Subpart J Welding and Cutting

1. Subpart JWelding and Cutting These handouts and documents with attachments are not final, complete, or definitive instruments. This information is for guidance purposes only. You should independently verify and satisfy yourself as to its accuracy. The AHBSIF does not assume any liability for damages arising from the use of this information or exhibits and attachments thereto and renders no opinion that any of the terms, conditions, and/or cited federal standards in this document and the exhibits and attachments should be explicitly followed by the fund member. Seek specific guidance from the appropriate regulator (OSHA) or professional advisor.

2. Potentially Hazardous Fumes and Gases • Fumes – Solid particles that originate from the welding media, base metal, or coating • Gas – Generated by the shielding gas or process radiation • Nickel • Zinc • Iron Oxide • Copper • Cadmium • Fluorides • Manganese • Chrome & Gases

3. Effects of Overexposure • Acute Effects • Irritation of eyes, skin, respiratory system • nausea, headaches, dizziness • Metal Fume Fever • Asphyxiation (confined space) • Chronic Effects • Central nervous system impairment • Respiratory illness • Reproductive disorders • Possible links to Parkinson’s

4. Radiation • Visible– intense light emitted during welding operations • Infrared - produced by electric arc and other flame cutting equipment • Ultraviolet - generated by all arc processes

5. Radiation Effects - Influencing Factors • Wavelength • Intensity • Duration of exposure • Exposure may result in skin burns or eye damage

6. Common Welding Techniques • MIG Welding • TIG Welding • MAPP Gas • Oxy-fuel Welding

7. MIG Welding • “Metal Inert Gas” • Semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun. • Can use alternating or direct current, DC is most common • Typically used with steel • Fast welding technique

8. TIG Welding • “Tungsten Inert Gas” • Uses a nonconsumable tungsten electrode and filler metal to produce the weld. • A shielding gas such as argon protects the process from atmospheric contamination • Commonly used with Aluminum, Magnesium, Copper, light gauge Stainless Steel • Slower than other welding techniques • Harder to master than other forms of welding but produces higher quality and stronger welds

9. MAPP Gas • “Methyl Acetylene Propodiene” • Consists of LPG mixed with MAPP • Does not require dilution or special container fillers during transport which allows a greater volume of gas to be transported at the same given weight • Most commonly used for brazing and soldering • Ideal for aluminum and copper

10. Oxy-fuel Welding • “Oxyacetylene Welding” aka Gas Welding • Two pieces are heated to a temperature that produces a shared pool of molten metal. • The molten pool is supplied with additional metal called filler.

11. Safe Work Practices • The surrounding work area should be clean and free of potentially combustible material • A fire extinguisher should be kept on hand at all times • Good ventilation is a must for all welding operations • Personal protective equipment (PPE) should include eye and face protection as well as protective clothing • Less toxic materials should be substituted when possible • Cadmium-free silver solders • Asbestos-free electrodes

12. Pre-Shift Inspection • Leads – insulation breech, kinks • Torch – tip, valves, tool body • Hoses & Fittings • Bottles & Valves • Cart or other CG Bottle Support • Surrounding Area • Fire Protection • Any defective equipment must be replaced, repaired, or removed from service

13. PersonalProtective Equipment Helmet • Must Comply with ANSI Z87.1 • Most equipped with auto-darken features, 1/10,000 of a second • OSHA 1926.102 Tables E-1 and E-2 specify minimum protection levels

14. Personal Protective Equipment Gloves • ANSI Z49.1 • Must be flame resistant • Gloves should be in good shape • Must resist potential electric shock from welding unit

15. Personal Protective Equipment Apron • ANSI Z49.1 • Produced in variety of fire retardant materials • Leather • Nomex • Chemically treated textiles

16. Compressed Gas Cylinders • Typical Oxygen cylinder pressures are around 2600 lbs/in² • Oxy fittings should be kept clean and free of oil and grease • Hose colors determine use: • Red – fuel gas hose • Green – Oxygen • Black – Inert gas

17. Compressed Gas Cylinders • Cylinder valves must be protected at all times • Cylinders should be stored in an upright and secure position • The tilt and roll method is accepted practice for movement, never attempt to hoist with chokers • Valve caps must be secure any time the cylinder is not in use • When stored, oxygen cylinders should be separated from other gas cylinders. • The required separation is 20’ or • A five foot high fire wall with an approved fire-resistance rating

18. Welding Torch - Cutting Torch Comparison

19. Cutting Torch Safety • Take appropriate precautions for flooring surface • Work benches made of steel or other fire retardant material is acceptable • Adequate ventilation • Confined Spaces • Toxic Fumes

20. Cutting Torch Safety • Appropriate personal protective equipment • Control potentially combustible materials around work area • Fire extinguisher handy at all times • Equipment maintenance

21. Safe Welding Checklist