1、The Independent Shops Guide toWelding Safety and Health550 N.W. LeJeune Road, Miami, Florida 33126THE INDEPENDENT SHOPS GUIDE TO WELDING SAFETY AND HEALTHCompiled/Written byJerome D. JenningsExpert ServicesThe information contained in this publication is intended for general information purposes onl
2、y and isprovided to help guide independent shops to understand the safety matters they need to know to comply withregulations and to make their workers and workplace safe. This publication is not a substitute for a thoroughreview of the applicable government regulations and standards, or other stand
3、ards from cited organizations,and should not be construed as legal advice or opinion. Readers with specific questions should refer to the citedregulation/standard/organization or consult with an attorney. This document is not a consensus standard. Thepublisher is not responsible for loss or damage r
4、esulting from use of this publication.iiPhotocopy RightsAuthorization to photocopy items for internal, personal, or educational classroom use only, or the internal,personal, or educational classroom use only of specific clients, is granted by the American Welding Society(AWS) provided that the appro
5、priate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive,Danvers, MA 01923, Tel: 978-750-8400; online: http:/. 2003 by the American Welding Society. All rights reserved.Printed in the United States of America.AUTHOR NOTESThis project began as the brainchild of the AWS Safety and Heal
6、th Committee. They recognized the need fora clear and direct guide to help independent shops get answers to their unique questions. Independent shopslack the resources of large companies, which have safety professionals on staff to keep up with the latestcodes, regulations, and needed training. As a
7、 result of this perceived gap, this booklet sprang to life. Anauthor and style was chosen, and the work began in earnest in cooperation with the AWS New ProductDevelopment Committee. In the process, the AWS Safety and Health Committee and the AWS SH4 Committeeon Labeling and Safe Practices reviewed
8、the publication at all of its stages and provided feedback to theauthor. These two groups of nationally recognized experts shared their knowledge and wisdom regularly,including technical information, helpful suggestions, and other details noticed during their reviews of thedrafts. Special recognitio
9、n goes to the following persons who took the time to share their expertise andcomments on a variety of areas and saw the project through to completion:Kris Bancroft, Safety Consultant/AuthorMember, AWS Safety and Health CommitteeKen Brown, Project Research Manager, The Lincoln Electric CompanyU.S. D
10、elegate to the International Institute of Welding (IIW)Cynthia Duffield, Industrial Hygienist, Occupational Safety and Health AdministrationSusan Fiore, Senior Engineer, Edison Welding InstituteChair, AWS Safety and Health CommitteeSteve Hedrick, Safety and Health Manager, American Welding SocietySe
11、cretary, AWS Safety and Health CommitteeAndrew Jennings, Safety/Environmental Engineer, Cooper Power SystemsLee Kvidahl, Manager, Welding and Manufacturing Engineering, Northrop Grumman/Ingalls OPChair, AWS New Product Development CommitteeAugust F. Manz, A.F. Manz AssociatesChair, ANSI Z49 Committe
12、e on Welding Safety and HealthMichael Synder, Supervisory Engineer, Mine Safety and Health AdministrationTruly the author stood on the shoulders of giants throughout this job. For their help and ever-available assis-tance, he is deeply grateful and indeed humbled to have worked with people of this c
13、aliber.Jerome D. JenningsWaupaca, WisconsiniiiTABLE OF CONTENTSPage No.Introduction1How to Use This Guide 1What is OSHA? 1Basic Safety Hazard Sources and Accident Results2Responsibilities of ManagementThe Shop Owner or Manager/Boss .2The Hazard Communication Standard (HCS) 3Protection of the Work Ar
14、ea and Personnel 4Ventilation.7Fire Prevention and Protection 9Confined Spaces.10All About Cylinders 11Electric Shock Protection 12Oxyfuel Gas Welding and Cutting15Information Sources and Web Resources.21Conclusion 23Material Safety Data Sheet Glossary.24ivLIST OF TABLESTable Page No.1 Lens Shade Se
15、lector.8LIST OF FIGURESFigure Page No.1 Precautionary Information for Arc Welding Processes and Equipment.42 Sample of a Material Safety Data Sheet (MSDS).53 Precautionary Information for Oxyfuel Gas Processes and Equipment .18Welding Safety and HealthIndependent Shops Guide 1IntroductionThe purpose
16、 of this publication is to provide theowners of small welding and cutting shops with apractical guide to help ensure the safety and healthof employees and the protection of property. Themaintenance of the health and safety of employeesis vital to the successful operation of any business.Healthy and
17、safe workers are productive and con-tribute to the profitability of the business. Con-versely, workers exposed to unhealthy and unsafework environments can be costly to a businessthrough decreased productivity, absenteeism, in-creased medical expenses, increased property dam-age, and fines up to a m
