Common welding injuries and how to prevent them

Below are some of the most common welding injuries that could happen on the job:

Burn injuries are among the most common faced by welders, due to exposure to intense heat, flames, sparks, or molten metal during the welding process. There are three main types of burn injuries that welders should be aware of:

• Thermal Burns. Thermal burns are caused by direct contact with hot surfaces, flames, or radiant heat. These burns can range from minor to severe, depending on the temperature and duration of exposure. Thermal burns can occur on any exposed skin, particularly the hands, arms, and face.
• Electrical Burns. Welders working with electric arc welding processes are at risk of electrical burns. These burns can occur when the welder's body becomes part of the electrical circuit, causing severe tissue damage and internal injuries.
• Chemical Burns. Certain welding processes involve the use of chemicals, such as fluxes or cleaning agents, which can cause chemical burns if they come into contact with the skin or eyes.

Prevention

To prevent burn injuries, welders should always wear fire-resistant PPE and a welding helmet with a proper filter lens (PPE). Besides following proper welding techniques, it’s also important to maintain a safe distance from the arc or flame and ensure adequate ventilation to reduce the risk of exposure to hot surfaces or molten metal.

Your employer is responsible for providing PPE - so if you believe yours to be defective or you’re unsure of where to source it, they will be your first port of call. Alternatively, alsico are manufacturers and suppliers of heat, flame and welding PPE - so if you’re an employer - contact us to find out more. 

One of the most common and serious hazards for welders is a flash welding eye injury from exposure to intense ultraviolet (UV) and infrared radiation produced by the welding arc. This radiation can cause painful inflammation of the cornea, permanent eye damage and vision impairment if not properly protected.

• “Arc eye” (welder's flash). Arc eye, also known as welder's flash or flash burn, is a painful eye condition caused by exposure to the intense UV radiation emitted by the welding arc. Symptoms include a gritty sensation, excessive tearing, light sensitivity, and the feeling of having something in the eye. These symptoms typically appear several hours after exposure and can last for days, severely impacting vision and productivity.
• UV radiation-based issues. Prolonged or repeated exposure to UV radiation from welding arcs can lead to more serious eye injuries. It can cause the formation of cataracts, which cloud the eye's natural lens and impair vision. UV exposure can cause growths on the eye called pterygium, which can eventually obstruct vision if left untreated.

Prevention

To prevent eye injuries, welders must wear proper eye protection designed specifically for welding operations. Welding helmets or goggles with appropriate shade lenses that filter out harmful UV and infrared radiation are essential. These lenses should be inspected regularly and replaced if damaged or if the lens tint has faded.

Welders should also be trained on the proper use and maintenance of their eye protection equipment. Installing protective screens or curtains around welding areas can help prevent accidental exposure to other employees.

Welding operations can generate various airborne contaminants, including fumes, gases, and metal particulates, posing significant respiratory hazards to welders. This can lead to acute and chronic respiratory diseases if proper precautions are not taken.

• Fumes. Welding fumes are a complex mixture of metal oxides and other compounds produced during the welding process. These fumes can contain toxic substances like hexavalent chromium, manganese, nickel, and lead, depending on the base metal and welding consumables used. Exposure to welding fumes can cause metal fume fever, a flu-like condition with symptoms such as fever, chills, nausea, and shortness of breath.
• Gases. Welding can also produce harmful gases, including carbon monoxide, ozone, and nitrogen oxides. Carbon monoxide is a colourless, odourless gas that can cause headaches, dizziness, and even death in high concentrations. Ozone, a byproduct of the welding arc, can irritate the eyes, nose, and throat, and prolonged exposure can lead to respiratory problems. Nitrogen oxides, generated during certain welding processes, can cause symptoms such as coughing, shortness of breath, and lung irritation.
• Metal particulates. Welding operations can generate metal particulates, such as iron, aluminium, and stainless steel, which can be inhaled and accumulate in the lungs. Long-term exposure to these particulates can lead to lung diseases like pneumoconiosis, a condition characterised by scarring and stiffening of the lung tissue.

prevention

To protect yourself or your employees from respiratory hazards, it is essential to use and/or supply appropriate respiratory protection equipment. Depending on the welding process and the level of exposure, welders may need to wear air-purifying respirators with particulate filters or supplied air respirators (such as FFP3 disposable mask or half-mask with P3 filter). Adequate ventilation, such as local exhaust ventilation systems, can also help reduce exposure to welding fumes and gases.

