Danielle Cyran

Chapter 4 Safety and Health of Welders

I.

Personnel Protection and Safety Rules

a. All personnel must be warned of the hazards of welding
b. The hazards that relate to welding are:
i. Electrical shock
ii. Arc radiation
iii. Air contamination
iv. Fire and explosion
v. Compressed gases
vi. Welding cleaning
vii. Other hazards related to specific processes or occupations
c. Welders work in a variety of conditions and are exposed to gases, radiation, and
heat
d. Welding Workplace Safety
i. Management is responsible for providing training for workers
ii. Employees must be informed and trained so that they can detect when
hazards are present and protect themselves from them
e. Heat Exposure
i. Workers should be supplied with sufficient cool air to avoid breathing
excessively hot air
ii. Special precautions must be taken and special procedures must be adopted
to protect the welder from the heat
f. Protective Clothing
i. Woolen clothing is much more satisfactory than cotton since it will not
disintegrate from arc radiation or catch fire as quickly
ii. Cloth gloves can be used for light-duty work
iii. For heavy-duty work, more thorough protective clothing is required
iv. Welder may wear a pair of welding leathers and gauntlet gloves, which
protect against sparks and molten metal
v. A headcap should be used
vi. Flame retardant clothing should be worn
vii. High top boots with steel toes should be worn
g. Safety Rules
i. Make sure that your arc welding equipment is stalled properly and
grounded and is in good working condition
ii. Always wear protective clothing suitable for welding to be done
iii. Always wear proper eye protection when welding, cutting, or grinding

iv.
v.
vi.
vii.

Do not look at the at the arc without proper eye protection

Avoid breathing the air in the fume plume directly above the arc
Keep your work area clean and free of hazards
Make sure that no flammable, volatile, or explosive materials are in or
near the work area
viii. Handle all compressed gas cylinders with extreme care
ix. Keep caps on when not in use
x. Make sure that compressed gas cylinders are secured to the wall or to
other structural supports
xi. When compressed gas cylinders are empty, close the valve and mark the
cylinder empty
xii. Do not weld in a confined space without special precautions
xiii. Do not weld on containers that have held combustibles without taking
special precautions
xiv. Do not weld on sealed containers or compartments without providing
vents and taking special precautions
xv. Use mechanical exhaust at the point of welding when welding lead,
cadmium, chromium, manganese, brass, bronze, zinc, or galvanized steel,
and when welding in a confined space
xvi. When it is necessary to weld in a damp or wet area, wear rubber boots and
stand on a dry insulated platform
xvii. Do not use cables with frayed, cracked, or bare spots in the insulation
xviii. When the electrode holder is not in use, hang it on the brackets provided.
Never let it touch a compressed gas cylinder
xix. Dispose of electrode stubs in proper containers; stubs on the floor are a
safety hazard
xx. Shield others from the light rays produced by your welding arc
xxi. Do not weld near degreasing operations
xxii. When working above ground, make sure that the scaffold, ladder, or work
surface is solid
xxiii. When welding in high places, use a safety belt or lifeline
h. Safety Precautions for Oxyacetylene Welding and Cutting
i. Make sure that all gas apparatus shows UL or FM approval, is installed
properly, and is in good working condition
ii. Make sure that all connections are tight before lighting the torch
iii. Do not use a flame to inspect for tight joints
iv. Use soap solution to detect leaks
v. Always wear protective clothing suitable for welding or flame cutting
vi. Keep work area clean and free of hazardous materials
vii. When flame cutting, sparks can travel 30 to 40 feet (10 to 15 meters)
viii. Do not allow flame cut sparks to hit hoses, regulators, or cylinders
ix. Handle all compressed gas cylinders with extreme care
x. Keep cylinder caps on when not in use

