Transcript The Welding Shop

Safety in the Welding Shop
Chapter 1
Learning Objectives
• Identify several common causes of accidents
• Recognize possible safety hazards in the
welding shop or other work environments.
• Select and properly use safety equipment
appropriate for work conditions.
• Recognize and evaluate potential safety
hazards and react appropriately to prevent
accidents.
Essential Question
• What are the common personal and physical factors
contributing to accidents in a welding environment?
• What are the common safety hazards in the welding
shop or other work environments?
• How can we eliminate and minimize safety hazards
with the proper selection and use safety equipment
appropriate for work conditions.
• How do we evaluate potential safety hazards and
react appropriately to prevent accidents.
Vocabulary
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Acetone
Acetylene
Earmuffs
Earplugs
Electric shock
Electrical ground
Electrical resistance
Exhaust pickups
First Degree Burn
Flashburn
• Flash Glasses
• Forced
ventilation
• GFCI
• Goggles
• Infrared Light
• MSDS
• Natural
Ventilation
• Safety Glasses
• Second Degree
Burn
• Third Degree
Burn
• Type A Fire
Extinguisher
• Type B Fire
Extinguisher
• Type C Fire
Extinguisher
• Type D Fire
Extinguisher
• Ultraviolet Light
• Valve Protection
Cap
• Ventilation
• Visible Light
• Warning Label
• Welding helmet
Accidents Will Happen
• Ultimately the responsibility for on the job safety
rests with YOU.
• A qualified person is someone who has the
knowledge and experience to handle problems.
• A competent person is someone who can identify
working conditions or surroundings that are
unsanitary, hazardous, or dangerous to employees
and who has authorization to correct or eliminate
these conditions promptly.
• OSHA requires a competent person at all jobsites to
ensure a safe workplace.
• Competent person can shut the operation down
until it is safe.
Three Categories of Events
• There are THREE categories of on the job
events.
• Incidents – It could have happened.
• Accidents – It did happen.
• Injuries – Someone got hurt.
• Proximity work is work that takes place
near a hazard but not in direct contact with
it.
Accidents Will Happen
• An accident: unexpected and undesirable event.
• Personal factors:
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Stress
Illness
Fatique
Lack of Job Knowledge
Age
Lack of Wisdom
Attitude
Drugs/Alcohol
Others??
Accidents Will Happen
• UNSAFE CONDITIONS:
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Equipment Failure
Time of Day
Poor Housekeeping
Excessive Noise
• Warning Label are not to be disregarded!
• MSDS- Material Safety Data Sheet
– What Information is on an MSDS Sheet?
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SMAW Safety
Fumes and Gases can be dangerous
– Keep your head out of the fumes
– Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases
from your breathing zone and the general area
– The SMAW process can withstand wind and exhaust near the arc from ventilation
equipment
Electric Shock can kill – to receive a shock your body must touch the electrode and
work or ground at the same time
– Do not touch the electrode or metal parts of the electrode holder with skin or wet
clothing
– Keep dry insulation between your body and the metal being welded or ground
Arc Rays can injure eyes and skin - Choose correct filter shade (See chart below)
** Information taken from ANSI Z49.1:2005**
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Signs in the Safety Lab
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Information
Safety
Caution *****
Danger
• A red barricade in a work area indicates danger from
falling objects.
• Posts and chain, steel cable, and wood rails are
acceptable materials for a protective barricade.
Shop Safety
• WELDING SAFETY CHECKLIST
• Electric shock can kill
– Water lessens resistance and therefore make
electricity more dangerous.
– A lockout/tagout system which protects
workers from hazardous energy while they
work with machines and equipment.
Shop Safety
• WELDING SAFETY CHECKLIST
• Fumes and Gases can be dangerous.
• Forced ventilation is essential where
inadequate natural ventilation is available
for the hazard.
Lincoln Electric Fumes Safety
Shop Safety
• WELDING SAFETY CHECKLIST
• Welding Sparks can cause fire or
explosion
– Factors to Consider
– Precautionary Summary
Lincoln Electric Fire Explosion Risk
Shop Safety
• WELDING SAFETY CHECKLIST
• Arc rays can burn eyes and skin
– Factors to Consider
– Precautionary Summary
– Never wear Contact Lenses when welding.
