reach 3,300°C. Metals melt Chlorinated solvents for degreasing, zinc chromate-
in a range from 260°C to 2,760°C. Welded materials, based paint for anti-corrosion coatings, cadmium or
the work environment, and weather are sources of chromium dusts from grinding, and welding fumes
excessive heat, which can cause muscle cramps, are all classified as chemical hazards.
dehydration, sudden collapse, and unconsciousness.
Arc welders are at particular risk since the high
Welders may suffer frostbite and hypothermia temperatures generated by the arc can release heavy
when working in extreme cold climates or with concentrations of airborne contaminants.
welding gases stored at temperatures as low as
-268°C. Exposure to freezing temperatures can Chemical hazards may injure welders through
lead to fatigue, irregular breathing, lowered blood inhalation, skin absorption, ingestion, or injection into
pressure, confusion, and loss of consciousness. the body. Damage to respiratory, digestive, nervous,
Heat stress and cold stress are both life-threatening and reproductive systems may result. Symptoms of
and, if not treated in time, can be fatal. overexposure to chemicals may include nosebleeds,
headaches, nausea, fainting, and dizziness.
Noise Read the manufacturer’s safety data sheet (SDS) for
Sound waves over 85 dBA emitted at high intensity information on protective measures for any chemical
by welding equipment can lead to hearing loss. you encounter in the workplace.
Noise has also been linked to headaches, stress, The most common chemical hazards from welding
increased blood pressure, nervousness, and are airborne contaminants that can be subdivided
excitability. (See Chapter 14: Hearing Protection for into the following groups:
information on maximum exposures for workers
not equipped with hearing protection.) 1. Fumes
2. Gases and Vapours
Welding noise is produced by the power source, the 3. Dusts.
welding process, and by secondary activities such as
grinding and hammering. Gasoline power sources may The amount and type of air contamination from
lead to sound exposures over 95 dBA. Arc gouging these sources depends on the welding process, the
may produce sound levels over 110 dBA. Grinding, base metal, and the shielding gas. Toxicity depends
machining, polishing, hammering, and slag removal all on the concentration of the contaminants and the
contribute to high levels of noise. Substantial hearing physiological response of individual workers.
loss has been observed in welders.

Tools and Techniques 41-3

WELDING AND CUTTING

Fumes Lead can be found in lead-based paints and some

metal alloys. Lead poisoning results from inhalation
Some of the metal melted at high temperates
of lead fumes from these lead-based materials.
during welding vaporizes. The metal vapour then
The welding and cutting of lead or lead-coated
oxidizes to form a metal oxide. When this vapour
materials is the primary source of lead poisoning for
cools, suspended solid particles called fume
welders. Symptoms include loss of appetite, anemia,
particles are produced. Welding fumes consist
abdominal pains, and kidney and nerve damage.
primarily of suspended metal particles invisible to
Under Ontario law, lead is a designated substance
the naked eye.
requiring special precautions for use and handling.
Metal fumes are the most common and the most
Nickel is found in many steel alloys including
serious health hazard to welders. Fume particles
stainless steel and monel. It is a sensitizing agent
may reach deep into the lungs and cause damage
and in certain forms is toxic and carcinogenic.
to lung tissue or enter the bloodstream and travel
Nickel fumes can also produce cyanosis, delirium,
to other parts of the body. The following are some
and death 4 to 11 days after exposure.
common welding fumes.
Zinc is found in aluminum and magnesium alloys,
Beryllium is a hardening agent found in copper,
magnesium, and aluminum alloys. Overexposure brass, corrosion-resistant coatings such as
may cause metal fume fever. Lasting for 18–24 galvanized metal, and brazing alloys. Inhaling zinc
hours, the symptoms include fever, chills, fumes during the cutting or welding of these metals
coughing, dryness of mouth and throat, muscular may cause metal fume fever.
pains, weakness, fatigue, nausea, vomiting, and
headaches. Metal fume fever usually occurs Gases and Vapours
several hours after the exposure and the signs A gas is a low-density chemical compound that
and symptoms usually abate 12–24 hours after normally fills the space in which it is released. It
the exposure with complete recovery. Immunity has no physical shape or form. Vapour is a gas
is quickly acquired if exposure occurs daily, but produced by evaporation.
is quickly lost during weekends and holidays. For
this reason, metal fume fever is sometimes called Several hazardous vapours and gases may be
“Monday morning sickness.” produced by welding. Ultraviolet radiation, surface
coatings, shielding gases, and rod coatings
Long-term (chronic) exposure to beryllium fumes are primary sources of vapours and gases.
can result in respiratory disease. Symptoms may Overexposure may produce one or more of the
include coughing and shortness of breath. Beryllium following respiratory effects:
is a suspected carcinogen—that is, it may cause
cancer in human tissue. It is highly toxic. Prolonged • Inflammation of the lungs
exposure can be fatal. • Pulmonary edema (fluid accumulation in the
lungs)
Cadmium coatings can produce a high • Emphysema (loss of elasticity in lung tissue)
concentration of cadmium oxide fumes during • Chronic bronchitis
welding. Cadmium-plated or cadmium-containing • Asphyxiation.
parts resemble, and are often mistaken for,
galvanized metal. Cadmium is also found in solders Hydrogen fluoride (HF) gas can be released by
(especially silver solder) and brazes. the decomposition of rod coatings during welding
and irritates the eyes and respiratory system.
Overexposure to cadmium can cause metal fume Overexposure can injure lungs, kidney, liver, and
fever. Symptoms include respiratory irritation, bones. Continued low-level exposures can result in
a sore, dry throat, and a metallic taste followed chronic irritation of nose, throat, and bronchial tubes.
by cough, chest pain, and difficulty in breathing.
Overexposure may also make fluid accumulate Nitrogen oxide (NOx) gas is released through a
in the lungs (pulmonary edema) and may cause reaction of nitrogen and oxygen promoted by high
death. The liver, kidneys, and bone marrow can also heat and/or UV radiation. It is severely irritating
be injured by the presence of this metal. to the mucous membranes and the eyes. High
concentrations may produce coughing and chest
Chromium is found in many steel alloys. Known to
pain. Accumulation of fluid in the lungs can occur
be a skin sensitizer, it may cause skin rashes and
several hours after exposure and may be fatal.
skin ulcers with repeated exposure. Chromium also
irritates mucous membranes in areas such as eyes Ozone gas is formed by the reaction of oxygen in
and nose and may cause perforation of the nasal air with the ultraviolet radiation from the welding
septa. Inhaled chromium may cause edema and arc. It may be a problem during gas-shielded metal
bronchitis. arc welding in confined areas with poor ventilation.
Overexposure can result in an accumulation of fluid
in the lungs (pulmonary edema) which may be fatal.

