Organization of a welder's workplace: requirements, descriptions

Ventilation of the welding shop: features of air supply

When installing a ventilation system, air exchange in the workshop can be supplied by both vertical and horizontal flows.

Horizontal air exchange

When supplying air flow in a horizontal direction, the ventilation system must be mounted in such a way as to capture the air space of the entire room. The formation of air stagnation is unacceptable. The air exchange rate must be more than 0.1 m/s. This scheme is great for small spaces. For example, in a workshop with parameters of 30x20 m, 7 fans are installed with a total capacity of 7000 m3/hour, which create horizontal air flows. The fans are installed on one wall at a height of up to 4 m and provide a stable supply of fresh air masses. Fans with a capacity of 7000 m3/hour are installed at the same height on the wall opposite the influx of air masses. They remove polluted air.

The bottom scheme can be used for workshops where the distance between the inflow and exhaust is not more than 100 m. In the case where the distance is greater, the air masses “hang” and harmful substances accumulate. The efficiency of the system is significantly reduced. If this problem occurs, it is necessary to install additional fans or jet devices that will accelerate the flow of fresh air masses.

Vertical air exchange

To arrange vertical air exchange, you will need to install several fans in the basement, which will supply fresh air to the workshop through ventilation shafts. The holes for this installation are mounted in the floor and closed with special gratings with cells whose diameter does not exceed 50 mm. The speed of air masses should be 4.5 m/s when leaving the fans and, accordingly, 0.1 m/s when entering the room. The productivity of supply fans for a room of 30x20 m is 3400 m3/hour. Exhaust fans are installed at a height of up to 6 m, usually on the roof. Their productivity is 6800 m3/hour. Such a ventilation system can quickly clean the air in the workshop and reduce the concentration of harmful substances in the air to an acceptable level of 2 mg/m3.

Electrical holders for manual arc welding

One of the main tools used by welders is the electric holder. Safety and productivity depend on it. The basic requirements for them are lightness and ease of use. The weight of the electric holder should not exceed 0.5 kg so that the welder’s hands do not get too tired. In this case, the holder should not be exposed to heat during operation.

Among all types of clamps, pliers are the most optimal.

Three types of electrical holders are available:

for current up to 125 A and wire cross-section 25 mm;
for current up to 315 A and 50 mm wire;
for current up to 500 A and 70 mm wire.

It is necessary to have insulation and reliable fastening of the electrodes. The holder must withstand 8,000 electrode clamps. The design allows you to replace the electrode in no more than 4 s.

Approximate cost of electrode holders on Yandex.market

Holders for currents of 500 A and higher are equipped with shields to protect hands from the heat of the welding arc and from metal splashes. Electrode holders are also used, which are equipped with devices to turn off the current when changing the electrode. This additionally ensures greater operational safety.

The welding station must be equipped with a tripod (stand), which is welded to the table, for placing the electric holder during breaks in work, in order to avoid the formation of an electric arc when the holder touches the table surface. The surface of the tripod or stand must be made of electrical insulating material.

During welding, splashes of metal stick to the holder, this leads to its weight and overheating. In order to avoid this, it is recommended to lubricate it with an auto scrap once per shift.

Fire safety

Safety precautions during welding work include fire safety. A phenomenon such as fire can occur both during industrial production and during individual work. To prevent a fire, all measures must be taken. This includes not only the procedure for carrying out welding work, but also preparatory operations.

In this sense, manual arc welding is particularly dangerous. Sparks in this type of welding process scatter over a considerable distance, reaching up to five meters. A fire may occur in the place where they fly. When performing welding work, TB strongly recommends that before starting the welding process, conduct a thorough inspection and clean up nearby flammable materials, oily rags and dry debris located at a specified distance.

If welding is carried out in a carbon dioxide environment, then splashing of the metal in a hot liquid state becomes possible. When using the gas option, the burner will become a source of increased danger. During electric welding, hot pieces of metal can fly a considerable distance and create a fire hazard there. If they come into contact with flammable substances, a so-called “silent fire” may occur. Over time it will begin to gain strength.

Potential causes of fire include faulty electrical wiring. If the safety precautions for welding with gas cylinders are violated, then there is a danger of their explosion, and, as a result, a fire. It can also be caused by flying sparks.

The presence of a human factor cannot be rejected, for example, if the smoking ban in the workplace is violated. Violations include improper transportation of gas cylinders. Their delivery to the work site must be carried out using a special trolley. If carried by hand, they may fall, causing an explosion. Cylinders should be located away from heating, and when working outdoors, in the shade. Exposure to sunlight on gas containers is unacceptable.

