International Journal of Mechanical Engineering and Technology (IJMET)

Volume 8, Issue 3, March 2017, pp. 433–441 Article ID: IJMET_08_03_048

Available online at http://iaeme.com/Home/issue/IJMET?Volume=8&Issue=3
ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

THE EFFECTS OF ARC WELDING HAZARDS

TO WELDERS AND PEOPLE SURROUNDING
THE WELDING AREA
Christopher T. Mgonja (PhD)
Department of Mechanical Engineering
Dar es Salaam Institute of Technology - Tanzania

ABSTRACT
Arc welding is a family of fusion welding processes that utilizes heat of an electric
arc for the purpose of welding. In every arc welding method, safety should be the
paramount consideration. It requires the most protection of the face, body and welding
area during welding to reduce the welding hazards to welders and non-welders. The
intensity of the arc produces strong ultraviolet and infrared radiation, fumes and dusts.
Any person exposed during the welding process can be affected.
This paper is adapted from different publications to provide an overview of welding
hazards, health effects and safety measures. The review describes information currently
available from different published research works. It involves the group of people that
can be affected by arc welding hazards including arc welders, the crafts constitute the
subset of welding group, passerby, bystanders and residents near the welding shop.
It has been revealed from different studies that the profession is very hazardous and
most of the stakeholders involved possess limited knowledge of welding hazards and
hence to avoid these hazards, it is advised to abide to all safety measures.
Key words: Arc Welding Processes, Welding Hazards, Health Effects, Safety Measures.
Cite this Article: Christopher T. Mgonja, The Effects of ARC Welding Hazards To
Welders and People Surrounding The Welding Area, International Journal of
Mechanical Engineering and Technology, 8(3), 2017, pp. 433–441.
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1. INTRODUCTION
Welding is a process of joining two metal parts together by applying intense heat between them,
which causes the parts to intermix after melting. Welding processes are widely used for the
manufacture of shipyards, civil engineering structures, mining industry, transportation means,
petrochemical industry, and metallurgy [1].
Workplace is an important part of human environment. The health and efficiency of workers
in any organization get influenced in large extent by conditions in their work environment. It is
an established fact that no occupation exists without risk of hazard [2]. Arc welders and other

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 Christopher T. Mgonja

people surrounding the welders have potential exposure to a number of hazards [3]. Arc welding
is a safe process when sufficient measures are taken to protect the welder from potential hazards
and when proper operating practices are followed [2, 4]. According to World Health
Organization (WHO), there are about 250 million cases of work-related injuries per year
worldwide. One of the jobs that contribute to these occupational injuries is the welding process,
especially in developing countries [2, 5]. Welding is common indispensable procedure in
engineering works and is associated with varied health hazards apart from injuries. Welding
operations lead to production of gases and small solid particles, together known as welding
smoke. Most of this is produced during arc welding [1, 2]. Major hazards welders can encounter
if these dangers are overlooked include fumes and gases, arc rays and sparks, and electric shock
[6]. The thermal effects can cause agglomeration of the particles into particle chains and clusters
that can be deposited in the human respiratory tract. Most of the fume particles are less than
1micron in diameter when produced, but they tend to grow in size with time due to
agglomeration [1]. Arc welding produces the full spectrum of ultraviolet radiation (UVR). It is
possible that welders are at greater risk of developing skin cancer than the general population.
Furthermore, thermal burns from hot metal can occur when welding and contribute to increased
risk of developing actinic skin and ocular damage [7]. Electric shock from welding and cutting
equipment can result in death or severe burns. Additionally, serious injury can occur if the
welder falls as a result of the shock [8].

2. ARC WELDING HAZARDS

Normally operations are not hazardous but a completely safe work-place is something non-
existent in the world. Because welding generally requires the use of electric current (including
high frequency high voltage current) and compressed gases as well as it involves burning of
fluxes, coatings, and gases therefore it may lead to accidents due to negligence and thus prove
hazardous [9]. The profession is regarded as the most hazardous and not all welders are aware
of all the Hazards [10]. The hazards which are more or less peculiar are: fumes and gases; arc
radiation; fire and explosion; electric shock; and compressed gases [9, 11].

