Table of Contents

• Purpose
  
• Responsibility
  
• Medical Montitoring
  
• Labeling and Posting
  
• Personal Protective Equipment
  
• Hazard Communication Training
  
• Asbestos Awareness Training
  
• Engineering Controls and Work Practices
  
• General Work Practices
  
• Confined Spaces
  
• Fire Safety

---

Purpose

This standard establishes the minimum safety requirements for performing welding, brazing and thermal cutting at Florida State University. It shall be used to ensure that an employee is physically able to perform the tasks required of them, are trained regarding transportation hazards and other potential hazards associated with the position and are provided with engineering controls and personal protective equipment to mitigate any hazards.

Back to Index

---

Responsibility

All employees shall receive training in the safe performance of their duties. This training shall be provided by the Department of Environmental Health and Safety. It is the responsibility of the supervisor to ensure that this training is provided to new or transferred employees.

Back to Index

---

Medical Monitoring

Welders face the potential to be exposed to various physical and chemical hazards while performing their duty. Data indicates that welders have an elevated risk of lung cancer and acute or chronic respiratory disease. The objective of these requirements is to provide a specific level of monitoring for workers who may be exposed to welding emissions or who may have been adversely affected by them in the past.

General

• A medical monitoring program shall be instituted for all workers who may reasonably be expected to be exposed to hazards from welding processes.
• All medical examinations shall be performed by or under the direction of a licensed physician.
• The required medical monitoring shall be provided to the worker without loss of pay or other cost to the worker.

Pre-placement Medical Examination - shall consist of:

• A comprehensive work and medical history that emphasizes identification of existing medical conditions and previous occupational exposure to chemical or physical health hazards, particularly those associated with welding processes.
• A comprehensive physical examination.
• A thorough examination of the respiratory system including a baseline pulmonary function test.
• A posterior-anterior chest radiograph that is interpreted by a qualified physician.
• A baseline audiogram.
• A thorough ophthalmologic evaluation.

Periodic Medical Examination

• Workers reporting signs or symptoms associated with exposure to welding emissions.
• Airborne concentrations of specific agents that exceed permissible exposure limits.

Periodic Medical Examinations - shall include:

• Updates of Medical and occupational histories.
• An evaluation of the respiratory system, including a pulmonary function test.
• Posterio-anterio chest radiograph interpreted by a qualified physician (optional at doctors discretion).
• An examination of the skin and eyes for scars that appear to have been caused by burns. The location of the scars should be noted.
• An ophthalmological evaluation.
• An audiogram.
• Other tests deemed necessary by the attending physician.

Back to Index

---

Labeling and Posting

Labeling

Workers shall be informed of exposure hazards, of potential adverse health effects and of methods to protect themselves in accordance with 29 CFR 1910.1200, Hazard Communication. Manufacturers of welding materials of welding materials shall warn employers and workers of the potentially hazardous components of the filler metals, electrodes and flu materials by applying precautionary labels to the packing containers.

Any secondary containers used by workers to hold filler metals, electrodes and flux materials must have the same safety information affixed to the temporary container as the manufacturer's original container.

Posting

In areas where welding is conducted, the following sign shall be posted in readily visible locations:

WARNING
Welding produces hazardous fumes, gases and radiation.
Appropriate personal protective equipment is required.
DO NOT LOOK AT ARC!
EYE INJURY MAY OCCUR!

Back to Index

---

Personal Protective Equipment

Safe work practices and engineering controls are the preferred method to keep emissions from causing injury or health problems to our workers.

However, a number of different types of personal protective equipment are required to be used to aid in keeping the worker safe while performing their duties. FSU will provide the following protective clothing and equipment:

Clothing

Shirts with sleeves and pants of sufficient length to protect the arms and legs from heat, ultraviolet radiation and sparks. Denim, wool or cotton materials are the preferred type for clothing. Synthetics are not acceptable.

• Fire-resistant aprons, coveralls and leggings or high boots.
• Fire-resistant shoulder covers (e.g. capes), head covers (e.g. skull caps), and ear covers for workers doing overhead work.