The necessary measures to ensure the safety of welding work in terms of the possibility of a fire can be divided into:

Organizational. These include briefing and familiarization with the technological map for a specific welding process.
Technical. Consists of preparing equipment and consumables.
Operational. Consists in the correct choice of operating modes.

Important fire-fighting measures include preparatory operations. They consist of properly equipping the workplace and clearing it of unwanted elements.

When working indoors, make sure that the exhaust ventilation is working properly. A fire extinguisher is required at the welder's workplace. The welding area must be fenced. The height of the partition must be such that sparks and splashes cannot fly through it. When working outdoors, the welding area should be fenced off and warning signs placed on the fence.

If a fire occurs, for example, in the event of an electrical fire, the area should not be filled with water, but rather a fire extinguisher should be used. There are different types of them. Universal fire extinguishers include powder ones marked “D”. In addition to fire extinguishers, it is advisable to have a box of sand, a shovel and a mound at the welding site.

To quickly evacuate people in the event of a fire, it is necessary to clear passages. If all fire safety regulations have not been met, then it is prohibited to begin the welding process. Fire safety includes requirements for personal protection of the work operator.

Mobile post

A mobile place can be created for a gas and electronic inverter. It is worth considering that a welding cabin is required for its installation in case of high ambient humidity.

The fewest problems arise when using gas welding. This is because electrical equipment must be reliably powered.

Additional Information

Organization of the welding place is important, but the rules will only work in conjunction with the correct selection of equipment and welding tools. We will give a couple of recommendations regarding welding clothing, a helmet, wires and a holder. This is the minimum set of tools for a welder, not counting the welding machine, of course.

Protective clothing and mask

Protective clothing and footwear are essential for any welder. If you do not use protective equipment, not a single welding station will help you. Even well stocked.

The welder must wear a special work uniform (trousers and jacket), gloves, and shoes. Clothing must be made of non-flammable materials that are resistant to stains. Shoes should not conduct current. Also, clothing must be resistant to molten metal.

A mask is necessary to protect your eyes, hair and skin. Welding work without a mask is prohibited. The mask must be equipped with a light filter that protects the eyes from radiation. Its weight should not exceed half a kilogram, otherwise the master will quickly get tired of constantly wearing a mask on his head.

We have previously talked about masks, read about it here. We recommend choosing chameleon masks in the mid-price category or above. They are great for regular work and do the job well.

Welding wires

The welding wires also need to be chosen correctly so that they do not cause a short circuit or fire. The better the cable insulation, the higher its strength and reliability.

Pay attention to the workmanship and wire cross-section. If the cross-section is too small, the cable will not be able to withstand the load and will melt, which can lead to dire consequences.

However, you should not choose cables with excess cross-section, since they are quite expensive and inconvenient to carry, store and use.

When organizing a welding workplace, make sure that it has a separate place for storing various cables. They should not constantly get tangled and dusty. They also need to be placed closer to the master, but away from explosive substances and materials.

Electrode holder

The correct organization of the workspace also depends on the “holder”. It must be easy to use so that the master can work productively. If you purchase a low-quality holder, all the convenience of the welding station will come to naught.

Any welding place must be equipped with several welding holders. Firstly, for their prompt replacement if necessary, and secondly, for performing various welding works.

When choosing a holder, make sure that its weight is not too heavy, but not too light. You should not experience constant arm fatigue from using a heavy holder. But at the same time, too light a holder can reduce the accuracy of the work. Select the tool individually.

The handle of the holder should be made of rubberized material. It should be easy to grip and not allow current or high temperatures to pass through. If the handle gets hot, the welder can feel it even through protective gloves.

The electrodes should be tightly attached to the holder and not “walk” from side to side.

For holders you need to provide a separate place in which they will be stored. It should also be close enough to the master’s hand so that he does not have to waste time searching for the right tool.

Welding wires: purpose, recommended cross-sections

The organization of the welding station involves the use of a cable of the most suitable cross-section. This indicator should be taken into account for the following reasons:

If the cross-section is too small, the cable cannot withstand the load and begins to overheat. As a result, heat acts on the insulation, causing it to melt. If the damage is severe, a short circuit may occur.
Large cables are expensive. At the same time, they are less practical to use; transportation and storage creates many problems.

Cable selection is carried out in accordance with regulatory documentation. The organization of the welder's workplace is carried out taking into account the fact that the cables should not be intertwined, all contacts should be fixed. Cable and other electrical equipment should not be located near flammable materials or water.

