Ergonomics in Welding

What will You learn

Identify WMSDs hazardous
exposures in welding jobs
Propose solutions for hazardous
exposures
Find further information about
ergonomics in welding operations

Hazards
Welding operations are necessary in many
industries such as construction, manufacturing,
maintenance, etc.
Welding has several hazardous conditions for
women and men in these jobs.

Hazards
Common hazards found in welding are:
inhaling metals fumes,
eye exposure to welding arc light (UV, visible),
foreign objects in eyes,
burns,
noise,
cuts, bruises, etc.

WMSD Hazards
Welding also includes musculoskeletal disorders
(WMSD) hazards such as:
awkward body postures,
lifting heavy equipment or materials,
static postures for prolonged periods,
awkward postures of the wrist, etc.

compensable claims Welders, Cutters

By Nature of Injury
Sprains account for
more than 1/3 of the
compensable claims
among welders in the
State of Washington.
Some of those could
be caused by
hazardous WMSD
exposures.

compensable claims Welders, Cutters

By Body Part
The back, neck and
shoulder together with
the arm and hand
regions make up more
than one half of the
injuries among welders
in Washington State.
Preventive efforts
should therefore focus
on those body parts
among welders at your
workplace.

Welding is a strenuous occupation involving

work in awkward postures and handling
heavy equipment, usually with a high degree
of sustained stress to arm and shoulders.

Consequences of a poor working

environment
Absences due to injury or illness
and the transfer of welders to
other tasks
Overtime for replacement
workers. Welders are skilled
employees
High employee turnover
Increased training and
supervisory time
Reduced productivity and quality

WMDS hazards most common in welding

OFTEN, MORE THAN 1 RISK FACTOR IS PRESENT

Rigorous manual precision

requirements
High degree of uniformity

Awkward and static postures

Difficult work position

Heavy lifting, difficult material

handling
Heavy objects, heavy welding
equipment

Repetition
High work intensity

Hazard Elements
Duration (how long?)

Frequency (how often?)

Intensity (how hard?)

Common postures adopted in welding

Working in
front

Working at
ground level,
precision work

Working at
ground
level

Working at
ground level,
confined space

Working
above the
shoulders

Working above
shoulders,
confined space
From: Torner et al, 1991

Awkward postures in welding

Severe torso flexion
Torso twisting
Kneeling, squatting
Bent wrists
Neck flexion/extension
Shoulder flexion/abduction (separation)

The goal of a healthy work environment

To simplify the welding performance for the
welder and reduce the physical load during
the work
Automate physically demanding or
repetitive jobs
Expand the work content of welders
(provide flexibility between jobs)
Multi-skilled workers who are able to
perform different tasks within a group)

The Real World

Often cost, ease of maintenance, space
considerations drive the design process
When hazards cant be engineered out,
using best practices is the alternative
Examples of good design: providing
opportunities for adjustments, providing
different sizes, using good planning to
eliminate unnecessary work

Possible Ergonomic Improvements

Heavy Lifting

Manipulators
Lighter welding
equipment, easier to
handle
Using lighter cables
with low stiffness
Use cable supporting
devices
(balancers)
Utilize overhead
hoists
Utilize lifting and
turning tables

Ergonomic improvements
Awkward Postures

Position work between

waist and shoulder,
when possible
Lifting tables
Motorized positioning
devices
Use welding guns with
swivels and designed
for use in both hands
Work stool

Ergonomic improvements
Team lifting helps
reduce heavy,
awkward lifting of
equipment and
materials.
AFTER

BEFORE

From: SIMA San Diego Ergonomics Program

Ergonomic improvements
To reduce working
with the back bent at
ground level, any
work table will help
to adopt a safer
posture

AFTER

BEFORE

From: Shipyard Ergonomics, 2003

Ergonomic improvements

Pre-assembly and
material handling
equipment helps reduce
unnecessary lifting or
any other kind of
manual material
handling

Ergonomic improvements

This rotational clamp

for pipe helps reduce
awkward postures for
the neck, shoulders
and arms.

Ergonomic improvements

Tables for welding

and transport reduce
manual lifting,
carrying of heavy
materials.
The tables also have
wheels.

Ergonomic improvements

Welding leads on
pulleys help reduce
heavy and awkward
lifting, static postures
for long periods.

Ergonomic improvements

Robotic automation, are

also feasible solutions to
highly repetitive motions
with the arms and
hands. May also reduce
the exposure to fumes.

Possible Consequences
Not
Not implementing
implementing
some
some or
or all
all these
these
ergonomics
ergonomics guidelines
guidelines
may
may result
result in
in the
the
following
following

Work-related musculoskeletal disorders

They are cumulative

(occur over
time and not a result of a single incident):

Often occur when the

physical demands of work
cause wear and tear
Involve soft tissues such
as muscles, tendons,
ligaments, joints, nerves,
blood vessels

Work-related musculoskeletal disorders

They are not acute injuries such as:
Broken bones
Cuts
Slips
Falls
Trips
Motor vehicle accidents
Being struck by or
caught with objects

Common disorders among welders

Back
Back injuries
injuries
Shoulder
Shoulder pain/loss
pain/loss of
of range
range of
of motion
motion
Tendinitis/Bursitis
Tendinitis/Bursitis
Reduced
Reduced muscle
muscle strength
strength
Carpal
Carpal tunnel
tunnel syndrome
syndrome
White
White finger
finger
Knee
Knee joint
joint diseases
diseases

The Ergonomics Cycle

ManagementEmployee
Support Involvement

The ergonomics cycle

provides with an
organized way to
start your
ergonomics effort.

Evaluate
progress

Training

Problem
Identification

Solution
Implementation
Address
Injuries