Welding and allied processes present a multitude of risks due to the use of high-heat, light-emitting equipment and materials containing hazardous substances. Welding work can be highly dangerous, and the appropriate measures must be taken to reduce exposure and control the risks. Workplace controls and PPE are required to make sure that employees are kept safe from injuries or illnesses.

HSE requirements and guidance for the control of welding fume were updated in February 2019, stating that no welding should be undertaken without appropriate control measures in place, regardless of duration.

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This guide provides a general overview of hazards associated with welding and the types of protection required.

Hazards

Welding fume

Hazardous fumes are released during welding. Welding fume is highly dangerous if inhaled and can cause cancers, lung diseases such as COPD, as well as greater susceptibility to pneumonia. Excessive exposure to some types of metal found in mild steels can cause irreversible neurological disorders.

Welder’s lung is a condition caused by deposits of metal in the lung from exposure to welding fume, and can worsen the symptoms of COPD.

Occupational asthma can be caused by exposure to welding fume. Stainless steel welding especially poses a risk of asthma, due to metals in the fume. This illness can have a long latency period, with symptoms not appearing until long after exposure, and symptoms include shortness of breath, coughing, and reduced lung function.

Metal fume fever is a common illness following exposure to welding fume. Though it does not tend to have lasting effects, the symptoms cause discomfort and suggest the potential for more serious damage.

Shielding gases

Metal welds are susceptible to contamination and shielding gases are used to protect the area from atmospheric oxygen and water vapour, helping to strengthen the weld and prevent corrosion.

Gases used for shielding include argon, carbon dioxide (CO2), and mixes incorporating oxygen, hydrogen, nitrogen, and helium. Shielding gases can therefore present a respiratory hazard, as when inhaled they can cause irritation and breathing problems, as well as asphyxiation in the event of high concentrations in a confined or restricted area.

Fume and dust from allied processes

Allied processes can also cause exposure to hazardous substances. The friction and heat created when cutting or grinding material with power tools generates fume and dusts which can be harmful when inhaled.

Optical radiation

The emission of optical radiation from welding arcs can differ for various welding techniques. Exposure to UV, blue light, and infrared radiation at differing levels can occur, depending on the arc current, which can injure the eye and even cause cancer.

Overexposure to UV radiation can cause an injury known as arc-eye. The cornea is damaged by optical radiation, and the eye area can become red and feel painful.

Ocular melanoma, a cancer of the eye, can be caused by exposure to UV radiation.

Emission from manual metal arc welding can be very intense, meaning the UV exposure limit can be exceeded within 100 milliseconds. The emission from gas welding, however, can be much lower, in some cases not exceeding the UV exposure limit for an 8-hr working day. It is therefore necessary to assess and understand the specific optical radiation exposure risks associated with the type(s) of welding being carried out.

Hot solids and molten material risks

Hot solids and molten materials are a pervasive risk in the welding industry, which can cause irreversible damage to the skin, eyes, and ears. Contact with spatter, hot slag, and sparks can cause burns to the hands, eyes, face, head, and inner ears. It is vital to wear the appropriate PPE to protect against contact with molten metal materials and hot solids that can be projected or drip from a surface into an area where an operative is working.

Impact risks

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Processes such as cutting and grinding present a risk of impact from high-speed particles which can cause eye injuries, as well as cuts and lacerations to the face and neck area.

Noise from allied processes

Cutting and grinding applications, as well as drilling, manual metal work, and other workplace operations create noise that can damage the hearing of those exposed. Control measures should be put in place to limit exposure to harmful noise. Noise above the relevant exposure values requires the employer to provide appropriate hearing protection.

Protection requirements

Respiratory protection

Control measures and respiratory protective equipment (RPE) requirements for welding vary depending on the type of welding, the amount or duration of work, and factors in the work environment.

Adequate ventilation is required for welding in all workplace environments, to reduce the concentration of fumes, and can take several forms: general ventilation, local exhaust ventilation (LEV), and forced ventilation.

HSE guidance sets out control approaches for welding fume:

• Control approach 1 – General ventilation

• Control approach 2 – LEV and RPE

In confined, restricted, or limited spaces, forced ventilation and higher efficiency RPE can be required.