The optimal cross-sections of the welding wire are presented in the following table. As previously noted, the choice of wires is selected depending on the power of the equipment used by the welder. The optimal indicator is selected in accordance with the table.

Table of cable cross-sections depending on power

Using tabular data allows you to avoid quite a lot of problems. A high-quality cable has effective insulation, which eliminates the possibility of a short circuit.

Installation of electrical equipment

An electric welding transformer and other units emit quite loud noise that has a bad effect on the human nervous system. Due to irritability, the quality of the seam deteriorates and productivity decreases. Therefore, humming equipment is installed at some distance from the work site. It is better to place the transformer or converter within 5-7 meters from the welder. This will reduce the noise emitted, but at the same time will not complicate the process of adjusting the device.

The source of welding current, located in the middle of the workshop, is protected with shields for safety. If there are multi-post installations, then a permanent mesh fence is built for them or they are taken out to a separate room. The distance from the wall to the device must be at least 500 mm. Outdoors, it is necessary to provide a canopy to protect the equipment from precipitation. The cables from the device are laid over the wall to prevent people from tripping over them.

What is a welding post and what does it consist of, types of welding posts

What is a welding post and what does it consist of, types of welding posts
? The welder's workplace is called a welding post, which can be of a mobile or stationary type. The work station is organized in such a way that the welder can easily carry out his work. Here are all the necessary tools for welding: welding machine, electrode holder, welding cable, etc.

A stationary welder's station is a canvas cabin with dimensions of 2x2.5x2 m. For its manufacture, both tarpaulin and other “light” but non-flammable building materials, for example, thin steel, can be used.

Mobile welding station - equipped directly at the workplace. Like the stationary station, the mobile one also has all the necessary tools that will be needed for welding in the field.

What is a welding post and what does it consist of?

A welding station is a specially designated place for a welder where he can perform work related to welding metal products. There are several types of welding stations; they will be discussed below in this article on welding from the website mmasvarka.ru.

The welder's place or welding station has all the necessary tools and equipment. The area of the stationary welding station must be at least 6 square meters. m. The welder's workplace must be comfortable, fireproof and have good exhaust ventilation.

In addition, the welding station includes:

Tabletop (welder's work table) of a rotating or non-rotating type;
Chair;
Welding source (AC/DC welder or other arc sources);
Electrode holder;
Cables for welding.

Among the tools and equipment, the welding station must have a welding mask and a hammer for beating off slag.

Types of welding stations

There are several types of welding stations: stationary and mobile.

Stationary welding station

- a specially equipped place for the welder, the area of which is at least six square meters.

This post is a booth without a ceiling, made of thin steel or plywood.

In any case, these must be fireproof building materials, and if plywood is used to build a post, then in any case it must be reliably protected against fire.

The stationary welding station contains all the necessary tools and equipment for welding. Also, a welding station cannot exist without a welder’s work table and a chair, as well as good exhaust ventilation. The welding table can be equipped with a fixed or rotating tabletop.

Mobile welding station

— such a welding station is equipped directly at the work site. First of all, these are welding works related to the welding of large metal structures. The mobile welding station also contains everything necessary for welding: arc source, electric current generator, tools necessary for welding.

A mobile welding station must have protection in the form of a canopy that would prevent precipitation from entering the welder’s workplace. Also, the post must have good lighting sources and all the necessary equipment for welding. The requirements for a welding station will be discussed in more detail below.

Requirements for a welding station

A stationary welding station, unlike a mobile one, has much more organizational requirements.

So, for example, a stationary welder’s station must have:

Sufficient air exchange, but not less than 40 m³/hour, as well as good lighting;
The total area is at least 3 m², while the ceiling height of the welding station must be more than 2 meters;
Non-flammable materials and steel frame;
Durable metal or cast iron table for welding, at least 2 cm thick;
The presence of grounding and a rubber mat under the welder’s feet.

A mobile welding station is installed directly at the workplace, where large metal structures need to be welded. Although such a welder’s station differs in many ways from a stationary station, it also has everything necessary for welding, including protective grounding.

4.1.1.Workplace

Workplace

called that part of the workspace where the production equipment is located, with which a person interacts in the work environment.

Places for welding work are divided into permanent and temporary. Permanent (stationary) places are intended for work that is performed in specially equipped workshops, workshops, etc. Install the welding machine in a weatherproof environment, welder’s table, manipulator, hood, etc. in a well-ventilated area of at least 3 m2. It is best if the floor is concrete, and the walls of the room should not reflect welding glare, which can pose a hazard to the eyes.