Shop Safety
• WELDING SAFETY CHECKLIST
• Confined Spaces
– Factors to Consider
– Precautionary Summary
Shop Safety
• WELDING SAFETY CHECKLIST
• General Work Area Hazards
– Factors to Consider
– Precautionary Summary
Licoln Electric Safety Lessons
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Electric Shock
Fumes & Gases
Fire & Explosion
Miscellaneous Welding Safety
Personal protective Equipment
Burn Classifications
• First Degree Burns – surface of the skin is
reddish in color, tender, and painful. No
broken skin.
• Second Degree Burns – surface of the
skin is severely damaged, blistered,
possible breaks in skin.
• Third Degree Burns – surface of the skin
and possibly the tissue below appears
white and charred.
Burns Caused by Light
• Three classifications of light:
– Visible – the light we see.
• Snow blindness, eye strain
– Infrared – light waves felt as heat
• Sunburn, blistered, etc.
– Ultraviolet – not seen or felt but very
DANGEROUS!
• FLASHBURN
– Can’t feel it until later. You may lose partial or complete
sight permanently or temporarily depending on how
badly the retina is damaged.
Lights, Welding, Hazard GO
PPE
• Never alter or modify your personal
protection equipment.
• Eye Protection:
– Two functions: flying debris, light reflection.
– Safety Glasses ANSI Z89
• American National Standards Institute
– Goggles (same ANSI classification)
– Full Face Shield (flying Debris)
– Flash Glasses (tint to UV rays, reg light and debris)
– Welding Helmets
Ear Protection
• Hearing loss due to excessive exposure to
loud noises.
• Sparks and hot metal shavings entering
the auditory canal.
• To prevent ear infections clean your
earplugs regularly with soap and water.
Lincoln Ear Advisory
Waist, Leg, Arm Protection
• You can purchase all sorts of covers for every
part of your body.
• Remember the basics in Unit 1:
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No loose woven clothing
No synthetic
Long cotton or wool pants
Leather gloves
Ballcap/skull cap optional.
Eye protection
No synthetic or cloth shoes
No chains/phones/keys/zippers/lighters
Reminder about covering up!
Hard Hats
• The outer shell of a hard hat protects your head
from a hard blow.
• Webbing keeps the hat 1 inch from your head.
• Old are Metal, bad for electrical work.
• Modern hard hats are made of Fiberglass.
Reminder about covering up!
Personal Ventilation
Reminder about covering up!
Ladder Positioning
Position ladders so that they are:
• Not in the paths of workers walking through,
• Not in front of unblocked exits,
• Not in front of doors that can open out into the ladder,
• Not on boxes, barrels or other unstable surfaces,
• On solid footing and level at the bottom,
• Stable at the top with each rail supported equally,
• Against a structure capable of supporting the intended load,
• Away from debris and other hazards.
Ladder Placement
Place ladders on solid surfaces
that will support the ladder and
prevent displacement by other
workers.
Block, tape, lock
or guard a door if
the ladder is
placed where the
door will hit it
when opened.
Step-Ladder Setup
Open up step ladder legs
completely and lock the
spreader bar braces.
Never use the top of a step
ladder
Warning labels on stepladders clearly state that
the top step and top cap are not to be used as a
step. The higher you are on a step ladder, the
less stable it becomes.
step ladder too
short for this job
Doing this….
…could lead to this!!
Setting up extension ladder
Place ladder base on a firm, level surface with secure footing.
Don’t place a ladder on unstable footing or soft ground.
As the ladder sinks into the ground or slips from where it is
positioned, it becomes very unstable.
Position the ladder
on solid ground or
shoring to ensure
stability.
An unstable base
Setting up an extension
ladder
When working
from an
extension ladder, make
sure it is set up at a 4:1
angle with secure
footing on a firm level
surface.
For accessing an upper
level, make sure the
extension ladder is set
up at a 4:1 angle on a
firm, level surface and
the side rails extend at
least 3’ above the
surface to be accessed.