41-4 Construction Health and Safety Manual

 WELDING AND CUTTING

Phosgene gas is formed by the heating of Fires/Explosions

chlorinated hydrocarbon degreasing agents. It
is a severe lung irritant and overexposure may There is always a threat of fire with welding. Fires
may result from chemicals reacting with one
cause excess fluid in the lungs. Death may result
another to form explosive or flammable mixtures.
from cardiac or respiratory arrest. The onset of
Many chemicals by themselves have low ignition
symptoms may be delayed for up to 72 hours.
points and are subject to burning or exploding if
Phosphine or hydrogen phosphide is produced exposed to the heat, sparks, slag, or flame common
when steel with a phosphate rustproofing coating in welding. Even sparks from cutting and grinding
is welded. High concentrations irritate eyes, nose, may be hot enough to cause a fire.
and skin.
In welding, oxygen and acetylene present the
Asphyxiants are chemicals that interfere with the most common hazards of fire and explosion. Pure
body's ability to transfer oxygen to the tissues. oxygen will not burn or explode but supports the
The exposed individual suffocates because the combustion of other materials, causing them to
bloodstream cannot supply enough oxygen for life. burn much more rapidly than they would in air.
There are two main classes of asphyxiants: Never use oxygen to blow dust off your clothing.
Oxygen will form an explosive mixture with
1. Simple asphyxiants displace oxygen in air,
acetylene, hydrogen, and other combustible gases.
thereby leaving little or none for breathing. In
welding, simple asphyxiants include commonly Acetylene cylinders are filled with a porous material
used fuel and shielding gases such as acetylene, soaked with acetone, the solvent for acetylene.
hydrogen, propane, argon, helium, and carbon Because acetylene is highly soluble in acetone at
dioxide. When the normal oxygen level of cylinder pressure, large quantities can be stored
21% drops to 16%, breathing as well as other in comparatively small cylinders at relatively low
problems begin, such as lightheadedness, pressures. When exposed to high temperature,
buzzing in the ears, and rapid heartbeat. excess pressure, or mechanical shock, acetylene
2. Chemical asphyxiants interfere with the body’s gas can undergo an explosive decomposition
ability to transport or use oxygen. Chemical reaction. In addition, if this reaction or an ignition
asphyxiants can be produced by the flame- of acetylene occurs within the torch base or supply
cutting of metal surfaces coated, for instance, hose, it can circulate back into the storage cylinder,
with rust inhibitors. Hydrogen cyanide, hydrogen causing it to explode.
sulphide, and carbon monoxide are examples of
chemical asphyxiants—all highly toxic. Preventive Measures
Dusts Welding hazards must be recognized, evaluated, and
controlled to prevent injury to personnel and damage
Dusts are fine particles of a solid that can remain to property. The WHMIS chapter in this manual
suspended in air and are less than 10 micrometres explains the information on hazardous materials that
in size. This means they can reach the lungs. Dusts can be provided by WHMIS symbols, labels, and
may be produced by fluxes and rod coatings, safety data sheets. Once a welding hazard has been
which release phosphates, silicates, and silica. identified, controls can be implemented at its source,
The most hazardous of these is silica which can along its path, or at the worker.
produce silicosis—a disease of the lung which causes
shortness of breath and can shorten life expectancy.
Exposure Factors
Biological Hazards Types and effects of airborne contaminants
produced by welding depend on the working
Biological hazards are a relatively minor concern environment, the kind of welding being done, the
for construction welders. However, exposure to material being welded, and the welder’s posture
bacteria may occur in sewer work, while air handling and welding technique.
systems contaminated by bacteria and fungi can
cause legionnaires’ disease and other conditions. The environment for welding is a very important
A fungus that grows on bird or bat droppings is factor in the degree of exposure to fumes, vapours,
responsible for a disease called histoplasmosis, and gases. Welding is best done outside or in open
producing flu-like symptoms. Contact may occur areas with moderate air movement. Air movement
where buildings contaminated with droppings are is necessary to dissipate fumes before they reach
being renovated or demolished. the welder. Enclosed areas with little ventilation
can lead to very high exposure levels because the
contaminant is not dispersed. In confined spaces,
fume, vapour, and gas levels that are dangerous to
life and health may result. Welding may also use up
the oxygen in a confined space, causing the welder
to lose unconsciousness or even die.

