Welding/Steel Fab Types and Regulations
Within the welding industry, there are several types of welding which may be used for different applications. Not all types are safe or beneficial for every project, and it’s important to know which type is right for each project as well as the code requirements for each one.
Arc Welding
One of the most common types of welding is the arc welding. Within this category, you’ll find multiple divisions. They come with letter designations, which can be confusing, such as FCAW, GMAW, and SAW. Each one is unique and fits a distinct job or task.
FCAW – Flux cored-arc welding is semi-automatic using an arc between the metal and filler wire or electrode where the heat melts the filler and the metal to fuse them together.
GMAW – Gas metal-arc welding uses a filler wire with an arc that comes from a DC power supply with a shielding gas.
GTAW – Gas tungsten-arc welding uses an electrode that is non-consumable with a separate filler wire. It can be used on ferrous and non-ferrous metals and doesn’t require a filler.
SMAW – Shielded metal-arc welding is a manual process with a coated electrode and requires minimal equipment.
SAW – Submerged-arc welding is semi-automatic or automatic using a layer of powdered flux over the workpiece to weld thick metal sheets or times when a long weld is needed.
These processes have been developed over time and are used for specific tasks. Consumable electrodes include carbon steel, stainless steel, aluminum, low-alloy steel, titanium, copper, and magnesium. Non-consumable electrodes include carbon and tungsten. The most common gases used in gas shielding are argon and carbon dioxide.
EPA Regulations for Welding Metal Fabrications
The Environmental Protection Agency has set some requirements for welding metal fabrications. They are as follows:
Welding processes must use reduced capabilities of fume generation
Variations of the welding process which may reduce the rate of fume generation
Filler metals, shielding gases, and other materials for the welding process should be capable of reducing the generation of fumes
Optimize the variables in the process to reduce the level of fumes that are being generated
Use a capture and control system for welding fumes
If the welding operation uses a small amount of wire or rode containing one of five metals, it may be exempt from the requirements. If emissions from the operation is visible more than once in a year, testing is required using Method 9. A management plan which is site-specific must be implemented.
Welding Safety
Four of the main dangers with welding, include burns, fumes, electrocution and fire. Eye injuries are the most common type of injury to occur with welders, according to OSHA. Special eye equipment is needed because regular protection isn’t strong enough.
Special welding gloves are necessary to prevent burns while welding. The gloves must be completely dry to prevent electrocution when handling welding equipment. A leather apron can protect the body because a synthetic apron or everyday wear won’t provide enough protection and can even act as a flammant.
Ventilation is another necessary consideration. With the special equipment and clothing, the risk for heat exhaustion and overexertion increases. Airflow helps keep the temperatures at a safe level.
OSHA has developed guidelines for a safe workplace environment with welding.
No flammable substances can be within the vicinity of the welding job
Floor cannot be made of wood
Any tanks or other containers that have contained flammable explosives must be cleaned
The floor cannot be wet
Clear workspace with no objects in the way
No congestion in the workplace
An emergency plan must already be in place for a welding workplace, which includes training for the welders. Fire extinguishers and other equipment should be easily accessible by welders and other workers in case of fire.