In cases where RPE is required in addition to ventilation controls, a UK Assigned Protection Factor (APF) of 20 for protection against particulates is the minimum requirement for welding fume. This can be achieved with an FFP3 disposable respirator or half mask with P3 filters. Disposable masks and filters with odour layers provide relief from nuisance odours.

JSP Springfit 436 FFP3OV disposable respirator, and the Force®8 half mask with PressToCheck™ P3 filters provide UK APF20 particulate protection against welding fume.

Powered respirators should be used when an operative is required to carry out welding for more than 1 hour per day. Powered respirators with welding shield headtops provide a combined unit with eye and face protection; guidance states that these can provide benefits by ensuring RPE remains in place throughout welding work.

The JSP Jetstream® Welder kit with Cobra™ welding / grinding faceshield offers TH2 protection, offering a UK APF of 20 with EN 175 welding shield and EN 379 auto-darkening lens to filter optical radiation.

See more information on requirements for welding fume control here.

Limited and restricted spaces require an APF of 40, in addition to forced ventilation. A full face mask with P3 filters or TH3P powered respirator provide APF40 protection.

In confined spaces, self-contained breathing apparatus (SCBA) can be required due to the potential for dangerous oxygen levels or high concentrations of shielding gases.

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See more information on requirements for welding fume control in confined, limited, and restricted spaces here.

Risk assessments and RPE programmesshould consider all respiratory hazards, including from gases, and particulates generated in allied processes.

Eye and face protection

Welding shields provide multiple forms of protection, made up of an opaque housing and viewing window with a filtering lens. Products can also incorporate impact resistant backing plates and anti-spatter accessories.

The standard for welding faceshields, EN 175, includes requirements for increased robustness and resistance to penetration by hot solids and molten metals.

The filtering lens, for protection against optical radiation can meet EN 169 for static welding filters, or EN 379 for auto-darkening filters which react to the light conditions automatically. Filters are designated by shade numbers, appropriate for different exposure levels. The welding shield housing is also assessed to ensure proper filtering of optical radiation.

JSP Cobra™ welding faceshield offers EN 175 protection with a shade 9-13 auto-darkening filter for optical radiation protection.

In addition to products with a head harness, helmet-mounted welding faceshields are available. Combining a welding faceshield with a safety helmet with molten metal resistance offers increased coverage for protection against risks from hot slag and sparks, as well as providing impact protection against falling objects in industrial environments.

JSP Cobra™ helmet-mounted welding faceshield offers EN 175 protection with a shade 9-13 auto-darkening filter. Compatible with a range of EVO® safety helmets, the helmet-mounted Cobra™ enables combined head and face protection.

Operatives working on other jobs and anyone passing through the welding area can also be exposed to optical radiation, people such as other employees and visitors. Welding spectacles can be used to provide protection to those who are not carrying out welding themselves but may be near to the hazard area. As well as filtering, safety spectacles provide impact resistance and increased durability, in case of accidents or damage.

For full protection against hot solids and molten metals, as well as radiation risks to the skin, gloves should be worn during welding. Welding gloves must provide the appropriate protection and dexterity levels for the task, following the appropriate risk assessments. Cloth caps and cowls can also be worn to increase coverage and protection for the head and neck areas.

Ear and hearing protection

Hearing protection can be required for welders in workplaces with high noise levels. Other allied processes, such as cutting, grinding, and manual metal work, produce noise that can damage the hearing of those exposed.

In addition to protecting the hearing, ear defenders and ear plugs can provide protection to the inner ears against burns from hot slags. Working below a weld area can put operatives at risk of contact with molten metal drips which can reach the inner ear and cause permanent damage to the hearing, serious burns and impairment of movement, such as loss of balance. Ear defenders and flame-resistant ear plugs can provide a barrier to prevent molten material or hot solids reaching the inner ear.

Noise levels should be assessed, and the attenuation data used to select adequate hearing protection. Where hearing protectors are worn, care should be taken to ensure wearers are not overprotected and unable to hear important instructions or warning sounds.

Ensuring the proper protection when welding is vital to protect operatives against hazards with the potential to cause immediate and long-term health damage. For more information on the health risks associated welding see the HSE website.

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