Tools and Techniques 41-5

WELDING AND CUTTING

The base metal to be welded is an important factor Natural dilution ventilation — The majority of
in the production of fumes, vapours, and gases. The construction projects depend on natural dilution
base metal will vaporize and contribute to the fume. ventilation (i.e., welding outside in a light breeze or
inside with doors and windows open). When using
Coatings such as rust inhibitors have been known to
natural dilution ventilation, you must make sure to
cause increased fume levels which may contain toxic
“keep your head out of the fume” (Figure 41-6).
metals. All paints and coatings should be removed
from areas to be welded as they can contribute to
the amount and toxicity of the welding fume.
Welding rod is responsible for up to 95% of the
fume. Rods with the fewest toxic substances can’t
always be used because the chemistry of the rod
must closely match that of the base metal.
Shielding gas used during SMAW can effect the NOTE: Welder must stay
contaminants produced. Using a mixture of argon and to one side of fume.
carbon dioxide instead of straight carbon dioxide has Figure 41-6: Natural Dilution Ventilation
been found to reduce fume generation by up to 25%.
Nitric oxide in the shielding gas for aluminum during
Mechanical dilution ventilation is common in most
GMAW has been found to reduce ozone levels.
welding shops. Fans such as roof exhaust fans
Welding process variables can have a big effect and wall fans force outside air into and out of the
on the fume levels produced. Generally, fume building. General mechanical ventilation in most
concentrations increase with higher current, larger cases will deflect the fume out of the welder’s
rods, and longer arc length. Arc length should breathing zone (Figure 41-7). Welders need
be kept as short as possible while still producing different amounts of fresh-air ventilation depending
good welds. Polarity is also a factor. Welding with on the specific task and the size of rod they’re
reverse polarity (workpiece negative) will result in using. For air volume recommendations, see the
higher fumes than welding with straight polarity American Conference of Governmental Industrial
(workpiece positive). Hygienists’ Industrial Ventilation: A Manual of
Recommended Practice.
The welder’s posture and technique are crucial
factors in influencing exposure. Studies have
shown that different welders performing the exact
same task can have radically different exposures.
Welders who bend over close to the welding
location, those who position themselves in the
smoke fume, and those who use a longer arc than
required will have a much greater exposure. The
welder should try to take advantage of existing
ventilation (cross drafts, natural, or mechanical) to
direct the fume away from the breathing zone.

Ventilation
Ventilation is required for all cutting, welding, and Figure 41-7: Mechanical Dilution Ventilation
brazing. Adequate ventilation is defined as the use
of air movement to Local exhaust ventilation consists of an exhaust
• Reduce concentrations of airborne contaminants fan, air cleaner, and ducted system dedicated to
below the acceptable limits in the worker’s removing airborne contaminants at the source and
breathing zone and the work area exhausting them outdoors. Local exhaust ventilation
• Prevent the accumulation of combustible gases is preferred over dilution ventilation because it is
and vapours, and better able to prevent airborne contaminants from
• Prevent oxygen-deficient or oxygen-enriched entering the welder’s breathing zone.
atmospheres. Local exhaust ventilation is recommended for
You need to take special steps to provide welding where toxic airborne contaminants are
ventilation in the following locations. produced and/or where a high rate of fume is
produced—for instance, during GMAW in confined
• Spaces with less than 283 cubic metres per welder areas with little ventilation where the shielding
• Rooms with a ceiling lower than 4.9 metres gases can build up to toxic levels.
• Confined spaces or where the area contains
partitions or other structures that significantly
obstruct cross-ventilation.

41-6 Construction Health and Safety Manual

 WELDING AND CUTTING

There are three types of local exhaust ventilation Ventilation Requirements

systems for welding:
There are two methods for determining ventilation
1) Portable fume extractor with flexible ducting requirements. One uses air sampling to measure
(Figure 41-8) the welder’s exposure to airborne contaminants
2) Fume extraction gun (Figure 41-9) and to determine the effectiveness of the
3) Welding bench with portable or fixed hood ventilation provided. Monitoring is not well suited to
(Figure 41-10). construction because site conditions are constantly
changing.
The other method uses tables to select the type
of ventilation according to the process, materials,
production level, and degree of confinement used
in the welding operation.
Ventilation guidelines for different welding
processes are spelled out in Canadian Standards
Association standard CAN/CSA W117.2-12: Safety in
Welding, Cutting and Allied Processes, © CSA.

Figure 41-8: Portable Fume Extractor Other Controls

An isolation chamber is a metal box with built-in
sleeves and gloves. The work is welded inside the
box and viewed through a window. This method is
used to weld metals that produce extremely toxic
fumes. The fumes are extracted from the isolation
chamber and ducted outdoors.
Respiratory protection will not be required for
most welding operations if adequate ventilation
is provided. However, when ventilation or other
Figure 41-9: Fume Extraction Gun measures are not adequate, or when the welding
process creates toxic fumes (as with stainless steel
and beryllium), respiratory protection must be worn.
Select respiratory protection based on estimated
exposure and the toxicity of the materials.
Disposable fume respirators are adequate for low
fume levels and relatively non-toxic fumes. For
higher exposures or for work involving toxic fumes,
a half-mask respirator with cartridges suitable for
welding fume should be used (Figure 41-11).
Facepiece
Replaceable
Filter Strap

Figure 41-10: Bench with Portable Hood

The effectiveness of local exhaust ventilation

depends on the distance of the hood from
the source, air velocity and volume, and hood
placement. Hoods should be located close to the
source of airborne contaminants. The hood is Inhalation Exhalation
placed above and to the side of the arc to capture Valve Valve

airborne contaminants. Figure 41-11: Half-Mask Respirator

Warning: In all processes that use shielding gas,
In areas where fume or gas concentrations may be
air velocities in excess of 30 metres/minute may
immediately dangerous to life and health, a self-
strip away shielding gas.
contained breathing apparatus (SCBA) or a supplied-
air respirator with a reserve cylinder should be used.
Use only supplied air or self-contained respirators in
areas where gases may build up or where there can
be a reduction in oxygen.

