Applying Safety

Practices
Shielded Metal Arc Welding (SMAW) NC I
 Table of Content
• Signs and Symbols at Workplace

• Handling Tools, Equipment and Materials

• Using Fire Extinguishers

Signs and Symbols at
Workplace
What are the safety signs and
symbols?

Safety signs and symbols are graphical

representations used to communicate specific
messages related to safety and health. They are
designed to prevent accidents, injuries, and illness
in workplaces, public spaces, and other
environments. These signs and symbols are
universally recognized and conform to certain
standards to ensure their effectiveness.
Importance of Safety Signs in the
Workplace
Safety signs and symbols are used to communicate
important information about potential hazards and
safe practices. They are designed to be easily
recognizable and understood, even by those who
may not speak the language or have limited literacy
skills. Safety signs can help prevent accidents and
injuries by alerting employees and visitors to
potential hazards and guiding them toward safe
practices.
In many countries, safety signs and symbols are
required by law in workplaces. These laws are in
place to protect employees and visitors from potential
hazards and to ensure that workplaces are safe.
Failure to comply with these laws can result in fines
and legal action.

Implementing safety signs and symbols in the

workplace can have many benefits. They can help
prevent accidents and injuries, reduce the risk of
liability, and improve overall safety culture. Safety
signs can also help improve communication and
reduce confusion, leading to a more efficient and
1. Danger

Danger is used to indicate an imminently hazardous

situation which, if not avoided, will result in death
or serious injury. The use of this signal word should
be limited to the most extreme situations.
2. Warning

Warning indicates a potentially hazardous situation

which, if not provided, could result in death or
serious injury
3. Caution

Caution is used to indicate a potentially hazardous

situation which, if not avoided, may result in minor
or moderate injury. CAUTION may also be used
without the safety alert symbol (the triangle with
exclamation mark) to indicate property-damage-
only
Color of Signs

Since color is typically the first thing draws the

attention of the viewer, the color-coded surround
shapes act as a first level of meaning and, as you
draw closer to the sign, you are able to distinguish
the specific information conveyed by the graphic
symbol.
To make this system work, the viewer must first
understand the color-coded surround shapes below:
 A B C
Example A is an ISO “Warning Safety Sign” This
type of label is meant to tell what the hazard is (e.g.
“fire hazard”)
Example B is an ISO “Prohibition Safety Sign”
This label tells about an action not to take in order
to avoid a hazard W(e.g. “no open flame”).
Example C is an ISO “Mandatory Action Safety
Sign” This label defines an action that needs to be
taken to avoid the hazard (e.g. “read manual”).
Understanding Safety Signs

Mandatory Signs
Mandatory signs are regulatory signs which
indicate that an instruction must be carried out.
When symbols are used they are white on a blue
disc. Text-only mandatory signs are black on white
in a portrait format
Understanding Safety Signs

Prohibition Signs
Prohibition signs are regulatory signs which
indicate that an action or activity is not allowed.
The symbolic shape used on prohibition signs is the
red circle and slash over a black symbol.
Prohibition signs may contain only the red circle
and text with no symbol.
Understanding Safety Signs

Warning Signs
Warning Signs are hazard signs which warn of a
hazard or hazardous condition that is not likely to be
life-threatening. The symbolic shape used on warning
signs is a black triangle with yellow interior and black
symbol. The word “Warning” is not required to be
printed on the sign, although it is often used for added
impact.
Other Common Signs in the
Workplace
Handling Tools, Equipment and
Materials
Handling Tools, Equipment and
Materials
Welders and other workers should have a definite
understanding of the requirements for a clean and
orderly shop. A disorderly shop can lead to many
unsafe condition which can result in accidents and
injury. A clear shop can also reduce the costs to the
business through lost or damaged tools and
equipment.
Shop Cleaning and Tool Storage

Tool Boards or Storage Cabinets

- The tool board should be large enough to handle all of the hand tools
used in the shop. A vertical tool board is recommended so all of the tools are
visible at once and easily accessible.
- The tool board or storage cabinet should have closing doors that can
be locked for security.
- The tools should be fitted so that each can hang individually when
not in use. A system should be set up to store similar tools in the same
sections to facilitate inventory checks. Nails and clips can be used to hang
each tool.
- Ideally, each tool is outlined, or silhouetted, so that each tool can be
returned quickly to the correct spot. Missing tools are easily detected using
this method.

Material Storage
- Lumber, angle iron, steel rods and scrap iron should be stored in
vertical racks. Vertical racks facilitate both long and short items and utilize
 - Separate vertical racks should be used to store different types and
widths of lumber and various metal materials.
- Do not store materials past the horizontal stabilizer bars. The
materials will no longer be supported from falling and can cause serious
injury.

Scrap Material
- Separate bins should be supplied for scrap lumber and scrap metal.
These bins should be for material that cannot be reused. Reusable scraps
should be stored in the vertical racks.
- Never allow the scrap bins to overflow. Scrap materials is a major
source of clutter in many shops. It can become either a fire hazard or an
accident risk if allowed to accumulate. Scrap materials can often be sold and
recycled. If not, these should be hauled to a dump on a regular basis.
- Nails, staples and other obstruction should be removed from scrap
wood before it is placed in the scrap bin.
- HOT METAL MUST NEVER BE THROWN IN THE SCRAP BIN. Burn
injuries are common in many machine shops because workers do not obey
this rule. Hot metal also creates a fire hazard when improperly stored. All
Flammable Liquids
- Flammable liquids such as grease, oil and solvents should be stored
in special storage containers designed for this purpose. These storage
containers are made of steel and are designed to close automatically in the
presence of fire to prevent the spread of the fire.
- Dirty rags are also a fire hazard in the shop. A metal container with a
sealable lid should be provided to store all rags that have been exposed to
grease, oil or solvents.
- Always store gasoline or rags that have been exposed to gasoline in a
separate, well-ventilated area. Gasoline should never be stored in the shop
due to its high combustibility.