18、aximum allowable penaltyof $70,000.001for a willful or repeated safety orhealth violation.This document describes the common potentialhealth and safety hazards that may be present in asmall welding and cutting shop and provides prac-tical advice on protecting workers and property. Itshould be unders
19、tood that not every potential haz-ard can be addressed in an overview publication,but additional sources of help are identifiedthroughout the publication. Some aspects of healthand safety, for example the assessment of workerexposures to welding fumes, may require personnelwith professional training
20、 and equipment not nor-mally employed in an independent shop. The shopowner may have to hire professional assistance incertain circumstances. When outside assistance isnecessary, AWS recommends the shop owner con-sider engaging a Certified Safety Professional (see“Websites,” page 23).How to Use This
21、 GuideStudy the information carefully. There are a series ofemphasis blocks, each identified by an icon. Theseblocks will summarize the situation, directly andquickly. Examples follow of the different types ofblocks and what you will find in them:1. A willful violation is defined by OSHA as one comm
22、it-ted with an intentional disregard of, or plain indifferenceto, the requirements of the Occupational Safety andHealth Act (1970) and regulations. The maximum finethat can be proposed for a willful violation is $70,000.What is OSHA?OSHA stands for the Occupational Safety andHealth Administration. S
23、ince 1970, OSHA has pub-lished requirements, called regulations, that spell outwhat safety measures must be taken for a variety ofsituations. They also are enforcers of these require-ments and have the power to fine employers whofail to comply. And keep in mind that ignorance ofthe regulations is no
24、t an accepted excuse. If you vio-late, you are fined. Period. OSHA sets the require-ments and assesses fines. Fines range up to $70,000per incident. Fines are adjusted for the size of thecompany and if the company is making a goodfaith effort to provide a safe and healthy workplace.OSHA publishes it
25、s regulations to ensure safe andhealthy working conditions. OSHA has contributedtoward the 50% decline in work-related fatalitiesand 40% decline in occupational injuries in the U.S.since its establishment. It has accomplished thisgoal by requiring that information, practice train-Helpful HintsIn thi
26、s type of box, you will findadvice on avoiding the problem/hazard or simple ways to deal withthe topic under discussion.Rapid ReviewInformation in this type of box is asummary and is generally found atthe end of each subject area.Technical TipsIn this type of box, you will findadditional technical i
27、nformation thathelps explain the topic underdiscussion.FundamentalsIn this type of box, you will find basicthings you need to know about thetopic under discussion.2 Independent Shops GuideWelding Safety and Healthing, and education be provided for all workers.OSHAs current welding and cutting standa
28、rds arebased on AWS/ANSI Z49.1, Safety in Welding, Cut-ting, and Allied Processes (see “Information Sources,”page 21), and the National Fire Protection Associa-tions (NFPA) 51B, Standard for Fire Prevention Dur-ing Welding, Cutting, and Other Hot Work. Theunderlying rationale and available provision
29、s forensuring a safe and informed workforce and work-place are indeed admirable. But, you must knowwhats required and how to comply. In this, youhave several options: You can acquire the skill andknowledge yourself and apply it in your operation,or you can hire a safety consultant to come intoyour b
30、usiness and evaluate it for you. Additionally,you can ask OSHA directly for help.Basic Safety Hazard Sources and Accident ResultsThere are many possible sources of accidents. Hereare some of the most common ones:Tools and equipmentChemicalsLaddersElectricityImproper LiftingFlammable liquids and gase
31、sConfined spacesOxidizersHelpful Hint: OSHA Can Be Your Free ConsultantOSHA plays a vital role in preventingon-the-job injuries and illnessesthrough outreach, education, andcompliance assistance. OSHA offers an exten-sive website at www.osha.gov. It includes a spe-cial section devoted to assisting s
32、mall businessas well as interactive e-Tools to help employersand employees. Free workplace consultationsare available in every state for small businessesthat want onsite help in establishing safety andhealth programs and identifying and correctingworkplace hazards. A list of the consultationoffices
33、can be found at www.osha.gov/oshdir/consult.html. In addition, OSHA has a network ofCompliance Assistance Specialists in local of-fices available to provide tailored information andtraining to employers and employees.The results of accidents involving these typicalsources can include:AmputationsCuts