Tools and Techniques 41-7

WELDING AND CUTTING

A welder required to wear a respirator must Drums, tanks, and closed containers that have held
be instructed in its proper fitting, use, and flammable or combustible materials should be
maintenance. For more information, refer to thoroughly cleaned before welding or cutting. As
Chapter 15: Respiratory Protection in this manual. an added precaution, purge with an inert gas such
as nitrogen or carbon dioxide and fill with water to
within an inch or two of the place to be welded or
Fire Prevention cut and vent to atmosphere (Figure 41-13).
Sparks and slag from cutting, grinding, and welding
Keep air space as
can travel great distances and disappear through small as possible
Joint to be repaired
cracks in walls and floors or into ducts. They
may contact flammable materials or electrical
equipment. Fires have started in smoldering
materials that went undetected for several hours Water
after work was done.
Take the following steps to prevent fires and
explosions.
• Obtain a hot work permit through the safety
Figure 41-13: Fill Tanks that Previously Contained
officer if required.
Flammable Material with Water
• Keep welding area free of flammable and
explosive material.
Many containers that have held flammable or
• Use a flammable gas and oxygen detector to
combustible materials present special problems.
determine whether a hazardous atmosphere
Consult the manufacturer or the product SDS for
exists.
detailed information.
• Provide fire barriers such as metal sheets or fire
blankets and fill cracks or crevices in floors to
prevent sparks and slag from passing through. Arc Welding and Cutting
• Provide fire extinguishers suitable for potential
types of fire. Know where the extinguishers are Equipment
and how to use them.
Use only manual electrode holders that are
• Provide a firewatch where necessary—a worker
specifically designed for arc welding and cutting
to watch for fires as the welder works and for at
and can safely handle the maximum-rated current
least thirty minutes afterward. The person must
capacity required by the electrodes.
be fully trained in the location of fire alarms
and the use of fire-fighting equipment. Some Any current-carrying parts passing through the
situations may require more than one firewatch, portion of the holder in the welder or cutter’s hand,
such as on both sides of a wall or on more than and the outer surfaces of the jaws of the holder,
one floor. should be fully insulated against the maximum
voltage encountered to ground.
Cutting torches should be equipped with
reverse flow check valves and flame arrestors to Arc welding and cutting cables should be
prevent flashback and explosion (Figure 41-12). completely insulated, flexible, and capable of
These valves must be installed according to the handling the maximum current requirements of
manufacturer’s instructions. the work as well as the duty cycle under which the
welder or cutter is working.
Normal Flow Condition Check Valve
Avoid repairing or splicing cable within 10 feet
of the cable end to which the electrode holder is
connected. If necessary, use standard insulated
connectors or splices which have the same
Reverse Flow Condition Check Valve insulating qualities as the cable being used.
Connections made with cable lugs must be securely
fastened together to give good electrical contact.
The exposed parts of the lugs must be completely
insulated. Do not use cables with cracked or damaged
insulation, or exposed conductors or end connectors.
Figure 41-12: Reverse Flow Check Valves
A welding cable should have a safe current carrying
capacity equal to or exceeding the maximum
capacity of the welding or cutting machine.