Fig. 14 Layout of the welding cabin:

1 – arc power source; 2 – grounding; 3 – power source starter; 4 and 5 – forward and return conductive wires; 6 – table; 7 – ventilation; 8 – rug; 9 – electrodes; 10 – shield; 11 – electrode holder; 12 – chair;

13 – waste box; 14 – doorway

Fig. 15. Welder workplace

The passages between multi-station welding units and between automatic welding installations must be at least 1.5 m; passages between single-station welding transformers or between welding generators, as well as passages on each side of a rack or table for performing manual welding work - at least 1 m. The distance between a stationary welding unit and a wall or column must be at least 0.5 m, and the distance between a wall or column and a welding machine - at least 1 m. The passages between spot and seam (roller) welding machines with workplaces located opposite each other must be at least 2 m, and between butt welding machines - at least 3 m. Depending on the location of the machines listed above with their back sides facing each other, the width of the passages must be at least 1 m, and when located with the front and back sides facing each other - at least 1.5 m.

For each stationary workplace during plasma and gas-plasma processing of metals, > 4 m 2 should be allocated, and when working in a cabin > 3 m 2.

Areas with hazardous production factors must be fenced off, safety signs must be in accordance with GOST 12.4.026-76*.

Depending on the dimensions of the products being welded and the nature of the production, the welder’s workplace can be located either in a special cabin, or in a workshop, or directly at the assembly facility. The dimensions of the cabin must be at least 2 × 2 m 2.

Fig. 16. Resistance welding booths.

The walls of the cabin are made 1.8-2 m high. For better ventilation, a gap of 150-200 mm is left between the floor and the lower edge of the wall. As a material for the walls of the cabin, you can use thin iron, as well as plywood, tarpaulin, treated with a fire-resistant compound, or other fire-resistant materials. The cabin frame is made of metal pipes or angle steel. The cabin doorway is usually covered with a canvas curtain mounted on rings. Plywood and tarpaulin must be impregnated with a fire-resistant compound, for example a solution of potassium alum.

The floor in the cabin must be made of fire-resistant material (brick, concrete, cement), fireproof and non-slip, and have low thermal conductivity.

The walls are painted light gray with paints that absorb ultraviolet rays well (zinc or titanium white, crown yellow). Painting welding shops and booths in dark colors is not recommended, as this deteriorates the overall illumination of the welding area.

Combined lighting should be provided for work of high and highest precision (grade I-III), in particular when welding and soldering materials with a thickness of 0.06...0.5 mm, when flaw detection of welds and other similar work.

To illuminate workshops, it is necessary to use, as a rule, gas-discharge light sources: DRL, DRI lamps; for lighting high workshops (up to 4 m) of a large area - fluorescent lamps. The use of incandescent lamps is allowed.

The illumination of the cabin should be at least 80-100 liters.

In production premises of welding and assembly-welding shops, microclimate parameters should be taken in accordance with GOST 12.1.005-88 (rooms with slight excesses of sensible heat, moderate work of categories IIa and IIb).

Cabin

Organization of a workplace for an electric welder who works in a permanent place in the workshop begins with the arrangement of the cabin. This helps you carry out welding work calmly and protects others from sparks and flashes of light.

The cabin must have dimensions that allow products intended for welding to be brought into it. If the structures being produced are small, then the minimum area of the cabin should be 2 x 2 meters. This will allow you to place everything you need and move freely around the product. To prevent welding radiation from disturbing others, the height of the cabin walls is set to 1.8 m. Since most welding operations are performed at table level, this height will be sufficient. The cabin frame is made of profile pipes or corners. The posts are attached to the floor with anchors. It is possible to provide a door that will completely isolate the welder’s workspace around the perimeter.

To improve natural ventilation, a gap of 150 mm is set between the floor and the beginning of the booth wall. This promotes air flow and raises harmful gases from welding upward. The sides of the cabin can be made of slate sheets or thin iron. Options made of tarpaulin and even plywood are allowed, but these materials must be impregnated with fire-resistant compounds. It is advisable to paint the walls with zinc or titanium white. Yellow crown will do. These substances on the surface of the cabin will absorb ultraviolet radiation well. If you paint such a structure black or dark blue, the overall illumination will deteriorate, since the light coming from the lamp above the workplace will be absorbed.