34、 and bruisesBroken bonesChemical burnsLoss of eyesightFires causing personal injury and property lossElectric shockChemical exposureIn plain language, accidents just do not happen outof the blue. They are either the result of an unsafeact or an unsafe condition or both. Common senseis not very commo
35、n. Unsafe acts cause most acci-dents. These unsafe acts include operating tools orequipment without training or permission; failureto use lockout procedures; horseplay; running; fail-ure to inspect equipment; attempting repairs whennot qualified to do so; not following common safetyprocedures; impro
36、per lifting; not using properpersonal protective equipment (PPE); and the im-proper use of chemicals.Unsafe conditions are everywhere. They include suchthings as damaged equipment or tools; poor light-ing; slippery walking surfaces; missing machineguards; inadequate training or supervision; ex-posed
37、 electrical circuits; worn or damaged PPE;improper storage; trash accumulation and poorhousekeeping; overloaded electrical circuits; con-gested walkways; trip hazards; missing hazardwarning signs; and unlabeled or incorrectly labeledchemicals or cylinders.Responsibilities of ManagementThe Shop Owner
38、 or Manager/BossWho is “management”? The term “management”means “all persons who are responsible for weldingoperations such as owners, contractors, andothers.”2OSHA requires that management showtheir commitment to the safety and health ofemployees by establishing guidelines and insistingthat everyon
39、e, including management, follow safepractices consistently. Without this from-the-topemphasis, on-the-job safety can become spotty andneglected. People, like electricity, tend to take thepath of least resistance, and safety usually suffers.2. AWS/ANSI Z49.1:1999, page 3.Welding Safety and HealthInde
40、pendent Shops Guide 3The owner/boss needs to do a number of things toensure safe welding and cutting in the shop. Themajor responsibilities include the following:Provide approved and inspected equipment thatis in safe condition and ready for use.Designate areas where welding and cutting canbe done s
41、afely. If it becomes necessary to do thework in a different place, ensure that propersafety procedures are followed to protect work-ers and property.Train persons using the equipment in its safeoperation and in safe use of the process.Train workers in emergency procedureswho tosee, where to go, and
42、what to do.Provide adequate supervision to ensure that allequipment is properly used and maintained.Have any repairs made by qualified personsbefore the equipment is returned to use.Follow the manufacturers recommendationsand instructions for operating and maintainingequipment.Communicate the hazard
43、s and safety precau-tions about the job before the work is started.Select contractors who know the risks and havequalified and trained workers who will worksafely.Understand what flammable and combustiblematerials are present or nearby, and explain theprocedures to follow to prevent fire and explosi
44、on.Have approved fire extinguishers of the correcttype nearby and be sure all know how to use them.Use a hot work permit system when required.How is an independent shop supposed to get thisdone? Where will the owner get the information?First, use the information provided by the manufac-turers of the
45、 equipment. Most provide complete in-structions about the proper use, handling, andmaintenance of their equipmenttake it out anduse it. These manuals normally contain safety infor-mation as well. In addition, there are labels on theproduct/machine to alert you to possible hazardsand show you how to
46、avoid them. Follow the labels.Obtain and read the Material Safety Data Sheets(MSDSs) for the metal being welded or cut, forcoatings, residual materials or liquids, and anyconsumables, such as rods, wires, and fluxes, beforestarting. These MSDSs have a wealth of informationabout the item and its haza
47、rds and use. Get to knowthe MSDSsa Glossary starts on page 23.The Hazard Communication Standard (HCS)The Hazard Communication Standard (HCS) is ap-plicable to all workers covered by the OccupationalSafety and Health Act. The HCS is based on a sim-ple concept: Employees have both a need and theright
48、to know the hazards and chemicals they areexposed to, and how to protect themselves fromany exposure while working. Simply put, the HCSrequires that all chemicals produced, imported, orused in U.S. workplaces be evaluated, and thathazard information be communicated to affectedemployees by means of b
49、oth precautionary infor-mation placed on containers and material safetydata sheets (MSDSs) supplied with materials.What does this mean for shop management? Itmeans employers have to inform workers of poten-tial hazards in the workplace and provide trainingregarding the safe handling of hazardous materials.In addition, employers must have a written HazardCommunication Program and an inventory list ofthe chemicals they use. This standard identifiesmany welding and cutting consumables as hazard-ous materials. Sounds very complicated, doesnt it?Well, again, method