41-8 Construction Health and Safety Manual

 WELDING AND CUTTING

Warning: Never use the following as part of the • All arc welding and cutting operations should
current path: be shielded by non-combustible or flame-proof
screens to protect other workers from direct rays
• Cranes of the arc.
• Hoists • Keep chlorinated solvents shielded from the
• Chains exposed arc or at least 60 m (200 ft) away.
• Wire ropes Surfaces prepared with chlorinated solvents must
• Elevator structures be thoroughly dry before being welded. This is
• Pipelines containing gases or flammable liquids especially important when using gas-shielded
• Conduits containing electrical circuits. metal-arc welding, since it produces high levels of
ultraviolet radiation.
The work lead, often incorrectly referred to as • Check for the flammability and toxicity of any
the ground lead, should be connected as close as preservative coating before welding, cutting, or
possible to the location being welded to ensure heating. Highly flammable coatings should be
that the current returns directly to the source stripped from the area to be welded. In enclosed
through the work lead. spaces, toxic preservative coatings should be
stripped several inches back from the area of heat
A structure employed as a work lead must have
application or the welder should be protected
suitable electrical contact at all joints. Inspect
by an airline respirator. In the open air, a suitable
the structure periodically to ensure that it is still
cartridge respirator should be used. Generally, with
safe. Never use any structure as a circuit when it
any preservative coating, check the manufacturer’s
generates arc, sparks, or heat at any point.
SDS for specific details regarding toxicity and
The frames on all arc welding and cutting machines personal protection required.
must be grounded according to the CSA standard
or the regulatory authority. Inspect all ground
connections to ensure that they are mechanically Oxyacetyelene Welding
sound and electrically adequate for the required and Cutting
current.
Handling Cylinders
Procedures • Do not accept or use any compressed
• When electrode holders are to be left gas cylinder which does not have proper
unattended, remove electrode and place holder identification of its contents.
so it will not make contact with other workers or • Transport cylinders securely on a hand truck
conducting objects. whenever possible. Never drag them.
• Never change electrodes with bare hands or with • Protect cylinders and any related piping and
wet gloves. fittings against damage.
• Do not dip hot electrode holders in water to cool • Do not use slings or magnets for hoisting
them off. cylinders. Use a suitable cradle or platform
• Keep cables dry and free of grease to prevent (Figure 41-14).
premature breakdown of insulation. • Never drop cylinders or let them strike each other
• Cables that must be laid on the floor or violently.
ground should be protected from damage and • Chalk EMPTY or MT on cylinders that are empty.
entanglement. Close valves and replace protective caps.
• Keep welding cables away from power supply • Secure transported cylinders to prevent
cables and high tension wires. movement or upset.
• Never coil or loop welding cables around any part • Always regard cylinders as full and handle
of your body. accordingly.
• Do not weld with cables that are coiled up or on • For answers about handling procedures, consult
spools. Unwind and lay cables out when in use. the manufacturer, supplier, or the SDS.
• Before moving an arc welding or cutting machine,
or when leaving machine unattended, turn the
power supply OFF.
• Report any faulty or defective equipment to your
supervisor.
• Read and follow the equipment manufacturer’s
instructions carefully.
• Prevent shock by using well-insulated electrode
holders and cables, dry clothing and gloves,
rubber-soled safety boots, and insulating material Figure 41-14: Use a Cradle or
(such as a board) if working on metal. Platform to Hoist Cylinders
• Shut off the power supply before connecting the
welding machine to the building’s electrical power.

Tools and Techniques 41-9

WELDING AND CUTTING

Storing Cylinders • Do not use oxygen in place of compressed air for

pneumatic tools.
• Store cylinders upright in a safe, dry, well-ventilated • Release pressure from the regulator before
location maintained specifically for this purpose. removing it from the cylinder valve.
• Never store flammable and combustible materials • When gas runs out, extinguish the flame and
such as oil and gasoline in the same area. connect the hose to the new cylinder. Purge the
• Do not store cylinders near elevators, walkways, line before re-igniting the torch.
stairwells, exits, or in places where they may be • When work is finished, purge regulators, then
damaged or knocked over. turn them off. Use a proper handle or wrench to
• Do not store oxygen cylinders within 6 m (20 ft) turn off cylinders.
of cylinders containing flammable gases unless
they are separated by a partition at least 1.5 m (5 Cylinder
Outlet
ft) high and having a fire-resistance rating of at Pressure Contents
Gauge Gauge
least 30 minutes (Figure 41-15).
• Store empty and full cylinders separately. Cylinder Valve
• Prohibit smoking in the storage area. Pressure
Adjusting
Screw

Hose Check Fire

1.5m (non-return) Extinguisher
Valves

Figure 41-16: Buggy Equipped with a Fire

Extinguisher

Pressure Regulators
Figure 41-15: Keep Oxygen and
Gas Cylinders Separated Pressure regulators must be used on both oxygen
and fuel gas cylinders to maintain a uniform and
controlled supply of gas to the torch.
Using Cylinders
The oxygen regulator should be designed with a
• Use oxygen and acetylene cylinders in a proper safety relief valve so that, should the diaphragm
buggy equipped with a fire extinguisher (Figure rupture, pressure from the cylinder will be
41-16). Secure cylinders upright. released safely and the regulator will not explode.
• Keep the cylinder valve cap in place when the
cylinder is not in use. Each regulator (both oxygen and fuel gas) should
• Do not force connections on cylinder threads that be equipped with a high-pressure contents gauge
do not fit. and working pressure gauge. Always stand to one
• Open cylinder valves slowly. Only use the side of regulator gauge faces when opening the
handwheel, spindle key, or special wrench cylinder valves.
provided by the supplier. To prevent regulators from being installed on the
• Always use a pressure-reducing regulator with wrong cylinders, oxygen cylinders and regulators
com­pressed gases. For more information, see the have right-hand threads while most fuel gas
box below. cylinders and regulators have left-hand threads.
• Before connecting a regulator to a cylinder, crack
the cylinder valve slightly to remove any debris Internal and external threads and different
or dust that may be lodged in the opening. Stand diameters also help to prevent wrong connections.
to one side of the opening and make sure the
opening is not pointed toward anyone else, other Hoses and hose connections for oxygen and
welding operations, or sparks or open flame. acetylene should be different colours. Red is
• Open the fuel gas cylinder valve not more than
generally used to identify the fuel gas and green
1 1/2 turns unless marked back-seated.
the oxygen. The acetylene union nut has a groove
• Do not use acetylene pressure greater than 15 psig.
cut around the centre to indicate left-hand thread.
• Never allow sparks, molten metal, electric current,
or excessive heat to come in contact with • Protect hoses from traffic, flying sparks, slag, and
cylinders. other damage. Avoid kinks and tangles.
• Never use oil or grease as a lubricant on the • Repair leaks properly and immediately. Test for
valves or attachments of oxygen cylinders. Do not leaks by immersing hose in water.
handle with oily hands, gloves, or clothing. The • Use backflow check valves and flame arrestors
combination of oxygen and oil or grease can be according to the manufacturer’s instructions.
highly combustible. (See Figure 41-12.)
• Never bring cylinders into unventilated rooms or • Do not use a hose which has been subject to
enclosed areas. flashback or which shows evidence of wear or
damage without proper and thorough testing.

