PEER CONSTRUCTIONS INTRANET

Manual metal arc welding procedure

PEER Construction is committed to the provision of a safe, healthy, and productive workplace. PEER Construction recognises the risk of injury to workers and has developed policies and procedures to reduce this risk.

Purpose

The purpose of this procedure is to:

  • set a standard for PEER Construction in terms of WHS risks and PPE requirements when using oxyacetylene equipment.
  • align with the standard set by Codes of Practice – Welding processes and the requirements of legislation, especially Work Health and Safety Act 2012 and Regulations 2012 (SA).

Applies to all workers including client, subcontractors, apprentices, employees, and contractors at PEER Construction.

Hot work permit

Hot work permits are a useful accountability tool to ensure that all necessary precautions are taken prior to commencing welding. They also ensure that employees are aware of and use the appropriate safeguards when performing welding operations. Employees must complete a hot work permit before commencing any hot work.

Always be aware of the potential hazards:

  • electric shock
  • fumes
  • radiation burns to eyes or body
  • body burns due to hot or molten materials
  • flying sparks
  • fire.

Process

The process has the following components.

Safety – set up

When performing hot metal arc welding you should:

  • wear the proper welding mask or goggles.
  • wear a welding jacket, welding gloves, long sleeve shirt, long pants and leather shoes.
  • wear head protection as sparks can burn your hair.
  • always wear the proper shoes; never sandals, as many sparks will drop to the floor when cutting.
  • read operators manual and risk assessment.
  • locate and ensure you are familiar with all machine operations and controls.
  • check workspaces and walkways to ensure no slip/trip hazards are present.
  • ensure the work area is clean and clear of grease, oil and any flammable materials.
  • ensure adequate ventilation at source when welding inside buildings. This is a requirement by law and is there to protect the operator and others. Welding of some materials (i.e. galvanised steel) produces highly toxic fumes.
  • keep the welding equipment, work area and your gloves dry to avoid electric shocks.
  • ensure electrode holder and work leads are in good condition.
  • start the fume extraction unit before beginning to weld.
  • ensure other people are protected from flashes by closing the curtain to the welding bay or by erecting screens.
  • faulty equipment must not be used. Immediately report suspect equipment.
  • clean and prepare materials for welding – if steam is available, use this to remove materials which are easily volatile. Wash material with strong soda solution or detergents to remove heavier oils. Note: Chlorinated hydrocarbon solvents must not be used for cleaning before welding.
  • when welding in confined spaces refer to separate training for entering and working in confined spaces as this requires specialist knowledge, training and equipment.
Procedure for manual metal arc welding

Temperatures in manual metal arc welding measure up to 6000°C. Do not use bare hands and never wrap electrode leads around yourself.

The heat at the upper end of the arc melts the consumable electrode, while the heat at the lower end of the arc melts the parent metal (the metal being welded). The arc will not start until the electrode touches the work. The arc is stopped, or broken, by moving the electrode further away.

  • Keep welding leads as short as possible and coil them to minimise inductance.
  • Have full control of the torch/gun and hold it steady. Concentrate on watching the welding operation.
  • Support the flexible hose assembly so that drag on the torch/gun is reduced.
  • Hold the torch/gun with just sufficient grip at the point of balance to give control, otherwise, it will cause muscle fatigue. Position yourself to avoid over balancing.
  • Warn any bystanders when about to strike the arc.
  • Ensure protection from radiation reflected from bright surfaces.
  • Ensure work return earth cables make firm contact to provide a good electrical connection.
  • Make sure the work piece has been prepared to be free of any paint, oxides or other surface finishes to ensure a good electrical strike contact.
  • Select the appropriate welding electrode (AS/NZS 4855 Welding Consumables).
  • Ensure the electrode holder has no electrode in it before turning on the welding machine.
  • Make sure current is correctly set according to electrode selection.
  • Keep the welding screen in front of the eyes until the arc is broken.
  • Switch off the machine and fume extraction unit when work is completed.
  • Remove electrode stub from holder and switch off power source.
  • Hang up electrode holder and welding cables. Leave the work area in a safe, clean and tidy state.

Work Health and Safety Act 2012 (SA)
Work Health and Safety Regulations 2012 (SA)
Environment Protection Act 1993
Codes of Practice

WHS policies and procedures

Version 1.0 – Last updated 19/2/2022