Ventilation in the workplace

The workplace of a manual electric welder, like those who do gas welding, must have ventilation. It is necessary to provide cooling for working tools and equipment that overheat greatly during operation. This helps reduce the temperature and ensure normal functioning. This also ensures a reduction in the concentration of toxic substances that are released from the molten metal. They are one of the main enemies of individual safety and if there is no ventilation and exhaust in the room, they greatly affect the human body. Ventilation also helps remove excess gases from the room, which can sometimes lead to detonation.

Ventilation at the welder's workplace

Ventilation is one of those important things that a welding workplace should be equipped with. There is natural, which is carried out by the flow of air from the street, and artificial. For artificial ventilation, special hoods, fans and other means are used that help circulate air where it cannot be done in the usual way.

Requirements and features

The organization of the welder's workplace is carried out in accordance with GOST 12.3.003-86.

Welding booth layout

Tables. These fixtures are used for welding and assembling parts. They are located inside the cabin at a height of 50-60 cm if the post is intended for welding in a sitting position, and also at a height of 90 cm if this will happen while standing. The table area should be approximately 1 square meter. The requirements for the welder's workplace require the presence of special bolts to which the current-carrying wires from the welding machine are attached. The table should have sockets for electrodes. If there is a drawer, then you can store documents and tools there.

There must be a rubber mat under the worker’s feet.”

Welding cabins. An isolated place where the welding table and other working equipment are installed. The cabin must be isolated from outsiders and have enough space. The size of the cabins is 2x2 or 2x3 meters, and the height is up to 2 meters.

To improve ventilation, the walls should have a gap of 20 cm from the floor.”

Electrode holder. It is one of the main tools that a welder uses. Safety and productivity depend on its serviceability. Its weight should not exceed 0.5 kg, and it should not heat up during operation. There must be insulation, as well as fastening of the electrode as securely as possible.

Among all types of clamps, pliers are the best to choose.”

Shields and helmets. The requirements for organizing a welder’s workplace require the use of such personal protective equipment. They must comply with GOST 12.4.035-78. The mask should not be heavier than 0.5 kilograms. There are 13 classes of filters for each power mode.

Products must be made from non-conductive materials.”

Cloth. Safety requirements for a welder's workplace will be incomplete if clothing is not used as personal protective equipment. The kit should include a jacket, mittens, trousers, special shoes, etc. Most types of workwear are made from tarpaulin interspersed with asbestos, which helps resist the ingress of molten metal.

Clothes should cover all parts of the body with reserve, leaving no bare spots.”

Welding curtains. Certification of a welder's workplace requires the presence of an overlap, especially for multi-station areas. These curtains are made from fire-resistant fabric, which is often the same as what work clothing is made from. Curtains must completely isolate the worker from strangers, so that neither the welding arc, nor sparks or other negative factors disturb other people.

Additional tools. An analysis of working conditions at a welder's workplace will be incomplete without additional tools. This includes screw terminals that are designed to provide tight contact with the product. Wire brushes are used to remove slag, rust and other deposits. Chisels and hammers are used to cut out areas with defects, install a stamp on a seam, eliminate residual splashes, and so on. Canvas bags are used to store electrodes.

Other requirements

Also, do not forget about the following additional tools that make the welder’s work easier. This:

screw clamps for tight contact with the product;
wire brushes (manual and electric) - to remove slag and rust;
narrow and wide steel brush for cleaning edges and seams;
chisels, stamps and hammers - for cutting out places with defects, eliminating splashes, installing a stamp, etc.;
a hammer with a pointed end for beating off slag;
a set of templates for measuring the size of seams;
canvas bags or glasses - for storing electrodes.

The welder should have easy access to consumables: electrodes, wire, flux, etc., so that he can easily change them during work. It is necessary to follow the labor protection instructions individually and generally.

If the welder works with a non-consumable electrode, then he must have a set of sharpened tungsten electrodes, pliers, wrenches, wire cutters, pliers, etc. The tool should be stored in a special box or bag.

Thus, the overall efficiency and safety of the work depends on how competently the workplace of a welder using the manual arc welding method was organized. The workplace is understood as an area assigned to the welder, which is equipped with equipment, tools and devices for welding. A properly organized place reduces injuries and accidents at work.

Types of ventilation systems and arrangement rules

An exhaust hood for a welding station, installed according to the rules, can significantly reduce the concentration of hazardous substances in the atmosphere and minimize harm to the environment. The type and power of fans, as well as the routing of air ducts, are selected taking into account the number and location of places for welders. Exhaust structures can be placed on the roofs of workshops or near them; the air intake should not be located in the area for the emission of polluted air.