xi. Make sure that all compressed gas cylinders are secured to the wall or to
other structural supports
xii. Keep acetylene cylinders in the vertical position
xiii. Store compressed gas cylinders in a safe place with good ventilation
xiv. Acetylene cylinders and oxygen cylinders should be kept apart
xv. When compressed gas cylinders or fuel gas cylinders are empty, close the
valve and mark the cylinder "empty."
xvi. Use oxygen and acetylene or other fuel gases with the appropriate torches
and only for the purpose intended
xvii. Avoid breathing the air in the fume plume directly above the flame
xviii. Never use acetylene at a pressure in excess of 15 psi (103.4 kPa)
xix. Higher pressure can cause an explosion
xx. Never use oil, grease, or any material on any apparatus or threaded fittings
in the oxyacetylene or oxyfuel system
xxi. Oil and grease in contact with oxygen may cause spontaneous combustion
xxii. Do not weld or flame cut in a confined space without taking special
precautions
xxiii. When assembling apparatus, crack the gas cylinder valve before attaching
regulators (cracking involves opening the valve on a cylinder slightly, then
closing) This blows out any accumulated foreign material
xxiv. Make sure that all threaded fittings are clean and tight
xxv. Always use this correct sequence and technique for lighting a torch:
i. Open acetylene cylinder valve
ii. Open acetylene torch valve 1/4 turn
iii. Screw in acetylene regulator adjusting valve handle to working
pressure
iv. Turn off acetylene torch valve (you will have purged the acetylene
line)
v. Slowly open oxygen cylinder valve all the way
vi. Open oxygen torch valve 1/4 turn
vii. Screw in oxygen regulator screw to working pressure
viii.
Turn off oxygen torch valve (you will have purged the
oxygen line)
ix. Open acetylene torch valve 1/ 4 turn and light with lighter (use
friction-type lighter or special provided lighting device only)
x. Open oxygen torch valve 1/ 4 turn
xi. Adjust to neutral flame
xxvi. Always use this correct sequence and technique of shutting off a torch
i. Close acetylene torch valve first, then close oxygen torch valve
ii. Close cylinder valves-the acetylene valve first, then the oxygen
valve
iii. Open torch acetylene and oxygen valves (to release pressure in the
regulator and hose)

iv. Back off regulator adjusting valve handle until no spring tension is
felt
v. Close torch valves
1. Note: Different torch manufacturers recommend different
shutdown procedures for the torch acetylene and oxygen
valves. Follow the procedure recommended for the torch
in use. If the oxygen valve is closed first, the yellow,
sooty acetylene flame enlarges appreciably and could
burn the welder. The carbon soot will deposit in the area.
If the acetylene valve is closed first, there will be a loud
"bang," which may distract nearby welders. In either case
the other valve should be closed quickly
xxvii. Use mechanical exhaust when welding or cutting lead, cadmium,
chromium, manganese, brass bronze, zinc, or galvanized steel
xxviii. If you must weld or flame cut with combustible or volatile materials
present, take extra precautions complete a hot work permit, and provide
for a lookout
xxix. Do not weld or flame cut on containers that have held combustibles
without taking special precautions
xxx. Do not weld or flame cut into a sealed container or compartment without
providing vents and taking special precautions
xxxi. Do not weld or cut in a confined space without taking special precautions
i. Material Safety Data Sheets
i. The employer must maintain continuous training concerning hazardous
materials and safety in general
ii. Provisions to safeguard employees are included in Material Safety Data
Sheets as prescribed by the Hazard Communication Standard of the U.S.
Department of Labor
iii. Each data sheet for welding products includes information about every
hazardous component comprising 1% or more of the contents, and for
every potential carcinogen
j. Electric Shock Hazard
i. Use only welding machines that meet recognized national standards
ii. Only insulated-type welding electrode holders should be used for shielded
metal arc welding
iii. Semiautomatic welding guns for continuous wire processes should use
low-voltage control switches so that high voltage is not brought into the
hands of the welder
iv. In fully automatic equipment, higher voltages are permitted but are
inaccessible to the operator during normal operations
k. Installation of Welding Machines
i. All machines must be installed in accordance with the National Electrical
Code

