Alongside fume, fire and explosion, welding exposes people to a range of physical hazards. These include intense radiation from the arc, burns from hot metal and spatter, electric shock from the welding circuit, noise and vibration from allied processes, and the everyday risks of handling heavy work and moving around a busy workshop.

This module explains each of these hazards, the harm they cause, and the precautions that control them.

By the end of this module, you will be able to:

• Explain how arc radiation causes arc eye and skin burns, and how to protect others nearby.
• Describe how to prevent burns from hot metal, spatter and sparks.
• Identify the conditions that increase the risk of electric shock, and the precautions that reduce it.
• Recognise noise, vibration, manual handling, and slip and trip hazards in welding work.

The welding arc gives off intense ultraviolet radiation, infrared radiation and very bright light.

Arc eye, also called photokeratitis or welder’s flash, is caused by ultraviolet radiation from the arc. Even a brief, unprotected glance can cause it. It feels like sand in the eyes, with pain, watering and sensitivity to light, and usually appears several hours later.

Infrared radiation can damage the eyes over time. Anyone who gets arc eye should seek medical advice.

• Protect your eyes with a welding helmet or face shield fitted with a filter of the correct shade for the process and current. Ordinary sunglasses give no protection.
• Ultraviolet radiation also burns exposed skin, like severe sunburn. Keep your skin covered, with sleeves down and collar fastened.
• People nearby are at risk too. Enclose welding bays with screens or curtains, and keep others clear.
• Never watch the arc without the correct eye protection.

Welded parts, electrode stubs and spatter stay hot long after they stop glowing. Burns are among the most common welding injuries, usually to the hands, forearms, neck and feet.

• Wear flame-retardant clothing, with no turn-ups or open pockets to catch sparks.
• Wear leather welding gauntlets, and safety boots with trousers over them.
• Handle hot work with tongs or pliers.
• Mark hot pieces, and never pick up metal that looks cool.

The welding circuit can give a dangerous electric shock. The risk rises sharply when the welder is:

• Wet or sweating, or working in damp conditions.
• Working in a confined space, such as a tank or vessel.
• Surrounded by metal, or lying or kneeling on steelwork.
• Working at height, where even a small shock can cause a fall.

Dry gloves, dry clothing and insulating mats reduce the risk.

The Electricity at Work Regulations 1989 require electrical systems and equipment to be constructed, maintained and used so as to prevent danger. In practice:

• Use welding equipment in good condition, with cables and holders fully insulated.
• Connect the return lead directly to the work, as close as possible to the weld.
• Switch off before changing electrodes, where possible.
• Use a voltage reducing device on alternating current sets in high-risk locations.
• Never wrap a welding cable around your body.

Arc air gouging, plasma cutting, grinding and hammering can be very loud.

Under the Control of Noise at Work Regulations 2005, employers must assess the risk, and act when daily exposure reaches 80 dB(A). At 85 dB(A), hearing protection must be worn, and hearing protection zones must be marked.

Noise damage to hearing is permanent, but it can be prevented.

Grinders, chipping hammers and needle guns cause hand-arm vibration. Regular exposure can lead to hand-arm vibration syndrome, which causes tingling, numbness, pain and white fingers, and can become permanent.

The Control of Vibration at Work Regulations 2005 require vibration exposure to be assessed and controlled.

Use low-vibration tools, limit time on them, keep them maintained, and report any symptoms early.

Welders regularly move heavy plate, steel sections, gas cylinders and equipment.

Under the Manual Handling Operations Regulations 1992, hazardous manual handling should be avoided where reasonably practicable. Where it cannot be avoided, the risk must be assessed and reduced.

Use lifting aids, cranes, trolleys and team lifts. Plan the route, and set work at a comfortable height, rather than welding for long periods in awkward postures.

Trailing welding cables, gas hoses, offcuts and spatter on the floor are frequent causes of trips. A trip near hot work, or at height, can be serious.

• Route cables along walls or overhead, and use cable covers across walkways.
• Keep the floor clear of offcuts and electrode stubs.
• Clean up regularly during the shift.

Good housekeeping also reduces the fire risk covered in Module 4.