Local

The welding shop or workshop has local and general exhaust

When creating a local type hood, the ventilation of the posts is selected taking into account the size of the elements being welded and the intensity of the work. The amount and composition of the gases formed depends on these nuances. Thanks to the simple design and design, the productivity of such a system reaches 5.5 thousand m3/hour. During welding and surfacing of large products on tables not equipped with devices, welding aerosols are removed using suction from mobile units with filtration ventilation. For some types of work, it is advisable to use lift-and-swivel hoods. Their design includes a flexible hose with a diameter of up to 200 mm, mounted on a console and directed to the desired area. The receiving pipe is placed at a distance of 7-8 meters from the worker.

General exchange

Exhaust fans at welding stations
The general-exchange type system includes a supply and exhaust fans, as well as air ducts equipped with filters and adjustable supply structures. Such ventilation is designed to provide fresh air to all areas of the workshop and reduce the content of harmful impurities in the atmosphere. It is worth choosing if more than 200 g/hour of electrodes per 1 m3 of the total volume of the room is used during the work. Otherwise, the influx of air masses will be provided naturally.

In winter, outside air is supplied to the workshop at a temperature not lower than +18 degrees. General ventilation for the welding station must be supplemented with filtration elements that purify the air before being released into the space. The performance of the devices is selected to ensure a 10-fold air exchange. The vertical speed of movement of air masses is maintained at no lower than 0.1 m/s. This value is sufficient for mixing media and eliminating welding aerosols from areas outside the posts.

Inside closed and semi-enclosed spaces

To organize a ventilation system inside a closed or semi-enclosed space, there are several available schemes. In the workshop, you can create an organized air exchange in one container, where clean air will be supplied from outside. Next, the air masses are removed mechanically due to the combined action of inflow and exhaust. The second method involves removing contaminated masses near electric welding arcs; there is also a third option, which involves ventilating only the worker’s breathing zone by supplying clean air under the shield.

The most common type of system is a tank ventilation scheme using a supply jet, which involves the installation of flexible hoses and high-pressure fans. The main advantage of this method is the supply of clean and heated air from the street during the cold season. Tanks in this arrangement are located in specially designated areas. To determine the volume of supplied air, its speed in the work area should not exceed 0.7-2.0 m/s for manual welding. You can avoid the entry of polluted air into the workshop by installing the mass supply from the opposite side.

Strip welding curtain

The protective curtain is selected taking into account various parameters. The main ones can be called:

Thickness and type of material. Some fabrics are characterized by increased resistance to temperature.
High-quality versions are stitched.
Type of supporting structure.

Strip welding curtain

Such protection can be installed quickly; after the process is completed, it is quickly assembled. The supporting element is made of corrosion-resistant metal.

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Electric welder mask as a means of protection

Safety precautions for organizing a place for welders include the use of special shields and a helmet. When manufacturing them, the standards established in GOST 12.4035-78 must be taken into account. Among the main standards we note the following:

The structure should not be heavier than 0.5 kilograms. Otherwise, it will be difficult to carry out the work. Filters are installed to protect your eyes.

They are divided into 13 classes, the choice is made depending on the power. When choosing a mask, attention is paid to ensuring that it fits comfortably. From time to time the welder has to open it for visual inspection of the seam.

Welder mask

There are a wide variety of protective masks available on the market. More expensive versions are characterized by greater efficiency. If you frequently carry out welding work, it is recommended to purchase a high-quality product, since ultraviolet and other radiation can be harmful to health.

What are the locations for welding work?

Safety precautions and many other regulatory documents determine the classification of the workplace into several types. An example is the information below:

The first type is most often associated with special premises in workshops, the second - mobile ones, required for traveling to the site of an accident or construction. The welder's cabin is equipped only once in accordance with safety regulations, after which attention is paid only to the technical condition of critical mechanisms and structures.

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Protecting skin and eyes

Not only labor productivity and the production of a high-quality weld, but also the safety of equipment and the creation of safe conditions for people to work depend on how carefully GOST requirements are observed in production and when a welder works in an open area.

The safety instructions are of equal importance regardless of the electric welding technique - in automatic control mode or semi-automatic

To protect the welder's eyes from the adverse effects of hazardous factors, it is important to know what radiation occurs during electric arc activity:

a bright flash of light is formed, which can blind a person for some time;
intense ultraviolet radiation can cause varying degrees of burns to the cornea of the eye;
Periodic exposure to infrared radiation over time causes the welder to develop cataracts and clouding of the cornea - these diseases cannot be treated and lead to blindness.