ii. Instructions for installation are given in the manufacturers manual

iii. It is extremely important when several welding machines are working on
the same weldment that the phases of a three-phase power line be
accurately identified
iv. This will ensure that the machines will be on the same phase and in phase
with one another
v. It is easy to check this by connecting the work leads together and
measuring the voltage between the electrode holders of the different
machines
vi. This voltage should be practically zero
vii. If it is double the normal open-circuit voltage, it means that either the
primary or secondary connections are reversed
viii. If the voltage is approximately one and onehalf times the normal opencircuit voltage, it means that the machines are connected to different
phases of the
ix. three-phase power line
x. Corrections must be made before welding begins
l. Use of Welding Machines
i. Electrode leads and work leads should not be coiled around the machine
nor should they ever be coiled around the welder
ii. Electrode holders should not be hung where they could come into
accidental contact with the other side of the circuit
iii. Welders should not make repairs on welding machines or equipment
m. Arc Radiation Hazard
i. It is necessary that welders and others close to the welding arc wear
suitable protection from the arc radiation
ii. The brightness and exact spectrum of a welding arc depend on the welding
process, the metals in the arc, the arc atmosphere, the length of the arc,
and the welding current
iii. The higher the current and arc voltage, the more intense the light from the
arc
iv. Like all radiation, arc light radiation decreases with the square of the
distance
v. Heat is radiated from the arc in the form of infrared radiation
vi. The infrared radiation is harmless, provided that proper eye protection
and clothing are worn
vii. To minimize light radiation, screens should be placed around the welding
area so that people working nearby are shielded from the arc
n. Eye Protection
i. Welders must wear protective welding helmets with specialized filter
plates or filter glasses

ii. The curved front welding helmets are preferred over straight front because
they reduce the amount of welding fumes that come to the welder's
breathing zone
iii. The shade of the filter glass used is based on the welding current
iv. Safety glasses should be worn underneath the weld helmet
v. These are required since the helmet is usually used when slag is chipped
or welds are ground
vi. Tinted glasses with side shields are recommended
vii. People working around welders should also wear tinted safety glasses with
side shields
viii. Safety glasses should meet all the requirements of the eye and face
protection standard
o. Contact Lenses
i. Contact lenses themselves do not provide eye protection in the industrial
sense
ii. The heat from the welding arc or flash is not intense enough to affect the
durable plastic from which contact lenses are made
iii. On occasion, welders and others have their eyes exposed to the arc for a
short period
iv. This will result in what is known as arc burn, arc flash, or welding flash
and is
v. technically called photokeratitis
vi. It is very similar to as unburn of the eye. For approximately 24 hours, the
welder will have the painful sensation of sand in the eyes.
vii. The condition is normally of temporary duration and should not last more
than 48 hours
p. Transparent Welding Curtains
i. Transparent welding curtains made of polyvinyl chloride plastic film are
sometimes used for screening welding operations
ii. The material is about 0.012 in. thick (0.3 mm), relatively tough, and
available in large sheets
iii. It comes in blue, green, gray, and yellow
iv. Tests performed by the National Institute of Occupational Safety and
Healt1P3) concluded that these curtains provide protection in the
ultraviolet range
v. The material is flame resistant
vi. It is intended to protect nearby workers from arc flash ad improve
communication with welders
q. Other Factors
i. Welding operations should be isolated from metal degreasing or solventcleaning operations
ii. Warning signs should be posted in welding departments advising visitors
not to look at the arc, since arc flash will injure eyes

r. Air Contamination Hazard

i. Arc welding and flame cutting produce air contamination
ii. Welding fumes contain two types of air contamination: particulate matter
and gases
iii. The American Welding Society's study entitled "The Welding
Environment" and several foreign studies indicate that there is no
significant health difference between welders and non-welders when the
welding process is carried out with adequate ventilation
iv. The potential harm from fumes and gases depend on:
i. The chemical composition of the particulate matter
ii. The concentration at the welder's breathing zone
iii. The length of time of exposure to these fumes and gases
s. Particulate Matter
i. Particulate matter is extremely small solids suspended in the air
ii. In welding the type of particulate matter relates to the welding process, the
type of electrode or filled, metal, the welding current employed, and the
welding location, atmospheric conditions, wind, and so on. It also depends
on the composition of the base metal being welded and on any coating on
the base metal near the arc
iii. All welding smoke is not the same, and the concentration can vary over a
wide range
iv. In general, welding with mild steel electrodes on clean steel produces
fumes containing a high proportion of iron oxide and small amounts of
calcium oxide, titanium oxide, and amorphous silica
v. The fumes produced when welding with low-hydrogen-type of electrodes
contain the same oxides and fluorides.
vi. When welding with stainless steel electrodes, the iron oxide is lower but
there are now oxides of chromium and nickel as well as fluorides.
vii. The flux-cored arc welding process seems to produce the most particulate
matter, or smoke. However, compared to the amount of weld metal
deposited, the particulate matter of SMAW and FCAW is similar
viii. The gas metal arc welding process produces less particulate matter, and
the submerged arc process produces a very small amount of particulate
matter, as do the gas tungsten and plasma arc welding processes
ix. When melted by an arc, the base metal may volatilize and produce
airborne contaminants
x. The metals that create hazardous airborne contaminations are beryllium,
brass, bronze, cadmium, chromium, cobalt, copper, lead, manganese,
nickel, vanadium, and zinc. Arc welding should not be done on any of
these metals unless mechanical ventilation is employed or unless the
welder is protected in some manner.
t. Gases
i. Gases are produced when:

i. or may be involved in many of the welding processes in oxygen

flame cutting and allied processes
ii. As products of combustion with the fuel gas
iii. steel is melted in the arc
iv. by some of the constituents of the coating on the shielded metal arc
welding electrode or the material contained in the core of a fluxcored electrode wire
v. fluxes used for gas welding and brazing, and for submerged
vi. arc welding and electroslag welding when they are heated
ii. Ultraviolet rays from the arc, particularly the high intensity gas tungsten
arc, react with the oxygen in the atmosphere to produce ozone
iii. The gas-shielded welding processes employ various gases to shield or
protect the arc area from the atmosphere
u. Confined or Enclosed Areas
i. All welding, flame cutting, and associated operations carried out in
confined or restricted spaces must be adequately ventilated to prevent the
accumulation of toxic materials, combustible gases, or oxygen deficiency
ii. An enclosed area or confined space is a relatively small or restricted space
such as a tank, vat, pressure vessel, boiler, compartment, small room, or
any enclosure that may have poor ventilation
iii. Welding or cutting apparatus should never be taken into the enclosed area
iv. A lookout, or watcher or attendant, must be signed to watch the welders
and other workers continuously and to have occasional voice contact with
those in the enclosed area
v. One lookout should be assigned to team of welders working in a specific
enclosed area
vi. The atmosphere within the enclosed area must be tested prior to entering
the area
vii. Having an environment with too much oxygen can cause a hazardous
situation due to rapid combustion
viii. Oxygen deficiency can be another hazard for workers in an enclosed area
v. Ventilation
i. Adequate ventilation must be provided for all welding
ii. Adequate ventilation depends on the following:
i. Volume and configuration of space where welding occurs
ii. Number and type of operations generating contaminants
iii. Allowable levels of specific toxic or flammable contaminants
being generated
iv. Natural airflow and general atmospheric conditions where work is
being done
v. Location of welders and other persons' breathing zones in relation
to the contamination, contaminants, or sources
iii. Adequate ventilation for welding can be obtained in three different ways:

w.

x.

y.

z.

i. Natural ventilation
ii. General mechanical ventilation
iii. Local exhaust ventilation
iv. Natural ventilation occurs when the welding is done out of doors
v. General mechanical ventilation using roof exhaust fans, wall exhaust fans,
or similar large-area air movers must be used if the space per welder is
less than 10,000 ft. 3 (284 m3), or if the ceiling height is less than 16 ft. (5
m) or the shop includes partitions, balconies, or other structural barriers
that obstruct cross ventilation
vi. There are basically two types of local exhaust ventilation systems: a lowvolume, high-velocity fume exhaust system and a high-volume, lowvelocity fume exhaust system
vii. For serious ventilation situations, welders should use faceplate respirators
Fire and Explosion Hazard
i. A large number of the fires in industrial plants are caused by cutting and
welding with portable equipment in areas not specifically designated or
approved for such work
ii. The three elements of the fire triangle-fuel, heat, and oxygen-are present
in most welding operations
iii. Hot pieces of metal may come in contact with combustible materials and
start a fire
iv. Cutting and welding fires can be prevented by eliminating all
combustibles from the welding area
Work Area
i. A safe workplace must be provided for welding and cutting operations
ii. Floors, walls, ceilings, and work spaces must be constructed of
noncombustible materials
iii. The work area must be kept clean and free of combustible and flammable
iv. materials
v. All fuel gas lines, manifolds, and branches must be installed in accordance
with specifications and codes
Fire and Extinguishers
i. In every situation where welding is done, in the welding shop and with
portable equipment in all other areas, fire extinguishers should be
available
ii. Depending on the work area, the appropriate extinguishers should be
available at the work site.
Fuel Gases
i. Many different fuel gases are used for welding and flame cutting
ii. Acetylene generators must be properly installed and maintained, and
should be operated only by trained and qualified personnel