Proper ladder set-up Lastly, make sure the
extension ladder is
secured at the top and
bottom
Improper ladder set-up
(not 3 ft. above roof line)
Proper Extension Ladder
Setup
For every four feet of ladder length
measured from where the ladder
contacts the support point, the base
of the ladder should be one foot
away from the supporting structure
(one to four rule).
The ladder must extend at least three
feet above the surface to provide
safe access or be rigidly secured at
the top with a grasping device if less
than three feet.
The ladder in the photo contacts the
supporting structure at 9 feet. This
means that the base of the ladder
should be 27 inches back from the
support.
Extended
3 ft. above
top surface
Secured
from
slipping
9 ft.
Determining proper ladder
setup angle
One way to ensure
proper angle is to stand
with your feet at the
base of the ladder and
extend your arms
straight out. If your
hands just touch, the
ladder will be very close
to the 4 to 1 ratio.
Ladder set-up on uneven
ground
Ladder can be set up straight and level on just about
any type of uneven surface using ladder levels
attached to the side rails.
Straight ladder stabilizers
The straight ladder side rails must be equally
supported at the top, unless the ladder is equipped
with an adequate stabilizer.
Ladders with top stabilizers
Climbing or descending a
ladder
When climbing a ladder, you must have both hands
free and face the ladder. This allows for three points
of contact with the ladder at all times and reduces the
chances of falling. The three point contact is two
hands and one foot or one hand and two feet.
This way
Not this way
Climbing and descending
This worker does not have
both hands free to hold onto
the ladder while climbing or
descending the ladder.
Proper ladder climbing with
tools on belt and both
hands free
Overreaching from the sides
Doing this….
Could result in this!
Electrical Hazards and
Ladders
Don’t use metal or conductive ladders near
energized electrical equipment or overhead
power lines.
Tying Extension ladders
Don’t tie or fasten ladder sections together to make a
longer ladder, unless the manufacturer specifically
endorses this modification using hardware fittings
designed for that purpose.
Ladder misuse
A ladder must be used only for purposes
specifically recommended by the manufacturer.
The ladder in this photo is being as a ramp to
enter the house interior.
Step Ladder Misuse
Rather than a firm, level surface, this
stepladder is positioned on a fence so
the such that the bottom step is taking
the load rather than the side rails.
It doesn’t extend three feet above the
roof surface, is not secured, and the
worker is standing on the top step to
access roof.
This stepladder is being misused to
access doorway.
Stepladders can’t be used partially
closed and leaned against the wall.
Stepladder Misuse
A 3-legged
step-ladder with
the worker
standing on the
top cap and
balancing on
one foot.
(Also, no safety
glasses while using a
nail gun and hard hat
is worn backwards)
Step ladder misuse
This step ladder is
not fully opened with
spreader bar locked
and the step ladder
side rails are
straddling a scaffold
plank being set up in
a position not
intended by the
manufacturer.
Hazardous Ladder Use
A 3-legged step-ladder
leaned against a 2x4
nailed across the
window.
A repair patch on the
left front side rail of
ladder.
No fall protection in use
while working at height.
Hazardous ladder use
Unsecured, folded step-ladder
set on an angled shed roof so
that only the tips of the side
rails lay on roof.
Extension ladder not extended
at least 3-feet above roof, set
up at an angle greater than a
4:1, and it’s not secured top
and bottom to prevent
movement.
No fall protection being used
while on this walking/working
surface.
Ladder Misuse
Two workers using two
step-ladders leaned
against wall, set up over
wood debris, with the far
worker standing on the top
step. (also, third worker needs
fall protection)
A better choice in ladders would make this job easier!!
More safe ladder practices
Use a ladder only when you are mentally alert and physically able.
Don’t let your belt buckle pass beyond either ladder side rails.
Hold the ladder with one hand while working with the other.
Don't hurry or skip rungs /steps when using the ladder.
Be careful when pushing or pulling anything while up on a ladder.
A few more ladder safe
practices
Don't test a ladder by jumping on it.
Don't paint a wood ladder.
