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Posted By SLS
Prior to posting this message i did take the time to trawl through past threads, unfortunately I'm still in need of help and advice.
I have reached a point where i need to produce risk assessments for our welding processes. Not being an expert on the subject, i have to admit to struggling to understand the different methods of welding and the hazards associated with them.
Initially I'm tackling the welding processes in our Bodyshop departments.
Oxy/fuel
MIG
TIG
Spot
I have spoken to the lads carrying out the work, and although helpful, I'm still unsure about the main differences between the different welding techniques.
Can i 'clump' a couple of the techniques together on one risk assessment?
I'm not asking for anyone to write the risk assessments for me, i simply need some advice on the best approach, things to be considered etc. If anyone has some examples they could let me see, i would be very grateful.
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Posted By holmezy
SLS,
other than the technical differences in the procees, the hazards are "generally" the same. Perhaps you should consider;
Heat, ie burns
Fumes
electrocution
radiation, ie arc eye or skin
fire, ie from splatter to flammable material locally
Flammables in the area, ie solvents, fumes etc
Electrodes, ie thoriated or not which lead to fumes etc
manual handling, ie some welding kit is quite bulky / heavy
gas, ie oxygen, argon, acetylene etc
Hope it helps......a little
Holmezy
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Posted By holmezy
SLS,
oh...yes you could clump them all on one assessment, but I would do an assessment for each process. Your choice really, do you want 1 big one or a few smaller specific ones?
Holmezy
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Posted By SLS
It does help Holmezy.......thanks.
I have made a good start on the r/assessment for Oxy/Fuel method of welding. Information i have found on the tin'ter'net has been helpful.
Still a little confused about the differences between MIG, TIG and SPOT.
Am i right in thinking that these methods of welding primarily involve the use of electric? And that, other than this difference, the hazards are much the same as those for the Oxy/Fuel method?
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Posted By Mitch
Spot welding is an entirely different process to MIG & TIG (both of which I would include on one RA) using a separate on for Spot. MIG and TIG are "aggressive" techniques whereby filler material is added using an electric arc and inert gas to shield the arc and protect from oxidisation. Spot is a passive resistance process and the only similarity is the use of electricity. And of course the joining of base materials!
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Posted By Christopher Boocock
SLS
MIG welding is "Metal Inert Gas" welding whereby a metal consumable electrode is used to strike the arc, and is continuously fed as the weld is laid down. The process uses no flux, as the arc is shielded by an inert gas - generally argon or specialist argon mix for welding.
TIG welding in "Tungsten Inert Gas" welding whereby a tungsten electrode is used to strike the arc, ans the metal consumable welding rod is manually fed into the arc. The tungsten doesn't burn away so long as the metal consumable is fed in. This process too is shielded by an inert gas.
Spot welding is used to join sheet metal together (as used on cars). Two pieces of sheet metal are placed between two electrodes (normally less than 6mm diameter) which are closed on the sheet metal thereby completing the electric circuit. The sheet metal acts as a resistor & heat up and ultimately fuses between the electrodes.
Hope this helps - otherwise e-mail me directly.
Regards
Chris
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Posted By SLS
I think there may be light at the end of the tunnel.............thanks Mitch.
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Posted By SLS
Christopher.......thanks for the info. Very helpful.
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Posted By Sally
Talk to the guys who are carrying out the work - they will be able to tell you about the different types and main hazards.
It isn't possible to do an adequate risk assessment about something you know little about. The safety professionals skills lies in getting this information from.
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Posted By Sally
........... those who do understand the process.
Sorry - too quick to press post.
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Posted By SLS
Paul..........spent quite a while yesterday trawling through the HSE guidance, ended up loosing the will to live. The more i printed off and read, the more confused i got.
I should have stuck to one type of welding at a time, instead of going head on into them all at once (important lesson learned).
Perhaps i am trying to be too in-depth/complicated with the r/assessments.
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Posted By Christopher Boocock
SLS.
If you e-mail me directly I can send you my RIsk Assesments which will give you a start - you might want to go through them with the welders - thismay prompt them to identify other hazards.
Chris
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Posted By SLS
My intention has never been to produce the risk assessments without the input from those who carry out the work.......I simply find it easier to produce an initial (fairly basic) assessment with information readily available to me via the Internet, books, leaflets etc.
which i then take with me onto the 'shop floor' where i proceed to add to it/delete things, and basically tweak it, with the help of 'those who know'.
The department is an incredibly busy area. Creating an initial assessment prior to approaching the workforce reduces the time in which i have to disturb them.
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Posted By SLS
Christopher....email sent.
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Posted By Jim Walker
Another issue to check is the regrinding of electrodes TIG (might be MIG though) I seem to remember (sorry its while since I did welding RAs)
The ground off metal dust is a hazard - MSDS for them will advise.
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Posted By Jane Blunt
I would suggest doing separate assessments here, since the hazards are rather different.
Oxyfuel - no UV light, fume levels not normally very high, no electricity directly associated with process; there are issues with fuel gases.
MIG - consumable electrode on a reel, electric process, lots of UV and sometimes ozone as well (amounts dependent on material being welded), more fume than oxy-fuel. Inert compressed gases used as shielding.
TIG a non-consumable electrode, but this process may also use a consumable filler wire; electric process, much less fume than MIG, inert compressed gas used as shielding. UV and ozone (amounts dependent on the material being welded). The electrode does not vapourise in the welding process, but as already mentioned by others the operator needs to grind the tip occasionally and this creates an inhalable dust.
You do need to check what materials they are welding. Certain metals produce fume that is more harmful - e.g. stainless steel, copper, lead.
The sorts of issue you will need to make decisions upon are:
What type of eye protection - the shields are graduated according to the amount of light to be filtered out.
Whether local exhaust ventilation is required, how it should be placed, and the maintenance and testing scheme to go with it. Whether masks are needed.
Housekeeping - lots of scope for fire and tripping over wires and hoses
Associated processes - e.g. grinding of the workpiece, grinding of electrodes (for TIG).
Whether the environment is one of increased risk (e.g. damp, highly conducting - where reduced voltages are advised)
Flashback arrestors for the fuel gases and oxygen
Storage of cylinders, regulators and their maintenance and inspection
Protective overalls and other clothing
Noise and vibration
Manual handling
This is not an exhaustive list.
Jane
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Posted By SLS
Very much appreciated Jane....thanks.
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Posted By Mitch
Go for Thoriated? Tungstens, this reduces problems/risk when regrinding.
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Posted By Jane Blunt
No, it is the thoriated tungsten electrodes that are slightly radioactive. Go for alternatives if you are concerned about this.
Jane
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Posted By Jane Blunt
Actually, the thoriated tungsten electrodes are slightly radioactive. Go for different types if you are concerned about this.
Jane
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Posted By Mitch
That's what I meant non-thoriated, my minds a bit addled after all those years of grinding radioactive tungstens!!
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Posted By Alexander Falconer
Sounds like many of the key issues have been covered, however you also have to consider the fumes given off, not just from the metal being welded, but also the filler metal too.
Dont forget to contact the manufacturers of the conumables and refer to the relevant filler material data sheets (oh yes, these exist too)
Also the welding institute is a valuable source of information. (www.twi.co.uk)
Regards
Alex
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