iii. Acetylene cylinders and other fuel gas cylinders should be stored in a
specified well-ventilated area or outdoors away from oxygen and in the
vertical position
aa. Apparatus
i. Gas welding and cutting apparatus must show the approval of an
independent testing laboratory
ii. Gas apparatus must be properly maintained and repaired by qualified
people
iii. Only approved gas hoses should be used with oxyfuel gas equipment
bb. Hot Work Permits
i. Welding permits are sometimes referred to as hot work permits
ii. These permits must be used when welding or flame cutting is done on
items that involve hazards
iii. A welding permit or hot work permit should be used when portable
welding or flame cutting equipment is used for maintenance welding in
plants where combustible materials are present, on ships, and on any other
type of potentially hazardous operations
cc. Welding on Containers
i. Any container or hollow body-a can, a tank, a hollow compartment
ii. in a weldment, or a hollow area in a casting, even though it may contain
only air, must be given special attention before welding
iii. Always vent confined air before welding or cutting on a hollow area
iv. Explosions and fires may result if welding or cutting is done on empty
containers that are not entirely free of combustible solids, liquids, vapors,
dust, and gases
v. Cleaning the container, which is normally made of metal, is necessary in
all cases before welding or cutting
dd. Hot Tapping
i. Hot tapping is the welding of a special fitting to a line carrying a
combustible liquid or gas, then cutting a hole in the pipe after the fitting
has been welded to it
ii. This must be done by experienced people using special equipment with
proper precautions.
ee. Compressed Gases Hazard
i. All compressed gas cylinders are potential hazards
ii. The major hazard is the possibility of sudden release of the gas by
removing or breaking off the valve
iii. Escaping gas that is under high pressure will cause the cylinder to act as a
rocket, smashing into people and property
iv. Escaping fuel gas can also be a fire or explosion hazard
ff. Treatment of gas cylinders
i. Gases used for welding-fuel gases, oxygen, or shielding gases-are
normally delivered in cylinders manufactured and maintained by the gas

supplier in accordance with the regulations of the U.S. Department of

Transportation
ii. In North America the authorities require that a cylinder be condemned
when it leaks or when internal or external corrosion, denting, bulging, or
evidence of rough usage exists to the extent that the cylinder is likely to be
appreciably weakened.
gg. Cylinder storage
i. Oxygen cylinders should be stored separately from fuel gas cylinders and
separate from combustible materials
ii. Store cylinders in cool, well ventilated areas
iii. The temperature of the cylinder should never be allowed to exceed 130 F
(54 C)
iv. Cylinders should be stored vertically and secured to prevent falling
v. The valve protection caps must be in place
hh. Oxygen
i. Combustibles should be kept away from oxygen, including the cylinder,
valves, regulators, and hose apparatus
ii. Oxygen cylinders or oxygen apparatus should not be handled with oily
hands or oily gloves
iii. Oxygen should never be used in any air tools or for any of the purposes
where compressed air is normally used
iv. Escaping oxygen can enrich the work area, especially enclosed areas, and
be a fire or explosion hazard
ii. Fuel Gases
i. All fuel gases are compounds of carbon and hydrogen, and all are
potentially hazardous
ii. When welding or cutting with oxygen and fuel gases, the welder should be
alert to backfires and flashbacks.
i. A backfire is an explosion in the torch head, usually accompanied
by a loud popping sound associated with a momentary
extinguishment and reignition of the flame at the torch tip
ii. A flasbback is the burning of the flame in the tip or torch, or even
in the hose, when an explosive mixture is present. It is usually
accompanied by a hissing or squealing sound and has the
characteristic smoky or sharp pointed flame
iii. Both backfires and flashbacks are dangerous and should be avoided by the
use of flashback arresters
jj. Shielding gases
i. Shielding gases are either inert or active.
i. True inert gases are argon and helium and are stored in highpressure cylinders. Nitrogen, considered inert at low temperatures,
is also stored in high pressure cylinders. These cylinders must be