Don't use any ladder that has been exposed to fire or other strong
chemicals.
Protect ladders from environmental elements such as: excessive
heat or cold.
Don't drop or throw ladders.
Store ladders out of the way of other employees.
Secure ladders firmly when transporting on vehicles.
More Information
OSHA Construction eTool – ladders
CPWR – Ladder Safety (safety meeting
topic)
CPWR Video – ladder safety (online video)
L & I Video Library (several videos on ladder
safety)
Introduction
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Subpart L specifies the requirements needed
to safely erect scaffolds or staging.
Scaffolds are temporary platforms workers
use in order to access their work area and to
hold the supplies needed for that job.
Because of the locations and dangers
involved,
• only trained and competent persons are to
erect
• scaffolds at the job site.
Operating Engineers National
Hazmat Program
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1926.451 Scaffolding
General requirements
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All scaffolds are to be
capable of supporting,
without failure, at least
4 times the maximum
intended load.
Operating Engineers National
Hazmat Program
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1926.451 Scaffolding
General requirements
Safety Precautions
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Never allow debris/materials to collect on
scaffold
Always use netting to catch anything that
falls
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Make sure scaffold is secure
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Operating Engineers National
Hazmat Program
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1926.451 Scaffolding
General requirements
Safety Precautions
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Do not stand
on ties,
guardrails,
or extensions
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Operating Engineers National
Hazmat Program
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1926.451 Scaffolding
General requirements
Safety Precautions
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Do not overreach
outside the guardrails
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Operating Engineers National
Hazmat Program
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1926.451 Scaffolding
General requirements
Safety Precautions
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Stay off scaffold during loading or
unloading
Replace guardrails after loading or
unloading
Use 3-point climbing
Don’t hang tarps without evaluation
Exit mobile scaffolds before moved
Operating Engineers National
Hazmat Program
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1926.451 Scaffolding
General requirements
Safety Precautions
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Always wear
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fall protection
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to avoid
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accidents
• Lanyard for harnesses
• Prevent falls from 6’.
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Operating Engineers National
Hazmat Program
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1926.451 Scaffolding
General requirements
Footing or Anchorage
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The footing or anchorage
is to be on a solid foundation;
sound, rigid, and capable of
carrying the maximum
intended load without
settling or displacement.
Operating Engineers National
Hazmat Program
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1926.451 Scaffolding
General requirements
Footing or Anchorage
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The use of unstable
objects to support
planks or scaffolds
is prohibited.
Operating Engineers National
Hazmat Program
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1926.451 Scaffolding
General requirements
Guardrails
•The use of guardrails is very
•important, preventing workers
•from falling. Nearly 3/4 of
•the reported scaffold accidents
•are caused by improper
•guarding.
Operating Engineers National
Hazmat Program
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1926.451 Scaffolding
General requirements
Guardrails
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Open-ended or opensided platforms must
have standard
guardrails and
• toeboards.
Operating Engineers National
Hazmat Program
61
1926.451 Scaffolding
General requirements
Guardrails
• The guardrails are to be 2 X 4 and
about 42”
• high with a midrail whenever needed.
The
• supports for the guardrails are to be at
• intervals no more than 8 feet.
Operating Engineers National
Hazmat Program
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1926.451 Scaffolding
General requirements
Protective Screening
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Overhead protection shall be provided for
men on scaffolds and, in the same sense,
a screen is to be placed
below the scaffold
where persons may in
danger of falling objects.
Operating Engineers National
Hazmat Program
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1926.556
Aerial lifts (Subpart N)
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These are vehicle-mounted
elevating and rotating work
platforms such as ladder
trucks and tower trucks.
Aerial lifts are to be
operated only by
authorized persons.
Operating Engineers National
Hazmat Program
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1926.556
Aerial lifts (Subpart N)
• Aerial ladders shall be secured in the
lower
• traveling position by the locking device
on top
• of the truck cab, and the manually
operated
• device at the base of the ladder before
the
Operating Engineers National
Hazmat Program
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1926.556
Aerial lifts (Subpart N)
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Never move an aerial lift
truck when the boom is
elevated in a working
position with men in the
basket, except where
specifically designed for
this type of operation.
