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Warning: Weld Safely

Welders on TV often use HAZARDOUS PRACTICES for the purposes of a better visual production.  The program credits may have Warning Statements to the effect that  simulations were made for TV viewing and normal safeguards were not used etc.  The following information is provided to assist in understanding proper WELDING SAFETY. 

As with other presentations on this web site, this safety information is referenced from authoritative sources.  In this case the American Welding Society (AWS) offers a FREE 61 page booklet entitled Safety in Welding, Cutting and Related Processes.  It is an American National Standard Document, ANSI Z49.1 "Safety in Welding and Cutting and Allied Processes."  This is the link to the AWS Page from which the most up-to-date document can be downloaded:  Click for AWS Web Page With The ANSI Z49.1 FREE Download

In addition to this AWS document, read all of the safety information from the manufacturer of the equipment and filler materials you are using such as Operating Manual, Warning Labels and Materials Safety Data Sheets.

The following statements in CAPITALIZED GREEN PRINT were abstracted from ANSI Z49.1 suggestions for inclusion on Warning Labels for carbon steel welding materials.  Some manufactures labels may have additional information, read and understand it.  Additional information is provided in Yellow Italic Print below each Z49.1 statement to explain some of the reasons for the warnings:

 

WARNING:

PROTECT YOURSELF AND OTHERS. READ AND UNDERSTAND THIS INFORMATION. 

If you have questions ask your supplier or write / email the products manufacturer for answers.

FUMES AND GASES CAN BE HAZARDOUS TO YOUR HEALTH.  USE ENOUGH VENTILATION, EXHAUST AT THE ARC, OR BOTH, TO KEEP FUMES AND GASES FROM YOUR BREATHING ZONE AND THE GENERAL AREA. 

The fumes  (smoke) coming from the welding arc contain potentially hazardous chemical compounds.  Be sure to keep your head out of the fume plum.  Although obvious, since the smoke is visible and doesn’t smell or taste good, be sure to position your head so the fumes are moving away from  your welding helmet. 

Less obvious is when welding in a pit, such as a garage floor repair pit, the MIG shielding gas your using is heavier than air and will sink to the pit bottom and displace some of the air.  This can also occur when welding in a confined area such as a car trunk etc.  Be sure to provide ventilation to assure you're not asphyxiated.  You could die!  (SEE HYPOTHETICAL EXAMPLE BELOW)

Much more information on ventilation and when welding special materials is available in the Z49.1 publication such as not welding on cadmium plated parts (those pretty gold colored parts often used  in older automotive bolts, etc.) or on painted or solvent cleaned surfaces.

ARC RAYS CAN INJURE EYES AND BURN SKIN.  

This is an area often see violated on TV.  The Ultraviolet Light coming from the arc is like looking at the Sun. DON’T DO IT!  Often some folks are seen turning their head away from directly looking at the arc; however the Arc Rays are  getting to the side of their eye which will still cause eye injury.

TV folks may be seen welding with short sleeves, open shirts or no gloves.  That may look “cool” for TV but Arc Rays can burn unprotected skin.  similar serious problems can occur as overexposure to the sun .  COVER UP!

ELECTRIC SHOCK CAN KILL. 

MIG welding wire on a spool is electrically “”hot” and is exposed on some welding machines.  The MIG torch tip and other torch parts are also electrically “hot,”  as are TIG torch parts and Stick  holders.  Depending on the specific welding machine being used, the voltage can be quite high.  TIG and Stick welders often have voltages of 70 and above and can deliver much more current than required to cause electrocution!

WEAR CORRECT EYE, EAR, AND BODY PROTECTION. 

If you need glasses to correct vision be sure to use them or a magnifying lens for your welding helmet.  This helps make you see clearly while your head is held away from the arc zone avoiding the fume plum.  Also, use safety glasses with side shields and see that those around you are also wearing them.  You only have two eyes, DON’T RISK THEM. Be sure to wear clothing that prevents sparks from hitting your skin.

BEFORE USING A WELDER, READ AND UNDERSTAND THE MANUFACTURERS INSTRUCTIONS AND ASK FOR THE THEIR MATERIAL SAFETY DATA SHEETS (MSDS) FOR THEIR WELDING MATERIALS. 

Companies that distribute welding materials can give you the MSDS having specific information related to the possible harmful products that may evolve from the welding wire or welding flux you are using.  Just ask.  Manufacturers of the materials can also supply you with he appropriate MSDS.   These are free for the asking, take advantage of the information. 

IF WELDING WHILE AT WORK, ASK FOR YOUR EMPLOYERS SAFETY PRACTICES.