41-10 Construction Health and Safety Manual

 WELDING AND CUTTING

Backfires occur when the flame burns back into the Silver Solder Brazing
torch tip, usually accompanied by a loud popping
sound. Backfires are usually caused by touching the Silver solder brazing is used for joining metals and
tip against the work or by using pressures that are steel and disimilar metal combinations where it is
too low. necessary to perform the joining of these metals at
low temperatures. Applications include medical and
Flashback is much more serious. The flame burns laboratory systems, refrigeration, aerospace, and
back inside the torch itself with a squealing or electronic equipment. In brazing, the major hazards
hissing sound. If this happens, follow the torch are heat, chemicals, and fumes.
manufacturer’s instructions to extinguish the torch
in proper sequence. Fumes generated during brazing can be a serious
hazard. Brazing fluxes generate fluoride fumes
Many different makes, models, and designs of when heated. Cadmium in silver brazing alloys
torches are available. There is no single procedure vaporizes when overheated and produces cadmium
or sequence to follow in igniting, adjusting, and oxide, a highly toxic substance. Cadmium oxide
extinguishing the torch flame. Always follow the fumes inhaled into the respiratory tract can cause
manufacturer’s instructions. pulmonary distress, shortness or breath, and in
cases of severe exposure may cause death.
Oxyacetylene Summary
The most serious cause of cadmium oxide fumes is
Startup overheating the silver brazing filler metal. Care must
• Keep cylinders away from sources of heat or be taken to control the temperature of the silver
damage and secure them upright. brazing operation. The torch flame should never be
• Stand to one side and slightly crack cylinder applied directly to the silver brazing filler rod. The
valves to blow out dust. heat of the base metal should be used to melt and
• Attach regulators to respective cylinders. Tighten flow the brazing filler metal.
nuts with a proper wrench. Cadmium-plated parts can be an even more
• Release pressure adjusting screws on regulators. hazardous source of cadmium fumes, since in
• Connect green hose to oxygen regulator and red brazing these parts the torch flame is applied
hose to fuel gas regulator. directly to the base metal. Cadmium plating should
• Connect hoses to the torch—green to oxygen be removed before heating or brazing. When in
inlet and red to fuel gas inlet. doubt about a base metal, check with the supplier
• Connect mixer and welding tip assembly to torch of the part.
handle.
• Open oxygen cylinder valve slowly and fully. Safe Silver Solder Brazing
• Open fuel gas cylinder 3/4 to 11/2 turns.
• Open oxygen torch valve. Turn oxygen regulator • Do not heat or braze on cadmium-plated parts.
pressure adjusting screw to desired pressure. • Read warning labels on filler metals and fluxes
Continue oxygen purge for about 10 seconds for and follow instructions carefully.
each 100 feet of hose. Close oxygen torch valve. • Work in a well-ventilated area or use a supplied-
• Open fuel gas torch valve. Turn fuel gas regulator air respirator.
pressure adjusting screw to desired pressure and • Apply heat directly to the base metal—not to the
purge for about 10 seconds for each 100 feet of brazing filler metal.
hose. Close fuel gas torch valve. • Do not overheat either the base metal or the
• To light torch, follow the manufacturer’s brazing filler metal.
instructions. DO NOT USE MATCHES. • Wash hands thoroughly after handling brazing
• Adjust to desired flame. fluxes and filler metals.

Confined Spaces
Closedown
Welding in enclosed or confined areas creates
• Close torch valves according to the additional hazards for the welder. The employer must
manufacturer’s instructions. have a written rescue procedure for confined spaces.
• Close fuel gas cylinder valve.
In addition to the procedures outlined in the
• Close oxygen cylinder valve.
chapter on confined spaces in this manual, take the
• Drain fuel gas cylinder line by opening torch
following precautions.
fuel gas valve briefly. Close valve. Drain oxygen
line in the same way. • Inspect all electrical cables and connections that
• Re-open both torch valves. will be taken into the confined space.
• Release pressure adjusting screws on both • Perform leak tests on gas hoses and connections
regulators. to eliminate the risk of introducing gases into the
Regulators and torches can now be disconnected. confined space.
• Check for live electrical systems and exposed
conductors.