treated with the same precautions as those used with oxygen

cylinders.
ii. The active gas normally used for weld shielding is carbon dioxide
(C02). It is stored as a liquid but gasifies upon release.
kk. Gas Cylinder Adapter
i. Adapters are connectors that convert one type of valve outlet to another to
allow connections to be made to devices such as regulators with different
connection threads
ii. When used judiciously by well-trained personnel who understand the
potential hazards of bringing incompatible gases together, adapters can
serve a useful purpose
iii. Review any adapters employed and control or limit them and prohibit the
making of special adapters without thorough investigation of their use and
potential hazards

II.

PSU Lab Rules

a. LS-1. General Lab Safety
b. LS-1.1 Absolutely no personal projects.
c. LS-1.2 Only students, faculty, and staff associated with Penn State University are
permitted in the lab areas unless special permission is obtained beforehand.
d. LS-1.3 Anyone that appears to be under the influence of any controlled substance
(alcohol, medication, or drugs) will be denied entrance into the labs. Additionally,
if you personally do not feel well enough to maintain the mental focus or strength
to safely perform your work or operate the machinery, you should refrain from
working in the labs.
e. LS-1.4 No one is permitted to be working in the lab areas alone. A member of the
lab staff must be in an adjoining lab area.
f. LS-1.5 All work areas are to be kept clean. Anything left in a common area may
be discarded if the project owner cannot be found. Any projects requiring a
dedicated space must be arranged with the Engineering Lab Supervisor.
Dedicated spaces are to be kept organized. It is highly suggested that anyone
working on a project in the projects labs allocate 10-15 minutes prior to leaving
for clean-up.
g. LS-1.6 Raw material supplies located in 106 Force should be approved by a
member of the lab staff prior to use. All sharp edges should be deburred before
returning extra material to the racks.
h. LS-1.7 Observe all posted warning signs and labels
i. LS-1.8 Respect the projects and tools of others. Respect the lab equipment and
facilities. Any sort of vandalism will result in escalation to Academic Affairs.

j. LS-1.9 Any supplies that are low in inventory should be reported to the Lab
Supervisor.
k. LS-1.10 Any damaged equipment must be reported to the Lab Supervisor to
facilitate repair, replacement or other appropriate action.
l. LS-1.11 Any hot work to be performed outside of the welding area needs a Hot
Work Permit, obtained from the Lab Supervisor. After the hot work is performed,
a fire watch is necessary for 30 minutes afterwards. Any issued Hot Work Permit
is only valid for 24 hours.
m. LS-1.12 Any tools or equipment permanently located in a lab should not be
removed from that lab.
n. LS-1.13 Safety glasses are to be worn during any drilling, cutting, soldering,
hammering, sanding or machining operation. Safety glasses are to be provided by
the individual user. Safety glasses are defined by protective lenses that meet
ANSI Z87.1 rating and display such rating either on the stems or lenses.
o. LS-1.14 Long hair must be tied back to eliminate the chance of it becoming
entangled in rotating machinery.
p. LS-1.15 No open-toed shoes are permitted in any project labs.
q. LS-1.16 No horseplay will be tolerated in the project labs or machine shop.
r. LS-1.17 Always walk in the lab. Do not run as metal grinding dust, chips, coolant
or saw dust may present a slippery condition.
s. LS-1.18 Any liquid, grease, dust, or chips must be cleaned up in an appropriate
timeframe.
t. LS-1.19 Use personal protective equipment (PPE) when necessary. PPE may
include gloves, hard hats, hearing protection, respiratory protection, special
protective clothing, and welding masks. Gloves are not to be worn when operating
machinery.
u. LS-1.21 Don't rush your work. Careless or hurried work rarely produces a good
product and often creates a safety hazard.
v. LS-1.23 All accidents, no matter how minor, need to be reported to the Lab
Supervisor.
w. LS-1.25 Keep pathways to exits clear.
x. LS-1.26 Do not place items in front of fire extinguishers.
y. LS-1.27 Always be aware of where the closest fire extinguisher is and what type
of extinguisher it is.
z. LS-1.28 Never alter a tool or piece of equipment in a manner which reduces its
effectiveness or safety.
aa. LS-1.29 Never use a tool until you've received instruction on how to handle it
properly.
bb. LS-1.30 Use caution when carrying sharp tools. Uncovered points should be
carried point down.
cc. LS-1.31 Only use sharp tools. Dull tools create a safety hazard and cause
excessive wear on equipment.

