Hazards and Risks Associated with Manual Welding Processes

Welding is a high-risk task with multiple hazards that pose potential risks to both personnel and equipment. Below is a detailed analysis of common hazards associated with manual welding processes, the causes of these risks, potential damage, mitigation measures based on the hierarchy of controls, and a risk rating based on probability and consequence.

1. Electric Shock

• Hazard: Contact with live electrical parts (e.g., electrodes, welding machine)

• Risk: Electrical burns, electrocution, or death

• Cause of Risk: Inadequate grounding, damaged cables, faulty equipment, wet or damp working conditions

• Damage: Severe injury or fatality, potential damage to welding equipment

• Mitigation Measures:

  • Elimination/Substitution: Use lower voltage equipment when possible.

  • Engineering Controls: Ensure proper grounding of welding equipment and use insulated electrode holders.

  • Administrative Controls: Regular inspections, training in electrical safety, and ensure dry work areas.

  • PPE: Use insulated gloves and boots, and fire-resistant clothing.

• Risk Rating:

  • Probability: Moderate (3)

  • Consequence: Severe (5)

  • Overall Risk: High (15)

2. Fire and Explosion

• Hazard: Sparks and molten metal causing ignition of flammable materials

• Risk: Fire, explosion, burns, and damage to equipment

• Cause of Risk: Welding near flammable materials, gases, or in confined spaces

• Damage: Burns to the welder or other personnel, fire damage to the facility and equipment

• Mitigation Measures:

  • Elimination/Substitution: Use non-flammable materials where possible and remove flammable substances from the work area.

  • Engineering Controls: Use fire blankets, welding screens, and flashback arrestors on gas welding systems.

  • Administrative Controls: Implement a hot-work permit system, ensure fire extinguishers are available, and keep fire watch personnel on standby.

  • PPE: Fire-resistant clothing, face shields, and heat-resistant gloves.

• Risk Rating:

  • Probability: Moderate (3)

  • Consequence: Severe (4)

  • Overall Risk: High (12)

3. Fumes and Gases

• Hazard: Inhalation of toxic fumes (e.g., metal oxides, ozone, nitrogen dioxide)

• Risk: Respiratory illnesses, lung damage, and long-term health issues

• Cause of Risk: Improper ventilation, welding on certain materials (e.g., galvanized steel), prolonged exposure

• Damage: Chronic respiratory diseases, reduced lung function

• Mitigation Measures:

  • Elimination/Substitution: Use materials that produce fewer toxic fumes or substitute welding processes that emit fewer fumes.

  • Engineering Controls: Ensure proper ventilation (local exhaust systems) and use fume extraction systems.

  • Administrative Controls: Limit exposure time, rotate workers, and train on safe practices for working in confined or poorly ventilated areas.

  • PPE: Use of respiratory protective equipment (RPE) such as appropriate masks or air-purifying respirators.

• Risk Rating:

  • Probability: Likely (4)

  • Consequence: Moderate (3)

  • Overall Risk: High (12)

4. Ultraviolet (UV) and Infrared (IR) Radiation

• Hazard: Exposure to harmful UV and IR radiation from the welding arc

• Risk: Eye injuries (welder’s flash), skin burns, and increased risk of skin cancer

• Cause of Risk: Lack of proper eye and skin protection, exposure to the welding arc

• Damage: Eye burns (photokeratitis), severe skin burns, long-term cancer risk

• Mitigation Measures:

  • Elimination/Substitution: Use alternative joining processes that do not involve arc welding (e.g., mechanical fastening).

  • Engineering Controls: Use welding screens and barriers to shield workers from radiation.

  • Administrative Controls: Limit exposure time, provide proper training on radiation hazards, and implement safe work procedures.

  • PPE: Use a proper welding helmet with UV/IR protection, along with protective clothing covering all exposed skin.

• Risk Rating:

  • Probability: Likely (4)

  • Consequence: Moderate (3)

  • Overall Risk: High (12)

5. Burns from Hot Metal or Equipment

• Hazard: Handling hot metal or welding equipment

• Risk: Burns, heat stress

• Cause of Risk: Inadequate PPE, accidental contact with hot metal or tools

• Damage: Severe burns to hands or exposed skin, potential for heat exhaustion

• Mitigation Measures:

  • Elimination/Substitution: Automate handling of hot materials where possible.

  • Engineering Controls: Use thermal barriers or tools designed to handle hot metal.

  • Administrative Controls: Establish safe work procedures for handling hot materials and provide adequate break times.

  • PPE: Use heat-resistant gloves, aprons, and face shields.

• Risk Rating:

  • Probability: Likely (4)

  • Consequence: Moderate (3)

  • Overall Risk: High (12)

6. Noise Exposure

• Hazard: Excessive noise from welding processes (e.g., arc welding, cutting)

• Risk: Hearing loss, tinnitus

• Cause of Risk: High-decibel welding environments without noise control or hearing protection

• Damage: Long-term hearing impairment, ear damage

• Mitigation Measures:

  • Elimination/Substitution: Use quieter welding techniques or noise-dampening equipment.

  • Engineering Controls: Install noise barriers, sound-dampening mats, or acoustic enclosures.

  • Administrative Controls: Limit exposure time, implement hearing conservation programs, and provide training.

  • PPE: Use earplugs or noise-canceling earmuffs.

• Risk Rating:

  • Probability: Likely (4)

  • Consequence: Moderate (3)

  • Overall Risk: High (12)

7. Eye Injuries from Flying Debris or Sparks

• Hazard: Flying debris from grinding, cutting, or welding sparks

• Risk: Eye injuries, foreign objects in the eye, blindness

• Cause of Risk: Lack of proper eye protection or proximity to welding operations

• Damage: Corneal damage, temporary or permanent vision loss

• Mitigation Measures:

  • Elimination/Substitution: Use protective curtains or barriers to contain sparks and debris.

  • Engineering Controls: Install screens or shields around the work area.

  • Administrative Controls: Establish clear zones around welding operations and train workers on safe work practices.

  • PPE: Use safety goggles and face shields rated for impact resistance.

• Risk Rating:

  • Probability: Likely (4)

  • Consequence: Severe (4)

  • Overall Risk: High (16)

8. Manual Handling and Ergonomic Issues

• Hazard: Lifting and moving heavy welding equipment or workpieces

• Risk: Musculoskeletal injuries, back strains, or sprains

• Cause of Risk: Poor lifting techniques, awkward body positioning, and repetitive motions

• Damage: Musculoskeletal disorders (MSDs), long-term chronic pain

• Mitigation Measures:

  • Elimination/Substitution: Use mechanical aids (e.g., cranes, lifting tools) to move heavy items.

  • Engineering Controls: Redesign workstations to improve ergonomics and reduce repetitive strain.

  • Administrative Controls: Train workers in proper lifting techniques and ergonomics, and provide rest breaks.

  • PPE: Use back braces or support belts where necessary.

• Risk Rating:

  • Probability: Moderate (3)

  • Consequence: Moderate (3)

  • Overall Risk: Moderate (9)

Risk Ratings Key:

• Probability:

  • 1: Rare

  • 2: Unlikely

  • 3: Moderate

  • 4: Likely

  • 5: Almost Certain

• Consequence:

  • 1: Insignificant

  • 2: Minor

  • 3: Moderate

  • 4: Severe

  • 5: Catastrophic

Conclusion

Manual welding processes pose significant risks, including electrical shocks, fire, toxic fumes, and musculoskeletal injuries. These risks must be systematically addressed through a combination of elimination, engineering, administrative controls, and PPE in line with the hierarchy of controls.