Tools and Techniques 41-11

WELDING AND CUTTING

• Use inspection ports, dipsticks, or a knowledgeable Protective screens or barriers should be erected
person to evaluate hazards from any liquids, solids, to protect people from arc flash, radiation, or
sludge, or scale left in the space. spatter. Barriers should be non-reflective and allow
• Isolate the space from any hydraulic, pneumatic, air circulation at floor and ceiling levels. Where
electrical, and steam systems which may barriers are not feasible or effective, workers near
introduce hazards into the confined area. the welding area should wear proper eye protection
Use isolation methods such as blanks, blinds, and any other equipment required. Signs should be
bleeding, chains, locks, and blocking of stored posted to warn others of welding hazards.
energy. Tag isolated equipment.
• A competent person must test and evaluate the Eye and Face Protection
atmosphere before workers enter a confined space,
Welding helmets provide radiation, thermal, electrical,
and at all times during work there. A hazardous
and impact protection for face, neck, forehead, ears,
atmosphere may already exist or gases and vapours
and eyes. Two types are available—the stationary plate
may accumulate from cutting or welding. Oxygen
helmet and the lift-front or flip-up plate helmet. There
content may become enriched or depleted.
• Ventilate space with clean air before entry and are also auto-darkening helmets that have a single
maintain ventilation as long as necessary to pane of self-darkening glass in the visor.
prevent the accumulation of hazardous gases, The lift-front type should have a fixed impact-resistant
fumes, and vapours. safety lens or plate on the inside of the frame next to
• Different gases have different weights and may the eyes to protect the welder against flying particles
accumulate at floor, ceiling, or in between. Air when the front is lifted. All combination lenses should
monitoring should be done throughout the have a clear impact-resistant safety lens or plate next
confined space. to the eyes.
• Keep compressed gas cylinders and welding power
sources outside the confined space. There are also special models incorporating earmuff
• Where practical, ignite and adjust flame for oxy-fuel sound arrestors and air purification systems. Special
applications outside the space, then pass the torch prescription lens plates manufactured to fixed powers
inside. Similarly, pass the torch outside the space, are available for workers requiring corrective lenses.
then extinguish it. The typical lens assembly for arc welding is shown in
• When leaving a confined space, remove the torch Figure 41-17.
and hoses and shut off gas supply.
• If adequate ventilation cannot be maintained, use a The arc welding lens
suitable supplied-air respirator. assembly consists of
3 parts. The outside
It is the responsibility of the employer to have a lens is clear plastic 1st: Clear Glass
or tempered glass. It or Plastic Lens
written emergency rescue plan and communicate protects the shade
the plan to all involved. Each person should know lens from damage. The
2nd: Shade
centre lens is a shade
what do to and how to do it quickly. (See Chapter Lens
lens that filters out the
33: Confined Spaces in this manual.) harmful light. The inner
lens is clear and must 3rd: Clear
be plastic. Plastic Lens

Personal Protective Equipment

In addition to the protective equipment required for
Figure 41-17: Typical Lens Assembly for Arc Welding
all construction workers (see chapters on personal
protective equipment in this manual), welders should
The filtered or shaded plate is the radiation barrier.
wear flame-proof gauntlet gloves, aprons, leggings,
It is necessary to use a filter plate of the proper lens
shoulder and arm covers, skull caps, and ear protection.
shade to act as a barrier to the harmful light rays
Clothing should be made of non-synthetic materials and to reduce them to a safe intensity. Guidelines for
such as wool. Woollen clothing is preferable to cotton selection are shown in Figure Table 41-1.
because it is less likely to ignite. Keep sleeves rolled
In addition to common green filters, many special
down and collars buttoned up. Wear shirts with flaps
filters are available. Some improve visibility by
over pockets and pants with no cuffs. Remove rings,
reducing yellow or red flare. Others make the
watches, and other jewelry. Never carry matches or
colour judgment of temperature easier. Some have
lighters in pockets. Clothing should be free from oil
a special gold coating on the filter lens to provide
and grease. Wear high-cut CSA grade 1 footwear laced
additional protection by reflecting radiation.
to the top to keep out sparks and slag.
Welding hand shields are designed to provide
radiation and impact protection for the eyes and
face. They are similar to welding helmets except
that there are no lift-front models.

41-12 Construction Health and Safety Manual

 WELDING AND CUTTING

Table 41-1: Lens Shade Selection Guide for Welding fogging and baffles to prevent leakage of radiation
Electrode Arc Minimum Suggested* into the eye cup.
Size Current Protective Shade No.
Process mm (in) (Amperes) Shade (Comfort) Welders should not wear contact lenses because
airborne dust and dirt may cause excessive
Shielded Metal less than 2.4 (3/32) less than 60 7 – irritation of the eyes under the lenses.
Arc Welding 2.4-4 (3/32-5/32) 60–160 8 10
(SMAW) 4-6.4 (5/32-1/4) 160–250 10 12
more than 6.4 (1/4) 250–550 11 14 Hearing Protection
Gas Metal Arc Welding less than 60 7 – The employer is responsible for assessing the
and Flux Cored 60–160 10 11 risk of hearing loss from exposure to noise and
(GMAW) 160–250 10 12
250–550 10 14
developing a plan to control or eliminate that risk. If
hearing protection devices (HPDs) are considered
Gas Tungsten Arc Welding less than 50 8 10 appropriate, earplugs may be a better choice for
(GTAW) 50–150 8 12
150–500 10 14
welders than earmuffs, which can be cumbersome
and interfere with the welding helmet. Training on the
Air Carbon (light) less than 500 10 12
Arc Cutting (heavy) 500–1,000 11 14 selection, use, and care of HPDs must be provided.
See Chapter 14: Hearing Protection in this manual.
Plasma Arc Welding less than 20 6 6 to 8
(PAW) 20–100 8 10 Welders should have their hearing checked every
100–400 10 12 year or so. A simple test can be arranged through
400–800 11 14
your doctor. Once hearing is damaged, the loss is
Plasma Arc Cutting (PAC)
less than 20 4 4
likely permanent. Checkups can detect any early
20–40 5 5 losses and help you to save your remaining hearing.
40–60 6 6
60–80 8 8




80–300
300–400
8
9
9
12
Radiographic and X-Ray Testing
400–800 10 14 Some construction trades will encounter situations
Torch Brazing (TB) – – 3 or 4 in which welds, metals, or special coatings require
Torch Soldering (TS) – – 2
onsite non-destructive testing.