dd. LS-1.32 When cutting, always cut away from the body. All cutting tools should
be directed away from aisle areas and others working in close proximity.
ee. LS-1.34 Never test the sharpness of a tool with your finger.
ff. LS-1.35 Measure twice, cut once.
gg. LS-2. Emergency Procedures
i. LS-2.1 Evacuate
ii. LS-2.1.1 Leave the area of concern in an expeditious and
controlled manner. Alert all others in the area of the emergency
and direct/assist them in departing to a safer location.
iii. LS-2.1.2 Without endangering yourself or others, quickly remove
any possible victims to a safer area with access to fresh air, paying
special attention to injuries (spinal cord injuries, deep punctures,
etc.). Immediately seek medical attention for those who have been
injured by calling 911.
iv. LS-2.2 Confine
v. LS-2.2.1 Close all doors and isolate the area. Restrict access to the
area and prevent people, other than emergency personnel, from
entering the area.
vi. LS-2.3 Report
vii. LS-2.3.1 From a safe place; call the first available person on the
following list. If using a university telephone, only use the last four
digits of each telephone number for faster access.
1. Eric Beaver - (814)949-5699, Engineering Lab
Supervisor, 105 Force
2. Lucas Jones/Tom Hatch - (814)949-5573, Engineering
Lab Coordinators, 105 Force
3. Dr. Barbara Wiens-Tuers - (814)949-5529, B&E Division
Head
4. Penn State Altoona University Police - (814)949-5222
viii.
LS-2.3.2 If no one from this list is available, contact
1. Environmental Health and Safety (EHS) 24 hours a day,
365 days a year at (814)865-6391.
ix. LS-2.3.3 Report your emergency, give your name, telephone
number, location, location of the emergency, type of emergency,
number of injured and extent of injuries, and the safest route to the
location. Stay by that telephone.
x. LS-2.4 Secure
xi. 2.4.1 Until the contacted personnel arrive, block off all areas
leading to the accident location, lock doors, post warning signs and
warning tape, and alert others of the situation.
xii. 2.4.2 Post personnel by commonly used entrances to the area to
help direct others.
hh. LS-3. Equipment Check-out

ii. LS-3.1 Equipment located in the equipment office (105 Force) labeled with an
inventory control barcode must be checked out with the inventory control system.
kk. LS-3.2 Equipment on loan from the equipment office is not permitted to leave
campus property unless an Equipment Loan Form is completed.
ll. LS-3.3 Most items on loan from the equipment office should be returned before
the labs close that day. Special permission must be obtained for any multiple-day
or longer periods.
mm.
LS-3.4 Equipment that is part of a larger set (a drill bit out of a set for
example), should be checked out as a set, not individually.
nn. LS-3.5 Damaged equipment should be reported when returned. This is merely to
facilitate replacement, not necessarily for disciplinary reasons. The staff
understands that equipment periodically breaks. Any equipment found to be
intentionally damaged may result in disciplinary action.
oo. LS-4. Machine Shop
pp. LS-4.1 General
qq. LS-4.1.1 Loose clothing and jewelry are not permitted in the machine shop.
rr. LS-4.1.2 Always take the time to set up a proper work area and workpiece
fixturing. It is not uncommon to spend 5 or 10 minutes setting up for a cut that
takes 1 minute or less. Work should always be clamped or fixtured properly to
assure accuracy and safety.
ss. LS-4.1.3 Do not machine a material until you know what it is and how it should
be handled. Even different alloys of a common metal machine differently.
tt. LS-4.1.4 Place scrap material into the appropriate receptacles. A bin for steel and
a bin for aluminum are located in the machine shop (107 Force).
uu. LS-4.1.5 Grinding with equipment other than the grinding wheel is prohibited in
the machine shop. Angle grinders should be used in the projects lab or outside and
all grinding dust should be cleaned up immediately.
vv. LS-4.1.6 Listen to the machines. If something doesn't sound right, stop and ask
for assistance. You may be doing something wrong or the machine may be
damaged.
ww.
LS-4.1.7 Never use a machine that has been red-tagged and is out of
service.
xx. LS-4.1.8 Always check a piece of equipment prior to turning it on. Check the
alignment of moving parts, breakage of parts, and cracks. Report any damage or
malfunction.
yy. LS-4.1.9 Never attempt to remove chips or cuttings with your hands or while the
machine is running. Chip brushes are available and should be used with the
machine stopped.
zz. LS-4.1.10 Clean up your work area immediately after finishing your work.
aaa. LS-4.1.11 Always run a machine at the proper speed. Feed rates that are too slow
can work harden the material and feed rates that are too high can damage tooling
and machines.