Management has the responsibility to ensure that the protective clothing is inspected, maintained and worn to preserve it's integrity. Items to inspect include:

• Upturned sleeves or cuffs shall be prohibited.
• Sleeves and collars shall be kept buttoned.
• Clothing shall be kept reasonably free of oil or grease.
• Clothing treated for fire resistance shall be retreated after laundering if necessary.

Eye and Face Protection

Welding helmets

Welding helmets with approved UV radiation filter plates or safety spectacles with side-shields or goggles for all workers exposed to arc welding or cutting processes.

Goggles or similar eye protectors with filter lenses for workers exposed to oxyfuel gas welding, brazing or cutting.

Goggles or similar eye protectors with transparent lenses shall be used for workers exposed to resistance welding or to mechanical cleaning or chipping operations.

Eye and face protectors shall be maintained and periodically inspected. Any piece of equipment found to be defective will be either repaired using replacement parts approved by the manufacturer or disposed of and replaced with an approved replacement.

Respiratory Protection

Engineering controls and good work practices are the preferred method for controlling exposure of the worker to air borne contaminates. However, should a situation arise such that these methods will not prevent the worker from being potentially exposed to harmful levels of air contaminates the respiratory protection shall be used by the worker.

When a worker must use respiratory protection, requirements of the FSU Respiratory Protection Program will come into effect. The elements of the program include:

• A written program for respiratory protection.
• Regular worker training.
• Routine air monitoring and work surveillance.
• Routine maintenance, proper storage, inspection, cleaning and evaluation of respirators (fit-testing).
• Performing of fit-checks by the worker while the respirator is worn to ensure proper fit.

Selecting the appropriate respirator depends on the specific contaminates and their concentration in the workers breathing zone. An assessment should be performed to ascertain the specific requirements for the proper respirator. The department of Environmental Health and Safety shall be responsible for selecting the appropriate respirator and conducting the environmental assessment.

If workers are exposed to a combination of contaminates in different physical forms, combination cartridge and particulate air-purifying respirators may be required to provide the appropriate level of protection. The Department of Environmental Health and Safety shall be responsible for selecting the appropriate cartridge combination.

Should circumstances arise such that air-purifying respirators will not be able to provide adequate protection for the worker-then a self-contained breathing apparatus or a supplied-air respirator system with an auxiliary self contained breathing apparatus shall be used. Working in confined spaces is an example of a location which would require the use of supplied air respiratory protection.

Hearing Protection

Normally welding operations are not associated with noise level problems which two exceptions: Plasma arc welding and air carbon arc cutting. If either of these two operations are to be performed then hearing protectors must be worn. There may be other occasions which would require hearing protection to be worn such as chipping and grinding.

If insert-type protectors are worn:

• They shall be fitted by a person trained in this procedure.
• Inspection procedures shall be established to assure proper issuance, maintenance and use of the ear protectors.
• Workers shall be trained in the proper care and use of all ear protectors.
• Training shall be the responsibility of the Department of Environmental Health and Safety.

Back to Index

---

Hazard Communication Training

All workers shall receive training in accordance with FSU's Right-To-Know Program. Emphasis will be placed on hazard recognition by the worker. Elements of the program are:

• Hazard Recognition
• Understanding and use of labels
• Use of material safety data sheets
• Use of safe work procedures when handling hazardous substances
• Training will be conducted by the Department of Environmental Health and Safety.

Back to Index

---

Asbestos Awareness Training

All workers shall receive Asbestos Awareness Training. This training is provided in accordance with FSU's Asbestos Operations and Maintenance Program. The elements of the program are:

• History of asbestos
• Health concerns
• Hazard recognition
• Exposure prevention
• FSU's Operations and Maintenance Plan
• Applicable federal and state regulations
• Identification of FSU's Asbestos O&M Program Coordinator

Back to Index

---

Engineering Controls and Work Practices

Engineering controls are to be used for the protection of both the worker and any other individuals in the vicinity. The following engineering controls shall be used whenever welding is performed.

Optical Radiation

• Welding shall be performed in booths or screened areas constructed of materials that are noncombustible, opaque and minimally reflective to light in the range of 200 to 3000 nanometers.