 

 

Warning: Shielding Gas Can Cause Suffocation Without Warning                      

 

 Hypothetical Example of  Shielding Gas Leaking in Garage Repair Pit

 

Scenario:

bullet Your welding a custom  exhaust system on a car.
bullet You leave a MIG welder in the repair pit while you go to lunch.
bullet The welding machine gas solenoid, gas control valve in the torch or gas hose fitting leaks the Argon/CO2 shielding gas at a hard to detect low flow rate of 15 CFH . (Note: some portable MIG welders and Spoolguns use a mechanical gas control torch valve .  The valve can  leak gas even when closed.  You should always shut off the gas at the cylinder when not welding.)
bullet The pit is 5 feet deep, 4 feet wide and 8 feet long with an air volume  of 160 CF. 
bulletFACT: there is 21% Oxygen in Normal Air.  At less than 18% Oxygen you can become dizzy and unconscious without warning signs.
bullet The 160 CF  pit normally has160 CF X 21% or 34 CF of Oxygen.
bullet However after you return to the pit 2 hours later the pit will contain 160 CF of air less 15 CFH x 2 hr or 30 CF of the shielding gas.   Therefore the  amount of Oxygen will be 0.21 X 130 CF of air = 27 CF of Oxygen or 27/160  = 17% Oxygen; less than the required minimum18%.  (This assumes that all the leaked shielding gas has mixed with the air in the pit.  However since the shielding gas is heavier than air it  sank to the bottom of the pit and in only 2 hours may have not had time to fully mix or diffuse out of the bottom.)
bullet You bend down to thread in a new spool of wire and are probably exposed to even a lower concentration than 17% Oxygen in the shielding gas rich atmosphere at the pit bottom!  No one knows your there; you pass out and die!!

Although the above example is hypothetical, an Internet search found these welders who where asphyxiated with welding shielding gas:

bullet In March 2007 three workers died in Quebec.  The situation is similar to our hypothetical example so we'll provide details.  Two welders had worked in a tank and left for the day leaving the tank open.  They died  the next day when they returned since there was argon leaking in the tank over night.  Even though the tank was left open, only 10 per cent oxygen was found to be in the tank.  A first responder also died trying to help the two welders!
bullet In March 2005, Robert Wilson died while welding a super duplex stainless tank in Moray, Scotland.
bullet In April 1994, a welder died while welding pipe in Alaska.
bullet In March 1989, a welder died while welding in a titanium tank in British Columbia.
bullet In April 1981 a welder, Jose Duncan, died in a shipyard in Mississippi.
bullet Other deaths have occurred which may not be documented on the Internet such as one in a Virginia shipyard in the 1980's.

While not involved in a welding incident, in May 2008  three workers unloading a ship died of Argon Asphyxiation in Fort Lauderdale FL.  One passed out in a confined area and two others trying to help their fellow worker went in after him.  A liquid Argon  container was found to be the culprit.  Remember liquid Argon containers vent to maintain the liquid temperatures as pressure builds in the container.  They must be stored where there is adequate ventilation.   Even Argon Cylinders can leak, especially in the valve area.  Always store where there is adequate ventilation an carefully follow other storage rules.  Consult your gas supplier.  ANSI Z49.1 publication has information and references on this subject.  As noted above, this publication is available as a  free download from the American Welding Society.

Carbon Dioxide Shielding Gas

Carbon Dioxide is even heavier than Argon; 52% heavier than air versus Argon which is 38% heavier.  Therefore it will sink to a low level before mixing by mechanical means or diffusion.

In addition, CO2 has the following effects on the human body:

bullet

At 1%; can cause drowsiness with prolonged exposure.

bullet

At 2%; causes increased blood pressure and a 50% increase in  pulse rate.

bulletAt 4  to 5% breathing increases about 4 fold, dizziness, confusion and difficulty in breathing accompanied by headache and shortness of breath occur.
bulletAt 8 to 10% it causes headache, sweating, dim vision, tremor and loss of consciousness after exposure for between five and ten minutes.
bulletOver 10% unconsciousness occurs more rapidly and leads to asphyxiation and death.

Bottom Line:

Always check all shielding gas lines and fittings for leaks.  Shut the gas supply off at the cylinder whenever you stop welding.  Be sure all areas where welding  is occurring have adequate ventilation.   Be especially vigilant in confined areas.   Always have a friend watching when you enter and work a confined area. Follow all safety regulations of an employer.  Read ANSI Z49.1 "Safety in Welding and Cutting and Allied Processes"  for further information.  Ask your welding gas supplier for gases safety information.

 

MIG Gas Delivery and the Small Block Chevy Evolved in a Similar Way and Time!

 Both had Advances and Setbacks Before

They Were Optimized!

 

Click for a PDF Report on the Similarities

 

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* US Patent  # 6,610,957;  "Welding Shielding Gas Saver Device" August 26, 2003,  Patent Pending in other countries.   The "Flow Rate Limiter" device is
 covered by 2008 US patent #7,462,709.  Other site material may be covered under our 2006 US Patents # 7,015,412 or # 7,019,248 .
Questions?   Send E-mail TechSupport@NetWelding.com
Last modified: 02/03/10

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