bbb. LS-4.1.12 Never leave a machine running. Stay with a machine until it has come
to a complete stop.
ccc. LS-4.1.13 Before starting a machine, check that wrenches and keys have been
removed.
ddd. LS-4.3.1 Always stand to the side of the grinder when starting the machine
eee. LS-4.3.2 Never grind non-ferrous metals. This includes aluminum, brass, bronze,
and others. Only grind ferrous metals such as steel.
fff. LS-4.3.3 Keep hands clear of the grinding wheels.
ggg. LS-4.3.4 Do not persistently grind in one location. This causes the expensive
grinding stones to wear unevenly and will require premature replacement.
hhh. LS-4.3.5 Use caution as ground metals will become very hot.
iii. LS-4.4 Vertical Bandsaw
jjj. LS-4.4.1 Do not try to force material through the blade. Let the machine do the
work.
kkk. LS-4.4.2 If the blade is dull and in need of replacement, notify the lab supervisor.
lll. LS-4.4.3 Always adjust the upper blade guide to the lowest position. This will help
the blade run properly and minimize the exposure to the dangerous blade.
mmm. LS-4.5 Horizontal Bandsaw
nnn. LS-4.5.1 Always make sure material is properly clamped
ooo. LS-4.5.2 Do not allow the auto-feed mechanism to run too fast. Start at the
slowest speed and increase as necessary.
ppp. LS-4.5.3 Use coolant when cutting metal. Make sure any coolant drips are
cleaned up when complete.
qqq. LS-4.10.1 Keep the workpiece against the platforms.
rrr. LS-4.10.2 Keep hands clear of the sanding belt and disc.
sss. LS-4.10.3 Do not persistently sand in one location. This will unevenly wear the
sanding material
ttt. LS-4.11.1 Weld only in the welding area.
uuu. LS-4.11.2 If you must unavoidably weld outside the welding area, a Hot Work
Permit is required.
vvv. LS-4.11.3 Welding gas must be turned off when you are done.
www. LS-4.11.4 The ventilation system in the welding area must be activated when
welding.
xxx. LS-4.11.5 Proper personal protective equipment is required. This includes
welding masks, gloves, jackets and more. Be careful of gloves or other clothing
that allow welding sparks to be trapped against the skin.
yyy. LS-4.11.6 Do not weld around any flammable materials. These must be cleaned
up prior to starting any welding.
zzz. LS-4.11.7 Do not attempt to weld galvanized steel.

Executive Summary

Welding involves the process of fusing metals together via heat, electricity and/or pressure. Due
to the hazardous nature of these, safety precautions must be utilized while doing any type of
welding. Safety equipment for welding includes items to reduce the exposure to heat, fumes and
flying debris. Items that should be worn during welding operations include but are not limited to,
a welding face shield with special lenses, flame resistant clothing; including, gloves and a coat,
and high topped steel toed boots. While doing any welding operations proper ventilation must be
ensured to prevent possible air particulate matter and fumes from entering the lungs of the
welder and nearby personnel. Though welding involves many different hazards, by taking proper
precautions, accidents and injuries can be prevented.