2.1. Welding Fumes and Gases/Dust

Shielded Meatal Arc Welding (SMAW), Submerged Arc Welding (SAW), Gas Tungsten Arc
Welding (GTAW), and Gas Metal Arc Welding (GMAW), cause very small particles that are
formed when the vaporised metal rapidly condenses in air, and are typically too small to be
seen by the naked eye, but collectively, form a visible plume. These fumes can be harmful if
inhaled through the nose and mouth of the welder. The content of the fumes may be either
asphyxiating or toxic [12, 8].
The electric arc welding processes generate dust and particulate fumes, which when inhaled
regularly over long periods can result in serious effects of the welder’s health. The fumes and
dust generated during arc welding may be carried into the zone around the welder’s face by
convection currents rising from the arc. Metallic vapours, mostly oxides and silicates of metals,
react with atmospheric oxygen resulting in the formation of fine dust. Especially dangerous are
the oxides of zinc, lead, cadmium, beryllium, and copper formed during welding copper, brass
and bronze [9].
Also during arc welding, the atmosphere surrounding the welder is contaminated with
manganese compounds, nitrogen oxides, ozone, carbon monoxide, and fluorides. Some fluxes
on melting give off oxides of manganese in dust form as well as hydrogen chlorides and
fluorides. In carbon dioxide (CO2) welding, carbon monoxide may be produced by
decomposition of CO2 in the shielding gas or of carbonates in flux cored wire [9].

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 The Effects of ARC Welding Hazards To Welders and People Surrounding The Welding Area

Some of the effects of fumes on welder and surrounding people including irritation of the
respiratory tract resulting in dryness of the throat, coughing, chest tightness, and breathing
difficulties. In this respect cadmium fumes have the worst effect. It can also result, in acute
influenza-like illness called metal fever. Continuous exposure to metallic fumes and dust can
lead to systematic poisoning and fibrosis causing the formation of fibrous or scar tissues in the
lungs [9, 13]. Therefore, health effects associated with metal fumes depend on the specific
metals present in the fumes, but there is a concern that these may range from short-term
illnesses, such as metal fume fever (i.e. flu-like symptoms), to long-term lung damage and/or
neurological disorders, such as lung cancer and/or Parkinson’s disease [8].
Fine particles are more hazardous than coarse particles because they can pass through the
nose and throat and lodge in the lungs, causing lung damage and premature death in persons
with heart or lung disease [14]. The most breathable particles are of sizes from 0.1 to 5 μm;
particles with more than 5 μm in size are deposited in the upper respiratory tract and those with
less than 0.1 μm in size are mainly removed from the body by exhalation [15]. Thus, welding
fume particles are among the most breathable ones. Fig. 1 shows particle sizes for a number of
familiar pollutants [1, 8, 15].

Figure 1 Particle sizes for different pollutants

Fig. 2 shows the concentration of respirable particulates in breathing zone of welders and
non-welders. The average concentration of respirable particulates in the breathing zones of
welders was four times as high as in the breathing zones of non-welders [1,16].

Figure 2 Concentration of respirable particulates in breathing zone of welders and non-welders [1,
16].

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 Christopher T. Mgonja

Fumes and gases are minimized by: working in a well ventilated area; wearing proper
respirator when necessary; using materials and welding process which generate fewer fumes;
Keeping the head out of the fumes, and avoiding breath the fumes [12, 17].