Operating Engineers National
Hazmat Program
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1926.556
Aerial lifts (Subpart N)
• Lifts that are used primarily as
personnel
• carriers must have both platform (upper)
and
• lower controls. The lower controls are
to
• override the upper controls, never to be
used
Operating Engineers National
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Hazmat Program
1926.556
Aerial lifts (Subpart N)
• While working on aerial lifts, employees
shall:
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Always stand firmly
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on the floor of the
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basket and not sit or
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climb on the edge
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Operating Engineers National
Hazmat Program
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1926.556
Aerial lifts (Subpart N)
• While working on aerial lifts, employees
shall:
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Wear a body belt
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and have a lanyard
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attached to the
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boom or basket
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for fall protection
Operating Engineers National
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Hazmat Program
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1926.556
Aerial lifts (Subpart N)
• While working on aerial lifts, employees
shall:
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Keep within specified load limits
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Use brakes and wheel chocks when
needed
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Operating Engineers National
Hazmat Program
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1926.556
Aerial lifts (Subpart N)
• Examples:
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Telescoping
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Rotating boom
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Scisor type
Operating Engineers National
Hazmat Program
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Handling/Storing Cylinders
• Oxygen and fuel cylinders must be stored separately.
– 20 feet apart
– 1.5 hour burn rate/5 ft. wall
– This will ensure that the heat of a small fire from
causing the oxygen cylinder safety valve to release. A
raging inferno would pursue with the oxygen.
• Inert gases may be stored with oxygen cylinders.
• Empty cylinders stored separately
Handling/Storing Cylinders
• Securing Cylinders:
– Chained to a wall.
– Upright Position.
– In areas away from halls of stairs
– Away from heat sources, radiators, furnaces, and
welding sparks.
• Valve Protection Caps
– Always on, unless in use.
– Cap protects the valve in the event the cylinder is
knocked over or bumped.
– Missile Effect.
Handling/Storing Cylinders
• Leaking cylinders, identified and supplier notified. Soap
stone to identify.
• Acetylene cylinders should never lay on their sides. If
so, they must stand upright for 4 hours before they can
be used.
• The way the acetylene tank works, it has a filler and
acetone in the tank to stabilize the acetylene. If you do
not allow these to separate you will get acetone mixed
with acetylene in your release and your flame intensity
will be compromised (lower temperature), thus ruining
your weld.
Welding with Oxy Fuel
• Welding considered HOT WORK by the National
Association of Fire Prevention.
• Plumbers required waiting period. (Fire Watch)
• Burn bans in fire storm areas (Southern California,
Colorado recently).
• PERMITS MUST BE OBTAINED.
• When welding Always check for three things:
– HOSES, REGULATORS (IF IN USE), AND ALWAYS CHECK
FOR FLAMMABLE MATERIALS WITHIN 35 FEET OF
WELDING AREA! ESPECIALLY OUTSIDE! LEAVES,
PINESTRAW, ETC. WILL BURN!
– ALWAYS USE A FRICTION STRIKER TO LIGHT A CUTTING
TORCH.
Welding with Oxy Fuel
• Always make sure regulators are installed
for the correct fuel. Acetylene vs. Fuel
• Threads for fuel different from oxygen
(reverse thread).
• Hoses for Oxygen are green.
• Hoses for fuel are red.
• Always weld in well ventilated area due to
the toxic fumes that may be created.
Fire Extinguishers
• A-Green triangle letter A
– Combustible materials such as paper, wood, and
cloth.
• B-Red square letter B
– Combustible liquids such as gas, and paint thinner.
• C-Blue Circle letter C
– Electrical Fires, motors, fuse boxes, and welding
machines.
• D-Yellow Star letter D
– Combustible metals such as magnesium, titanium,
zinc.
Fire Extinguishers
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Location is very essential.
Marked with red paint and signs
High enough to be seen
Appropriate for the material in the area.
Maxwell fire extinguishers are
multipurpose ABC Dry Chemical.
• What type of exposure is NOT covered
with our current system?