Carbon Arc Welding (CAW) – – – 14

Methods include
1) radiography using a radioactive source for
Plate Thickness
mm in. general materials
Oxy-fuel Gas
Welding (OFW) 2) x-rays for testing thicker sections.
Light under 3 under 1/8 4 or 5
Medium 3 to 13 1/8 to 1/2 5 or 6 Radiography is federally regulated across Canada
Heavy over 13 over 1/2 6 to 8 by the Atomic Energy Control Board. Users
must be licensed and operators must be trained
Oxygen Cutting (OC)
Light under 25 under 1 3 or 4 according to a Canadian Government Standards
Medium 25 to 150 1 to 6 4 or 5 Board (CGSB) program.
Heavy over 150 over 6 5 or 6
X-ray testing is provincially regulated—in Ontario
Source: ANSI Z49.1: 2012—Safety in Welding, Cutting, and by Regulation 861/90. While many requirements
Allied Processes apply to licensed users in both situations, this
Reproduced with the permission of the American section will only cover the basic health and safety
Welding Society. guidelines for field use.
NOTE: Shade numbers are given as a guide only and may
be varied to suit individual needs. Radiographic Testing
*As a rule of thumb, start with a shade that is too dark Licensed users of radiographic testing systems
to see the weld zone. Then go to a lighter shade which are responsible for general safety in the field,
gives sufficient view of the weld zone without going transportation, emergency procedures, and
below the minimum. In oxy-fuel gas welding, cutting, or record-keeping.
brazing where the torch and/or the flux produces a high
Radiographic testing must be carried out in the
yellow light, it is desirable to use a filter lens that absorbs
the yellow or sodium line of the visible light spectrum.
presence of persons certified to CGSB Standard
48GP4a. In general, these people are employees of
Spectacles with full side shields designed to protect a recognized testing agency.
against UV radiation and flying objects and suitable Radiographic materials and equipment must be
filter lenses should always be worn in conjunction kept locked up in shielded storage containers
with full welding helmets or welding hand shields. accessible only to certified personnel. The
Where only moderate reduction of visible light is containers must be conspicuously marked and kept
required (for instance, gas welding) use eyecup in an area not normally occupied by the workforce.
or cover goggles with filter lenses for radiation
protection. Goggles should have vents to minimize

Tools and Techniques 41-13

WELDING AND CUTTING

There may be other special requirements which • The housing must adequately shield the
apply, depending on the strength of the radioactive equipment operator.
source and the location. • Employers using x-ray equipment must advise
the Ministry of Labour that they have such
Radiographic cameras in the field must be equipment.
used in conjunction with pocket dosimeters, • Employers must designate certain persons to be
survey meters, directional shields, barrier ropes, in charge of x-ray equipment who are trained and
radiographic warning signs, and an emergency competent to do so, and must give the Ministry of
source container. Labour the names of these designated persons.

General Safety Precautions Measures and procedures at the x-ray testing

site are similar to those required for radiographic
• Radiographic testing should be conducted,
testing. The following are the employer’s
whenever possible, on an off-shift with as
responsibilities.
few workers as possible in the work area. The
radiographic source should be no stronger than • Test during off-shifts.
is required for the job. Determining the strength • Cordon off the test area if it cannot be isolated or
of the source is not generally the responsibility of if entry cannot be controlled.
construction site personnel. • Post warning signs along the barrier or at the
• Equipment should be checked before use. The entrance to the room where testing is taking
regulation includes a list of items to be checked, place.
but doing so is not usually the responsibility of • Have a patrol to prevent unauthorized entry.
site personnel. • Install shielding as required before any equipment
• After taking tests where the camera will be is activated.
moved, the area should be checked using a • Ensure that employees in the controlled area
survey meter. wear personal dosimeters.
• Licensed users are required to keep records • Keep dosimeter records.
regarding the use of sources, including dates, • Keep at least one radiation survey meter of a
times, locations, and other details. These records suitable type with each portable x-ray machine
must be made available to inspectors from the and calibrate it at least once each year.
Atomic Energy Control Board. Users are also
responsible for advising the local fire department
when radioactive material will be in a municipality Training
for longer than 24 hours. Welders, fitters, and welding supervisors should
Specific requirements for radiographic camera be trained in both the technical and safety aspects
users are the responsibility of the certified persons of their work. Health and safety training should
operating the equipment. include but not be limited to the following.
• The survey meter must be checked to ensure that • Hazard identification
it is working and calibrated properly. • Safe welding, brazing, and cutting practices
• Barrier ropes should be set up around the area • Fire and safety precautions
where testing will be carried out unless this area is • Control methods for welding hazards
isolated and access can be controlled. Barriers must • Use, maintenance, and limitations of personal
be set up according to the strength of the source. protective equipment.
• Warning signs must be posted along the barriers.
• A patrol must be provided to ensure that no The effectiveness of health and safety training
unauthorized persons enter the testing area. should be periodically evaluated through the
• Before the camera shutter is opened and testing following:
is conducted, the area must be properly shielded. • A workplace inspection to ensure that safe
• Personnel working within the testing area should working procedures, equipment, and conditions
carry personal dosimeters. Dosimeters may also are implemented
be advisable for workers in the immediate vicinity • Air monitoring of common contaminants to
outside the barriers. determine the effectiveness of controls and
compliance with acceptable limits
X-Ray Testing • An assessment of control performance (for
Certain basic health and safety precautions are instance, testing of the ventilation system)
required for the x-ray testing of welds and metals. • Review of lost-time-injuries
• Discussion of the program with the health and
• There must be suitable means to prevent safety committee or representative(s).
unauthorized persons from activating the
equipment. Any corrective actions necessary should be taken
• There must be some device to indicate when the immediately.
x-ray tube is energized.

41-14 Construction Health and Safety Manual