Weld Australia warns that electrical safety must be taken seriously.

If proper precautions are taken, welding is a safe occupation. However, if safety measures are ignored, welders will face a series of potential hazards that may lead to electric shock or even death.    

In the last month alone, Weld Australia was invited to investigate two different accidents that resulted in severe electric shocks to inexperienced welders. In both cases, these young men were hospitalized for evaluation. Although they all recovered completely, it was more luck than judgment.    

The first electric shock occurred during the arc starting process, and the welding machine used high frequency TIG. Several conditions combine to create a highly dangerous situation. The welder was wearing inappropriate clothing and personal protective equipment (PPE), including defective gloves, and the return cord was connected to an old, rusty workbench. Therefore, when the welder leaned on the workbench, he inadvertently became part of the circuit with 6,000 volts passing through it.    

The second safety incident investigated by Weld Australia could easily lead to death. Another inexperienced welder is TIG welding, and it appears that the filler rod is in contact with the charged tungsten electrode. At the time of the incident, the welder reported an electric shock on his left forearm, and the return path of the current was unknown. A week later, the welder reported cramp-like pain in both his left arm and leg, indicating that the return path was through his left leg. In Weld Australia's view, the welder is lucky to be alive.  

The problem is that these are not isolated incidents. Every week, accidents and serious "near mistakes" occur in workshops across Australia. These accidents are unlikely to occur in large advanced workshops owned and operated by major Australian manufacturers-they have in-depth workplace health and safety plans and procedures. Instead, these accidents occurred in small welding shops, body repair shops, family garages and farm buildings.   

Perhaps the most worrying thing is that such security incidents are likely to become more common. According to a major tool retailer in Australia, since the outbreak of the COVID-19 pandemic, their largest single seller is gas metal arc welding (GMAW) machines.  

These GMAW machines are likely to be purchased by small workshop owners, unqualified merchants and home DIY enthusiasts-most of them do not know how to weld or how to use GMAW machines correctly.   

Electrical safety must be taken seriously when welding. Electricity is an important part of welding work, but if not handled properly, it may cause serious personal injury and death. Between 2014 and 2016, 7 people died of electrocution while working.   

According to Safe Work Australia's welding process operating specifications, direct contact with electrodes, live parts, workpieces, or contact with ungrounded cables or tools and other equipment may cause electric shock or electrocution. Humidity and high humidity can increase the risk of electric shock, both of which are common in welding environments.   

Both welding professionals and inexperienced hobbyists need to be familiar with the processes required to minimize the risk of electric shock. Simple operations, such as checking whether the equipment is dry and well-maintained, and installing shut-off mechanisms such as fuses and low-voltage safety switches, can save lives. Ensuring that any welder is equipped with the required knowledge and safety equipment is the key to preventing serious accidents, such as the one recently investigated by Weld Australia.  

Weld Australia has a wide range of welding safety resources, many of which are open to the public-completely free.   

Technical Note 7: Health and Safety in Welding  

This technical note provides guidance on health and safety practices in welding, cutting and related processes (such as brazing, welding, pre- and post-welding material handling and metal spraying) to prevent injuries, poor health and discomfort, and damage to fire and Damage to property, equipment and the environment caused by the explosion.  

Technical Note 22: Welding electrical safety  

Although arc welding can be performed completely safely, in some cases there is a great risk of electric shock. Preventive measures against this risk include the use of properly maintained equipment, proper protective equipment, and good work practices. With reference to industry best practices, Technical Note 22 explains how to protect people from electric shock, reviewing the following elements: equipment, human body, workplace Australian standards.  

Education is the key to ensuring the safety of welding personnel. Employers, professional welders and DIY enthusiasts must invest in comprehensive and up-to-date training to ensure a thorough understanding of the risks associated with welding, the mitigation strategies that can be used, and the equipment that can be used to prevent accidents and injuries.   

If you know welders without proper training or experience, be sure to pass on Weld Australia's free resources. All these resources are available through the resource center on our website: https://weldaustralia.com.au/    

Weld Australia is proud to support the Endeavour Award again by sponsoring the Best Industrial Internet of Things Application Award in 2021. The award will recognize the most outstanding applications used to improve manufacturing processes in smart factories.  

Advanced manufacturing processes rely on innovative technologies and methods such as the Internet of Things, robotics and automation to help make welding a safer profession. For example, the use of robots and collaborative robots (especially in confined spaces) helps protect welders from direct exposure to welding fumes, ultraviolet radiation, heat, and sparks.  

After a year when uncertainty was the only certainty, it is time to celebrate the resilience of Australian manufacturers more than ever. Their ability to innovate, collaborate and respond to manufacturing needs demonstrates the capabilities of Australian manufacturers. Local manufacturers unite to establish working groups and design prototypes of complex products (such as ventilators) to bring them to market in record time.  

Weld Australia is very pleased to take this opportunity to join our sponsors to focus on manufacturers that have performed well in their respective fields and to celebrate Australian manufacturing in an all-round way.  

Geoff Crittenden – Chief Executive Officer of Weld Australia

For 55 years, Manufacturers Monthly has led and informed Australian manufacturing with its highly credible editorial environment and acclaimed analysis of issues affecting manufacturing.