Fire Extinguisher
• When using a foam extinguisher, allow foam
to fall lightly on the base of the fire.
• Carbon Dioxide extinguisher, get as close to
fire as possible, start at the edge and go to
the center.
• Dry Chemical extinguishers, direct the
extinguisher at the base of the flames.
Maintenance Plan
• Maxwell will have planned maintenance days
when the equipment, bays, lab condition will be
inspected and improved upon.
• Assigned welding bays to ensure you are cleaning
your mess. We will expect that spatter is grinded
daily!
• Sign out equipment and return it.
• Grind your tables and positioners to remove
spatter.
• No food or drink EVERY in the welding lab. (If you
spill a coke and you may die of electrocution!)
Maintenance Plan
• Electric cables that are damaged may be spliced,
but NEVER less that 10 feet from the electrode
holder.
• Use Electrodes to the numbers. Put stubs in the
stub box.
• Be clean and aware of your surroundings and
conditions. If you are sweating and are all wet,
you may want to change your shirt.
• Any work left out that is still hot should be
identified as HOT in your bay by posting the “HOT
JOB INSIDE” magnet on your threshold.
Lincoln Electric Additional Safety Info
Electric Shock and Safety
• CAN CAUSE DEATH!! NO ShhhhhUGAR!
• Electrical resistance is lowered in the
presence of water!
• All cables and contact are tight! Never a gap
for metal shavings to get into.
• ALWAYS CHECK THE CONDITION OF
YOUR CABLE BEFORE YOU BEGIN A
NEW DAY OF WELDING!
Electric Shock and Safety
• ALWAYS TURN OFF POWER WHEN WELDING
STATION IS LEFT UNATTENDED.
• MAKE SURE ALL HAND POWER TOOLS HAVE
A GROUND THAT HAS NOT BEEN DAMAGED.
SOME PEOPLE PULL OUT THE GROUND TO
MAKE THE PLUG FIT INTO A 2 PRONG
RECTACLE. THAT IS DANGEROUS. TWO
PRONG UL APPROVED MACHINERY HAS A
DOUBLE INSULATIVE WIRING THAT WOULD
REMOVE LEAKING CURRENT AWAY FROM
THE USER. DON’T SCREW WITH ENGINEERED
EQUIPMENT!!!!! ITS THERE FOR A REASON!
Voltage/Current and Tools
• Always make sure you look at the voltage rating of
a tool and use it with the appropriate power
supply.
• A power source with a voltage greater than the
specified voltage can lead to serious injury.
• A power source that is a lower voltage than the
rating on the tool can lead to motor damage.
• Higher the amps the more powerful the motor.
• GFCI – Ground fault circuit interrupter: sense the
surge and shut down the circuit to save the device
and the user.
Grinding
• Pedestal
• Portable
• Smoothing a weld, grinding a groove,
removing rust and spatter.
• The stone has a max rpm on the paper
label. Must match with the grinding tool. If
you exceed rpm, can explode your stone,
dude, causing serious injury or death even!
Grinders
• NEVER use stone is cracked.
• Never grind aluminum on a stone meant for
mild steel, glazes the stone.
• Surface becomes clogged with metal.
• Remove gloves when using pedestal
grinder. Caught, and sparks fly away!
Drill Press
• Always clamp item to table to be drilled.
• Do not try and hold it. The torque from this
machine will rip your fingers off!
• When possible use the center punch
machine to pre punch a small opening and
then drill your hole.
Metal Cutting Machines
• Shears and Punches
• Motorized usually. Cuts ½” mild steel like
butter.
• Angle Bender
• Horizontal Saw: JET
• Demonstration of Each
Guest Speakers
• Dr. Gary Pence, Georgia Optometry
• Anatomy of the Eye
• Eye Conditions
– Color Blindness and Other Eye Tests
• Injuries & Horror Stories
• Eye Care & Correct use of an eye wash
• Prescription Welding Eyecare
Guest Speakers
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Dustin Wagner – GCFD Station 22
Electric Shock and Burn First Aid
CPR
Special procedure
Fire Marshall Inspection