In addition to the negative impact on the organs of vision, during welding poisoning occurs from evaporating gases, which leads to nausea, severe headaches and weakness. To protect your eyes and respiratory system when performing welding work, it is necessary to provide ventilation and use special face protection using a welding mask. Modern models of masks provide an influx of oxygen under the influence of a turbo unit and reliably protect the worker’s eyes with light-filtering glass. For example, a chameleon-type mask can be adapted for any type of welding work and provides reliable protection even during a long welding process.

As for respiratory protection, in addition to exhaust hoods, welders additionally use special respirators worn under a mask, and sometimes gas masks, especially if the work is performed in a small room. In addition to following safety standards related to proper handling of a welding machine, a specialist can protect himself from the harmful chemical effects of burning electrodes by replacing acid-coated electrodes with rutile ones. At the same time, the quality of the seam will remain consistently strong, while the toxicity for the welder during the work will be significantly reduced.

To protect the surface of the skin and eyes while welding, these rules should be taken into account:

For welding, it is not recommended to use excessively long electrical wires and durite hoses; the optimal length is no more than 10 m;
It is not recommended for a beginner in welding to work in rain or high humidity conditions;
During the work process, all exposed areas of the body should be protected, as there is a high probability of getting burned;
When performing welding work at height, you must always use safety equipment in the form of a special belt.

Regardless of how long the welding work takes, safety precautions must be observed by the welder in any case. Even if a specialist needs to make a very small seam, before work he must change into protective clothing and put on a welding mask.

How to choose an electric holder

When organizing your workplace, you also need to choose the right electrical holder. How safe the workplace will be and what labor productivity will depend on its technical condition. The welding station can be equipped with several types of holders, it all depends on the type of work being carried out.

When choosing such a device, pay attention to the following points:

Weight should not be more than 0.5 kilograms. Excessively heavy versions complicate the welder's task. When welding for a long time, your hands will get tired, which will ultimately reduce your productivity.
Attention is paid to how comfortable the grip is. To prevent the handle from slipping, its surface is often grooved.
During operation, the structure should not become very hot. Otherwise, problems may arise during prolonged welding. Although the welder must use special gloves, high heat causes significant discomfort.
The surface must be insulated, since such an element should become a barrier to electricity in the event of a malfunction. When organizing the workplace, attention is paid to the quality and integrity of the insulation.
The fastening of the electrodes must be strong, since at the moment of contact with the surface they are subject to mechanical stress.

It is recommended to purchase original electrical holders recommended by the manufacturer for organizing the workplace. Before each work, the condition of the structure is checked.

Assembly and welding of pipelines

Pipelines are classified as particularly important objects. If their parts are connected poorly by welding, a serious accident may occur.

Therefore, SNiP pays special attention to pipeline welding. In this case, the requirements of GOST 16037 are taken into account

SNiP for pipeline welding gives, in particular, the following recommendations:

Welders with the appropriate category for this type of activity are allowed to weld these products.
Before welding, pipelines must be cleaned of various types of contaminants.
Welding of metal pipes can be done at a temperature of at least minus 50°C.
Welding of pipelines is not allowed under adverse weather conditions.

Since welding is carried out at height, much attention is paid to safety measures. For proper welding of pipelines, other basic requirements of SNiP for welding of metal structures are also applied.

SNiP imposes special requirements for welding galvanized pipes.

Advantages of welding curtains

Special curtains are very popular. They make it possible to significantly simplify work and divide the site into several sectors. The features of such equipment include the following points:

Fire-resistant fabric is used in production.
The material used can also withstand minor mechanical stress.

Variety of welding curtains

There are several versions of such equipment, each characterized by its own characteristics.

Installation of gas equipment

The gas welder's workplace is set up according to a similar principle. The color of the walls of the protective shields does not matter here, since the gas flame does not emit ultraviolet radiation. The main thing is that the welder can clearly see all the parts in the workplace.

A significant difference is the location of the cylinders. Although a trolley is used for transportation, on which an oxygen and acetylene cylinder are immediately installed, before performing welding work they must be separated from each other by at least 5 meters. The same should be done with propane equipment.

In this case, it is important to maintain a distance of 5 m between the cylinders and the area to be welded. As a result, the arrangement should look like a triangle, with the element to be welded on one vertex and gas cylinders on the other two

It is important that there is nothing in the way of the acetylene generator or cylinders. This allows quick access to equipment in the event of a flashback.

This can prevent an explosion and serious injury. The hoses are located on the side so that they are not walked on or driven on. Otherwise, the flame will go out and rubber communications may deteriorate.

