5 steps to improve the welding environment

OSHA’s Hierarchy of Controls outlines the steps employers should take to comply with environmental regulations and improve worker safety. Considering this hierarchy is one of the key steps in improving the welding environment.

Establishing a safe, compliant work environment is key in attracting and retaining skilled employees, and weld fume management can be a critical part of this process. Regulations established by the Occupational Safety and Health Administration (OSHA) must be followed to ensure compliance.

OSHA's Hierarchy of Controls is a tool that companies can utilize to eliminate or minimize hazards within the workplace. The hierarchy outlines steps employers should take to comply with environmental regulations and improve worker safety.

This article discusses five steps a company can take to improve its welding operations through proper weld fume management.

Note: The examples following each of the steps are not inclusive; many other activities are associated with each step. Those listed are for the purpose of this article only.

1. Know the Regulations

Each country, state, and region may have varying enforcement levels or requirements regarding weld fume exposure. Logically, the first step in any improvement process is to be aware of the regulations that apply in your area. Be sure to consider facilities with multiple operations that span different geographic regions — they may be held to different regulations, depending on their location.

Check with national, state, or regional agencies in your area to determine applicable regulations. OSHA and the American Conference of Governmental Industrial Hygienists (ACGIH) are good starting places to gather information. A certified industrial hygienist can further explain relevant regulations and aid in developing a weld fume management plan.

2. Conduct a Site Evaluation

Before implementing any weld fume management controls, it is important to conduct air sampling and a thorough site evaluation to understand the types and levels of contaminants in the welding environment — and in the entire facility. Because every welding environment is different, an evaluation by a qualified industrial hygienist can help determine the appropriate course of action.

Consider not only the direct welding operations, but also the overall environment, as fumes generated by the welding process may be impossible to confine to a certain area. Recognizing exposure levels in various areas throughout the facility helps in creating the most comprehensive weld fume management plan.

3. Choose the Appropriate Fume Management System(s)

The first step in OSHA's Hierarchy of Controls is to find ways to address weld fume exposure, through process modification or substitution, before it occurs. Therefore, companies should first consider whether changing the shielding gas, using low-manganese filler metals, or changing the weld transfer method, for example, is a feasible course of action.

If process modification or substitution measures are not feasible or do not reduce weld fume exposure levels enough, there are three remaining steps in the OSHA Hierarchy of Controls to consider:

Placing a priority on a safe and comfortable environment can give companies a competitive advantage in attracting and retaining skilled welding operators. Fume extraction systems, such as the one shown in action here, capture weld fume at the source before it reaches the welding operator’s breathing zone.

• Engineering controls involve changes to the manufacturing process such as implementing fume extraction equipment, centralized ventilation systems, or fume guns. Source capture is among the most effective means of managing weld fumes, because it removes contaminated air at the source before it reaches a worker's breathing zone. Capture devices are available in different shapes and sizes, rated based on the amount of cubic feet of air they extract each minute (cubic feet per minute, or CFM). New source-capture technology on the market has improved the capture distances (compared to conventional methods), extending the capture area up to 5 ft. deep and 3 ft. wide.
  
  Other engineering control options include process enclosure; ambient or general filtration systems; and fume extraction guns, which are designed for flux-cored and gas metal arc welding and connect with a portable fume extraction system.

• Work practice controls require changes in workplace procedures and policies to prevent or limit fume exposure. Simple steps such as training workers to keep their heads out of the weld fumes or positioning their bodies so that airflow is moving from their back to their front, when possible, can help reduce fume exposure.
  
  This step in the hierarchy extends to fume extraction equipment positioning as well. When using a movable hood, for example, be sure to position it above the arc and angled at about 45 degrees so that the fume is pulled away from the breathing zone.

• Personal protective equipment (PPE) requires operators to wear some kind of respiratory protection that creates a barrier between the hazard and worker. Common welding respiratory protection includes disposable respirators, half masks, powered air-purifying respirators (PAPR), and supplied air respirators.
  
  To determine which type of respirator is appropriate, consider the maximum use concentration (MUC), which is calculated by multiplying the assigned protection factor (APF) of a respirator by OSHA's permissible exposure limit (PEL) for the contaminant:  MUC = APF x OSHA PEL. OSHA considers the MUC to be the upper limit at which the respirator class is expected to provide protection.
  
  Because respirators aren't one-size-fits-all, proper fitting is important as well. Specifically, a half-mask respirator requires a mandatory fit-test to ensure a proper seal. Fit-testing can help identify the make, model, style, and size of respirator best suited for each employee and can help confirm the respirator provides necessary protection level as designed.

4. Proper Training

Once an appropriate fume management system is selected, proper operator training is critical to obtain intended compliance.

Employees must understand any risks that are present within their workplace, why protection from those risks is necessary, the products available to best safeguard them, and how to use those products properly. You can implement numerous controls and systems, but if employees aren't using them properly, it is difficult to gain the desired results.

Employee training also includes establishing an understanding of proper maintenance and care of the fume equipment. You must maintain fume extraction systems by cleaning or changing the filters regularly, for example, to ensure the system keeps working at its fullest capacity.

Respirator inspection, maintenance, and proper storage also are important to help fully protect the welder. Establish a filter change schedule as part of your written respiratory protection program.

5. Evaluation and Retesting

Once all the controls and equipment are in place, it is important to conduct air sampling again to verify that everything is operating as planned. Fume levels should be retested anytime there is a change in the workplace, such as alterations in the production process, raw materials, equipment, personnel, work practices, or control methods used.

Weld fume management is an ongoing process, as workplace conditions and regulations change. Occasional re-evaluation and retesting of a facility's air quality can determine whether the implemented system still is maintaining compliance.

OSHA has regulations regarding the required frequency of retesting when exposure levels are found to be within a certain range, so it's important to be aware of those requirements as well.

If you are using respiratory protection, you must train and fit-test (if applicable) operators on an annual basis — sooner if there is a change to the employee or environment — and document the process.

An Important Part of the Process

Implementing process changes and technologies that reduce weld fume helps increase productivity, improve weld quality, and create a safer environment for employees. A weld fume management program also can extend equipment life and ensure regulatory compliance.

Welding fume management should not be an afterthought. Looking ahead and being proactive to regulations elevates your company's culture, while also improving welding operations, clearly establishing a distinct competitive advantage.