Chemicals (gases, fumes and particulates)

• Fixed-station exhaust ventilation shall be used whenever welding is performed in the shop areas. The exhaust ventilation systems shall conform to the following requirements:
• Exhaust hoods and ductwork shall be constructed of fire-resistant materials.
• The ventilation system shall be equipped with devices to indicate a malfunction or blockage of the system.
• The ventilating airflow shall be directed to carry the contaminants away from the breathing zone of the worker.
• Portable local exhaust ventilation systems shall be used when it is unfeasible to work in front of the shops fixed station exhaust ventilation system or if the work must be done at a remote location.
• Local exhaust systems must have in-line duct velocities of at least 3000 feet per minute to prevent particulates from settling out in horizontal duct runs.

Back to Index

---

General Work Practices

This following list of work practices is not an exhaustive list. It contains only a few basic guidelines which should be followed while conducting welding operations.

• Workers shall wear protective clothing.
• Workers shall use welding helmets. Hand held screens shall be prohibited during welding.
• Workers shall not conduct welding on materials that may produce toxic or combustion products.
• Workers shall follow all fire precautions as listed in the Fire Safety section of this manual.
• Whenever possible, the material being worked on should be positioned to minimize worker exposure to molten metal, sparks and fumes.
• Minimize emissions by using the lowest acceptable amperage.

Back to Index

---

Confined Spaces

Performing welding tasks in a confined space can be extremely dangerous. The air inside the space may be acceptable when initially tested, however, the act of welding can produce oxygen-deficient, toxic or combustible atmospheres. Before welding can commence in a confined space all aspects of FSU's Confined Spaces Entry Program must be followed. A basic outline of those requirements is listed below.

• All pipes, power lines which could potentially cause harm to the worker must be disconnected or shut-off. All shutoff valves and switches must be tagged out and secured with a safety lockout device.
• Continuous mechanical ventilation must be provided when welding or thermal cutting is performed. Oxygen must never be used for ventilation purposes.
• Initial monitoring must be performed to determine if flammable or toxic atmosphere or if there is a sufficient amount or excessive amount of oxygen. Continuous monitoring should be performed while work is in progress.
• Gas cylinders and power sources for welding must be located in a secure position outside the confined space.
• A worker must be stationed outside the space to assist and maintain visual and voice contact with the worker inside the space or to call for help if required. The outside worker must never attempt to rescue the inside worker himself.
• The worker entering the space must be outfitted with a safety harness, a lifeline and appropriate personal protective clothing and equipment, including a respirator if required.
• Lifelines must be of the type that will pull the welder out without jamming, a parachute type is recommended.
• When not in use, torches and other gas or oxygen supplied equipment must be removed from the confined space.
• All personnel involved in work in or around a confined space must receive training. The training shall be conducted by the Department of Environmental Health and Safety.

Back to Index

---

Fire Safety

Combustible Material

When welding or cutting operations are performed above, or within 35 feet of combustible construction; or when combustible material is exposed to the operation; or when such operations are within 35 feet of floor, ceiling or wall openings so exposed:

• Such combustible construction or materials shall be protected by noncombustible shields or covers from possible sparks, hot metal or oxide;
• Such floor, ceiling or wall openings shall be protected by noncombustible shields or covers;
• One or more 4 A 40 B/C portable fire extinguishers shall be kept at the location where welding or cutting is to be done.
• Fire sprinkler protection shall not be shut off while welding or cutting work is being performed. When welding or cutting is done close to automatic sprinkler heads, damp cloth guards may be used to shield the individual heads, but shall be removed when the work is completed.
• After welding operations have been completed, the areas should be thoroughly inspected for smoldering material.

Flammables

Welding or cutting shall not be done in or near rooms or locations where flammable gases, liquids or vapors, lint, dust or loose combustible stacks are present, when sparks or hot metal from the welding or cutting operations may cause ignition or explosion of such materials.

Welding or cutting shall not be performed on or in the near vicinity of containers and equipment which contain or have contained flammable liquids, gases or solids until these containers and equipment have been thoroughly cleaned or purged of inert gases in accordance with the Occupational Safety and Health Act, 29 CFR, 1926.352.

Back to Index