2.2. Electric Arc Radiation

An electric arc gives off visible light (wavelength 0.4 to 0.75 µm) of high intensity with a
brilliance 10,000 times the safe glare level of the eyes. The intensity of emitted light depends
upon the current level, and the presence of flux [9, 12]. The welding arc also emits ultra violet
(UV) and infra-red rays [7, 9, 12] with wave length less than 0.4 µm and higher than 0.7 µm
respectively [9]. UV rays can damage both eyes and skin. Even an accidental exposure to UV
light from an arc can cause a condition known as arc eyes. This is characterized by painful gritty
feeling as if sand has gone under the eye lids. This painful condition does not develop
immediately after exposure and may take 4 to 8 hours and normally takes 24 to 48 hours to
disappear [9, 18, 19].
Radiation in the visible and near infrared spectrum (400-1400 nm) penetrates the eye, to be
absorbed by the retina where, given sufficient intensity and duration, causes thermal or
photochemical damage which may be permanent and sight threatening [18].
Welders’ face shields are fitted with shaded lenses that help to protect their eyes from
ultraviolet (UV) radiation, which prevent arc eye or welder’s flash. Unfortunately, some other
crafts do not have the protecting gears and many passerby and residents leaving near the
welding shops do not even know that the arc’s bright light can burn their eyes in just a few
seconds. In fact, many welding-related eye injuries each year are to bystanders, passerby and
residents who are watching someone that welds. [3, 12]. A summary of actinic UVR hazards
are posed to persons working around electric arc welding processes as follows [20]:
• Hazardous Exposure. The level of hazardous exposure affecting welders’ helpers and other
personnel forklift and overhead crane operators, for example) located in the vicinity of open arc
welding can now be determined. The intensity and wavelengths of nonionizing radiant energy
produced depend on many factors such as the process type, welding parameters, electrode and
base metal composition, fluxes, and any coating or plating on the base material.
• Exposure Time. Exposure to actinic UVR is considered to be cumulative with each exposure
over an 8 hours workday and within a 24 hours period. Therefore, two 5 min exposures during
a workday could be considered as a single 10 min exposure.
• Reflections. Actinic UVR can reflect significantly from some common surfaces and these
reflections might also create potentially harmful exposure to unprotected personnel. Unpainted
metals (particularly aluminium) and concrete floors readily reflect actinic UVR. On the other
hand, lightly coloured paints often use pigments of zinc oxide or titanium oxide and have a low
reflectance of actinic UVR.
• Safety Information. Welders, welders’ helpers, and their supervisors should periodically
include a discussion of actinic UVR hazards in normal safety reviews and within written safety
procedures. Concern for actinic UVR is especially important to discuss with new employees
and personnel who work in the vicinity of open arcs.
• Nearby Persons. Persons in the vicinity of welding operations can be protected from exposure
to actinic UVR by use of screens, curtains, or adequate distance from aisles, walkways, etc.
Welders’ helpers, overhead crane operators, and forklift operators who have a line of sight to
any open arcs should consider wearing appropriate safety equipment such as safety glasses with
side shields or even a clear, full-face shield and long-sleeved shirts.
• Skin Protection. While standards exist for welders and their helpers, skin protection has not
been uniformly prescribed for other personnel who work in the vicinity of open arcs. Fabric
measurements have shown that natural materials (leather, cotton, wool) are better for absorbing

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 The Effects of ARC Welding Hazards To Welders and People Surrounding The Welding Area

actinic ultraviolet radiation than synthetic materials (polyester, nylon). Incidental personnel
should consider wearing a long-sleeved shirt.
• Warning Signs. Warning signs are useful when persons unfamiliar with actinic UVR and other
welding hazards are nearby. Such warnings are especially important to have on portable welding
screens that can be used at field sites near the general population. A suitable sign could simply
state “Danger” or “Warning” and be posted conspicuously at entry points or doors to welding
areas. Such signs might also include the warning “Avoid Exposure of Eye and Skin to Arc and
Harmful Ultraviolet Emissions.”