The welder's main tool is the holder. Productivity and quality depend on its convenience and thoughtfulness. The holder can be of two types: to clamp the electrode like a clothespin, or to tighten it by twisting the handle. Regardless of the type, it should allow the electrode to be changed in 4 seconds.

The structure is well insulated to prevent electric shock. The cable and the holder itself constantly exert their weight on the welder’s hand. Therefore, the mass of these elements should be minimal so as not to overwork the welder and not limit movement.

If work is carried out at high current (from 500 A), then the holder is equipped with a protective pad that prevents the welder’s hand from being damaged by high arc temperatures. When the welding current exceeds 600 A, the cable is passed to the electric holder, bypassing the handle that the worker grasps. The sides that secure the electrode are subject to the adhesion of molten metal splashes, making it difficult to replace a new consumable element. This slows down the entire process and the welder gets tired faster. To prevent this effect, the surface of the holder on which drops of metal fly is lubricated with a scraper and cleaned at the end of the day with a needle file.

For convenient welding operations, it is practical to place the product on the table. This increases the speed of welding and the convenience of welding in hard-to-reach places. The welder's table is made to individual sizes, based on the dimensions of future products. The legs must be height adjustable to accommodate workers of different heights.

The table should include devices for:

safe placement of the holder during the process of rearranging the product;
quick access to consumables and easy electrode change;
location of tools (hammer, file, flashlight, slag separator, metal brush);
ignition of the electrode on the rough surface;
installation of non-standard structures with protrusions in special holes.

An important attribute of an electric gas welder’s workplace is a hood. It ensures the removal of harmful heavy gases from the melting metal and electrode coating. It is not practical to place it in the form of a large umbrella over the table, since part of the harmful mixture will pass through the welder’s respiratory system.

It is advisable to install a flexible side air suction system, which will immediately pick up harmful gases without allowing them to rise to the worker’s face. Such a line will ensure that the hood can be moved to any location within the welding cabin. At the same time, it is worth remembering that the noise of the engine disturbs the worker, so the power unit for pumping air is located outside the room.

Creating comfortable conditions for the welder improves the quality of seams and the process of producing finished products. Reducing passive harm at work and protecting personnel from injuries helps maintain a permanent team and harmonious interaction among employees.

Solid standard curtain

Most often, a continuous curtain is installed. It is represented by a solid material that is attached to special load-bearing elements. Among the features we note:

Visual protection and blocking ultraviolet radiation.
Protects the environment from splashes and molten metal.
The negative impact of side air flows is reduced.

Solid standard curtain

When choosing the most suitable curtain, attention is paid to the width of the seams, the thickness of the material and some other points.

Table

The table should include devices for:

safe placement of the holder during the process of rearranging the product;
quick access to consumables and easy electrode change;
location of tools (hammer, file, flashlight, slag separator, metal brush);
ignition of the electrode on the rough surface;
installation of non-standard structures with protrusions in special holes.

Requirements for special clothing

Special clothing can be considered personal protective equipment. It is manufactured taking into account the characteristics of metal processing, as well as the possible impact. The kit includes:

In most cases, they are made using tarpaulins to which asbestos is added. Due to this composition, the surface becomes much more resistant to the ingress of molten metal.

Introduction

Electric welding of metals is considered one of the most important technological processes of any production.

Each welder relies on a pre-prepared work plan to create the correct shapes and patterns of the required items. In this case, the welding operator must in each case take into account some operating errors during the welding procedure. It is worth considering that during the working process local heating occurs, which deforms the parts. The welding process requires constant changes in modes during operation.

That is why every day specialists are developing more and more efficient and automated welding equipment, which will simplify the complexity of the work as much as possible and allow you to obtain ideal products.

What is welding? This is a process in which a permanent connection is obtained as a result of the fastening of elements by intermolecular and interatomic bonds. This phenomenon is achieved by heating or plastic deformation.

Today, welding is very widely used for reliable connection of various metals, as well as their alloys.

The welding process requires energy. In this case, sources such as an electric arc, ultrasound, friction, gas flame, electric current, electron beam, or laser radiation can be used.

Modern technologies make it possible to carry out the welding process not only at specially equipped enterprises, but also during steppe or field work. But even this is not the limit. It became possible to do this even under water or in outer space.

Do not forget that carrying out this work is very dangerous and involves enormous risks. Cases of poisoning by harmful gases, electric shock, infrared or ultraviolet radiation, or injury from splashes of hot metals cannot be ruled out. In order to avoid the dangers listed above, you need to maintain your workplace in proper condition. We'll talk about this in this article.