Your building’s local exhaust ventilation system (LEV) will also need to be in full working order and fully compliant to reduce welding fumes in the surrounding work environment.

Welding can be noisy, often exceeding safe exposure limits. The intense noise generated by welding equipment - such as arc welding machines, grinders, and other tools - can cause NIHL over time. The main cause of NIHL in welding is prolonged exposure to high decibel levels of noise - typically around 85 dB and above. It’s a permanent and irreversible condition that can significantly impact a welder's quality of life and ability to work safely.

NIHL can have severe consequences for welders, including:

• Temporary or permanent hearing loss
• Tinnitus (ringing, buzzing, or whistling in the ears)
• Difficulty understanding speech, especially in noisy environments
• Increased risk of accidents due to impaired communication and situational awareness

prevention

Using ear defenders is imperative when welding and to prevent the risk of NIHL. Here are some other ways you can reduce the risks:

1. Earplugs. Disposable earplugs or earmuffs designed for high-noise environments can effectively reduce noise exposure. Ensure they are properly fitted, can protect against the right decibel amount and replaced regularly.
2. Consider welding booths. Welding booths or enclosures with sound-absorbing materials can significantly reduce noise levels at the source.
3. Implement frequent welding shift rotations. Work rotation schedules to limit individual exposure time, and provide quiet areas for breaks and rest periods.

Welding work often involves sitting and bending your neck and/or back into awkward postures, repetitive motions, and heavy lifting, which can lead to musculoskeletal disorders (MSDs) such as back pain, neck strain, carpal tunnel syndrome, and tendonitis. These injuries can be debilitating and may require time off work for recovery.

Unfortunately, ergonomic risks in welding arise from the nature of the work itself. Welders frequently have to bend, twist, and reach into confined spaces, putting strain on their backs, shoulders, and necks. Holding welding guns or torches for extended periods can cause hand, wrist, and arm fatigue. Plus, welders may need to lift and manoeuvre heavy materials, increasing the risk of back injuries.

prevention

Hope isn’t all lost, and there are lots of ways to prevent MSDs. Including:

• Providing adjustable workstations and welding booths that allow for comfortable postures and minimise reaching and bending.
• Using ergonomic tools and equipment, such as counterbalanced welding guns or torches, to reduce hand and arm strain.
• Implementing job rotation and frequent breaks to alleviate repetitive stress and fatigue.
• Training welders on proper lifting techniques and using mechanical aids for heavy loads.
• Encouraging stretching and warm-up exercises before, during (shifts) and after work.

Employers should also conduct ergonomic assessments to identify and mitigate specific MSD risks in their welding operations. Regular monitoring and adjustments to work practices can help prevent musculoskeletal injuries and ensure a safer and more productive welding workforce.

Welding work often involves sitting and bending your neck and/or back into awkward postures, repetitive motions, and heavy lifting, which can lead to musculoskeletal disorders (MSDs) such as back pain, neck strain, carpal tunnel syndrome, and tendonitis. These injuries can be debilitating and may require time off work for recovery.

Unfortunately, ergonomic risks in welding arise from the nature of the work itself. Welders frequently have to bend, twist, and reach into confined spaces, putting strain on their backs, shoulders, and necks. Holding welding guns or torches for extended periods can cause hand, wrist, and arm fatigue. Plus, welders may need to lift and manoeuvre heavy materials, increasing the risk of back injuries.

prevention

Hope isn’t all lost, and there are lots of ways to prevent MSDs. Including:

• Providing adjustable workstations and welding booths that allow for comfortable postures and minimise reaching and bending.
• Using ergonomic tools and equipment, such as counterbalanced welding guns or torches, to reduce hand and arm strain.
• Implementing job rotation and frequent breaks to alleviate repetitive stress and fatigue.
• Training welders on proper lifting techniques and using mechanical aids for heavy loads.
• Encouraging stretching and warm-up exercises before, during (shifts) and after work.

Employers should also conduct ergonomic assessments to identify and mitigate specific MSD risks in their welding operations. Regular monitoring and adjustments to work practices can help prevent musculoskeletal injuries and ensure a safer and more productive welding workforce.