2.3. Fire and Explosions

Fire in a welding area can be caused by the ignition of inflammable or combustible materials
lying in the vicinity of the welding zone, and also due to electrical short-circuit. Electric arcs,
hot metal, slag, sparks and spatter are sources of ignition and explosion if precautionary
measures are not followed. A safe distance for welding in the general area of combustible
materials is normally considered to be 10.7 m. Many of industrial fires have been caused by
sparks that can be flying to a certain area with combustible materials [9, 12, 21]. Sparks and
molten metal can travel greater distances when falling. Sparks can pass through or become
lodged in cracks, clothing, pipe holes, and other small openings in floors, walls, or partitions.
Typical combustible materials inside buildings include: wood, paper, rags, clothing, plastics,
chemicals, flammable liquids and gases, and dusts. Parts of buildings such as floors, partitions,
and roofs may also be combustible. Typical combustible materials outside buildings include
dry leaves, grass, and brush. Welding can cause explosions in spaces containing flammable
gases, vapors, liquids, or dusts. Special precautions are needed for any work on containers [21].
The following measures have to be taken to avoid fire and explosion hazards [21, 9, 12]:
Remove combustible materials for a minimum radius of 35 feet (10.7 metres) around the
work area or move the work to a location well away from combustible materials. If relocation
is not possible, protect combustibles with covers made of fire resistant material. If possible,
enclose the work area with portable, fire-resistant screens. Cover or block all openings, such as
doorways, windows, cracks, or other openings with fire resistant material. Do not weld material
having a combustible coating or internal structure, such as in walls or ceilings, without an
appropriate method for eliminating the hazard. After welding, make a thorough examination of
the area for evidence of fire. Keep appropriate fire extinguishing equipment nearby, and know
how to use it. Do not weld in atmospheres containing reactive, toxic, or flammable gases,
vapours, liquids, or dust. Do not apply heat to a workpiece covered by an unknown substance
or coating that can produce flammable, toxic, or reactive vapours when heated. Do not apply
heat to a container that has held an unknown substance or a combustible material unless
container is made or declared safe. Provide adequate ventilation in work areas to prevent
accumulation of flammable gases, vapours, or dusts. No smoking should be allowed in the
welding area where inflammable goods are being used.

2.4. Electric Shocks

Electric shock is defined as a sudden violent response to electric current flow through any part
of a person's body. Electrocution is death caused by electric shock. Primary electrical injury
(230, 460 V) is tissue damage produced directly by electrical current or voltage. Secondary
injuries (20 – 100 V), such as falls, are common [4, 13, 22]. Electric shock may occur in welding
if current happens to pass through the welder’s body; the magnitude of the current depends
upon the resistance offered by the body. A current of 0.1 A or above, be dc or ac, is taken to be
lethal to humans. Since the human body resistance is a maximum of 600 ohms, the lethal current
is provided by voltage of 60 V (V = IR). In human body the maximum resistance is offered by
the skin, however, wet skin has lower resistance than the dry skin. Generally, it is taken that

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 Christopher T. Mgonja

current up to 0.002 A do not produce pain, those between 0.002 and 0.05 A do so and are
dangerous, and those higher than 0.05 A cause heavy shock and can be lethal [9].
To avoid electric shocks, Read all instructions, labels, and installation manuals before
installing, operating, or servicing the equipment and train all personnel involved in welding
operations to observe safe electrical work practices also touching the live electrical parts should
be avoided. Have all installation, operation, maintenance, and repair work performed properly
and only by qualified people and input power cord for damage or bare wiring should be
inspected and replaced immediately if damaged. Further, do not work alone where there are
electrically hazardous conditions. Wear dry, hole-free, insulating gloves in good condition and
protective clothing. Do not touch the electrode with a bare hand. Insulate yourself from the
workpiece and ground using dry insulating mats or covers big enough to prevent any physical
contact with the work or ground and the electrode holder has to be well insulated and dry. Do
not allow the electrode holder or electrode to come in contact with any other person or any
grounded object and not wrap cables carrying electric current around any part of the body.
Special care must be taken when welding in confined spaces like inside a boiler, tanks or pipes
which usually have ample contact with the ground; due to low contact resistance even a low
open circuit voltage (OCV) of the welding power source may become dangerous to the operator.
Extra precautions are also needed when welding outdoors after rain or snow. In all these cases
it is imperative to use protective means like dielectric gloves and rubber mats atc [22, 24].

2.5. Compressed Gases

Gases used in arc welding processes are the shielding gases. Shielding gases used in arc welding
are argon, helium, and carbon dioxide [9]. The gases have a remarkable effect on the overall
performance of the welding system. The main function of these gases is to protect the weld pool
from adverse reactions with atmospheric gases. Oxygen, nitrogen and water vapour present in
ambient air can cause weld contamination. Weld shielding, always involves removal of
potentially reactive gases from the vicinity of the weld, preventing the detrimental effects on
the molten metal of the surrounding atmosphere. Shielding gases can also stabilize the arc and
enhance the metal transfer mode in arc welding processes. The shielding gas also interacts with
the base and filler metal and can thus change basic mechanical properties of the weld area, such
as strength, toughness, hardness and corrosion resistance. Shielding gases moreover have
important effects on the formation of the weld bead and the penetration pattern. The application
of different shielding gases can result in different penetration and weld bead profiles [25].
However, apart from all these important effects the gases have to be handled with care. These
gases are stored in compressed gas cylinders which are potentially hazardous because of the
possibility of sudden release of gas by removal or breaking off of the valve. High pressure gas
escaping from such a cylinder causes it to be like a rocket which may smash into people and
properties [9]. In storage, transport and operation of compressed gas cylinders it is imperative
to observe the following rules [9]:
Whether in use or stored, the cylinders should be kept vertical and secured to prevent falling
by means of chains and clamps. Hammers or wrenches should not be used to open cylinder
valves. Proper trolley should be used for moving cylinders from one point to another in the
workshop. The cylinder should never be carried on shoulders because in case it falls it can not
only injure the person but may also explode. Compressed gas should not be exposed to sunlight
or heat as this may lead to increase the pressure leading to explosion. The temperature of gas
cylinder should not be allowed to exceed 54 oC. Cylinder valve should be opened gradually
without jerk otherwise it may damage the regulator diaphragm. Cylinders should be provided
with their caps during storage and transport.

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 The Effects of ARC Welding Hazards To Welders and People Surrounding The Welding Area

3. REMARKS FROM DIFFERENT RESEARCHERS

To minimize ocular injury and promote eye health among industrial welders, it is recommended
that work safety intervention programs should be carried out by eye care providers through
leaflets, posters, and television and radio advertisements [6].
The education and training of employers and employees on Occupational Health and Safety
(OHS) issues, a great European challenge, needs to be expanded in order to address also the
highly demanding field of radiation. Radiation experts can play a critical role in highlighting
the characteristics, hazards and protection approaches required to deal with this field [26].
Health and safety in welding are very important issues that need to be addressed worldwide.
Europe is strongly investing in clarifying the long term impact of the use of welding
technologies in the human body [15].
Suitable means of protection from UVR exposure while arc welding include wearing
protective gloves together with clothing that covers the arms and forearms down to the gloves.
However, the radiant heat from welding can be quite uncomfortable, and welding on a hot day
compounds the problem. Discarding heavy welders’ clothing and gloves in favour of short-
sleeved shirts (unbuttoned at the top) exposes the hands, forearms, neck and manubrium to a
considerably increased level of UVR. Wearing protective clothing while welding is a hindrance
not only for full-time welders. Other tradespeople who perform welding occasionally (e.g.
motor mechanics) find it inconvenient to put on protective clothing, while sculptors and
tradespeople doing highly intricate work also experience difficulty in achieving fine detail when
wearing heavy clothing and thick gloves. Furthermore, while welders are invariably trained in
health and safety issues, assistants or other workers in the vicinity may not be aware of the
possible risks [7].
Welders have been advised to minimize the chance of overexposure to welding fume using
adequate ventilation and keeping heads out of the plume. However, welding requires close
observation and many workers tend to put their head where ever necessary to see the work. This
may include putting the head in the plume if required [27].
In order to effectively protect welders from combined exposure to welding fumes and gases,
use of the supplied air respirator, or combined use of a half-facepiece dust respirator and a local
exhaust system, is recommended [28].
There is need for proper education of this economically viable group on workplace hazards,
the types and proper use of different protective devices in order to safeguard their health.
Similarly, training in ergonomics could contribute toward reduction of work-related accidents
[5].
To minimize integumentary disorders, such as skin cancer, can be prevented by the use of
suitable face screen during welding activity; respiratory, gastric, and cardiac disorders, such as
lung and stomach cancer and cardiac arrhythmias, can be prevented by the use of a respirator,

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 Christopher T. Mgonja

doing physical activities in order to facilitate gas exchange, and washing hands after working
with weld to prevent ingestion of metals [29].

4. CONCLUSION
This review has shown that welding profession is very hazardous however, not all welders are
aware of all the hazards. This is even worse to those who surround the welding area that are not
dealing with welding works. In this respect, some welders and other people are affected by
welding hazards only because they are not aware of welding hazards. To avoid the arc welding
hazards, this paper has suggested some safety measures to be taken during welding activities.

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