Shop Cleaning Procedures

A well organized and properly cleaned shop is the responsibility of

every worker. The supervisor should act only as an overseer once the workers
are oriented with cleanup procedures. The cleaning procedure should follow
a systematic approach. Some of the steps included in a thorough shop
cleanup are as follows:
- The supervisor or appointed worker signals for all work to cease at an
appropriate interval before the end of the working day.
- Each worker clean up his or her individual work area. Projects are
properly stored and tools and equipment are returned to their proper
places.
- Solvent, grease, oil, paints, and other flammables are stored properly.
Paint brushes are cleaned and dried.
- Scrap wood and metal are separated and place in the appropriate waste
bins. Scrap metal is cooled before being placed in the bin.
- All spare metal and wood stock is returned to the appropriate racks.
- All benches and machines are cleaned with a brush. Dust, scraps, and
waste are then swept towards the center of the aisle or floor. Assigned
workers use push brooms to clear the floor. All waste and trash is placed
in the appropriate containers.
- The supervisor or an appointed worker checks to make sure all of the
tools and equipment have been returned to their appropriate places. All
cleanup jobs are checked for completeness.
- The tool cabinet and the material area are locked if a lock system is
available.
Equipment Used in Are Welding
Before we discuss the different types of welding machines, you
must first have a basic knowledge of the electrical terms used in welding.

Electrical Terms
Many terms are associated with are welding. The following basic
terms are especially important.

Alternating Current (AC) - is an electrical current that has alternating

negative and positive values. In the first half-cycle, the current flows in one
direction and the reverses itself for the next half-cycle. In one complete cycle,
the current spends 50 percent of the time flowing one way and the other 50
percent flowing the other way. The rate of change in direction is called
frequency, and it is indicated by cycles per second.

Amperes - sometime called “amps,” refer to the amount of current that flows
through a circuit. It is measured by an “amp” meter.
Conductor - is any material that allows the passage of an electrical current.

Current - is the movement or flow of an electrical charge through a

conductor.

Direct Current (DC) - is an electrical current that flows in one direction

only.

Electrical Circuit - is the path taken by an electrical current flowing

through a conductor from one terminal of the source to the load and
returning to the other terminal of the source

Polarity - is the direction of the flow of current in a circuit. Since current

flows in one direction only in a DC welder, the polarity becomes an important
factor in welding operations.

Resistance - is the opposition of the conductor to the flow of current.

Resistance causes electrical energy to be changed into heat.
Because arc welding involves an electric arc, the source of power is the first
point to check.

Power Supply
- The power source used in arc welding is called a Welding Machine
or a Welder
- The power supply of the arc welding apparatus must maintain a
relatively constant current with only a slight change in voltage.
- Varying voltage and current will result in an uneven arc that creates
splatters and uneven welds.
- Three basic types of welding machines are presently in use: Motor-
generators, Transformers
and Rectifiers.
Motor-Generators – These types of
welding machines are powered by
electrical, gasoline or diesel motors. The
diesel and gasoline motors are ideal for
use in areas where electricity is not
available.

These machines usually have the

capability of generating alternating or
direct current. On the newer machines,
when you are welding in the direct-
current mode, the polarity can be
changed by turning a switch.

light-shielded metal-arc
Welding machines welding
are made and for inert-gas arc welding. They are also
in six
for general-purpose
standardized ratingsjobs or shopwork.
for general
purposes and are listed as follows:

Machine rated 150 and 200 amperes –

Machines rated 200, 300, and 400 amperes – 40 volts are general welding
purposes by machine or manual application.

Machines rated 600 amperes – 40 volts are for submerged-arc welding

carbon-arc cutting.

Transformers – practically all the alternating current (AC) arc-welding

machines in use are the static-transformer type. These machines are the
smallest, least expensive and the lightest type of welders made.
The transformers are usually equipped with arc-
stabilizing capacitors.

One major advantage of AC transformers is the

freedom from arc below, which often occurs
when welding with direct current (DC) machines.
Arc blow causes the arc to wander while you are
welding in corners on heavy metal or using large
coated electrodes.
Rectifiers – Rectifier welders are single-
phase or three-phase transformers that
have selenium or silicon rectifiers added to
rectify (or change) the output current from
alternating to direct current.

Most of these machines have the capability

of producing either AC or DC straight or
reverse polarity current. By flicking a
switch, the welder can select the current
that best suits the job.
Cables – Welding cables carry the current to and
from the workpiece. One of the cables runs from
the welding machine to the electrode holder and
the other cable connects to the workpiece to the
welding machine

The cable that connects the workpiece to the

welding machine is called the ground. When the
machine is turned on and the operator touches
the electrode to the workpiece, the circuit is
completed, current begins to flow and the
welding process commences.

The welding cables must be flexible, durable,

well insulated and large enough to carry the
required current. Only cable that is specifically
designed for welding should be used.
Two factors determine the size of welding cable to use: the amperage
rating of the machine and the distance between the work and the machine.
If either amperage of distance increases, the cable size also must increase.

A cable that is too small for the amperage or the distance between the
machine and the work will overheat. On the other hand, large size calbes
are more difficult to handle, especially if you are working on a structure
that requires a lot of moving around.

As a rule, the cable between the machine and the work should be as short
as possible. Joints in the cable should be at least 10 feet away from the
operator.
Electrode Holder – an electrode holder,
commonly called a stinger, is a clamping
device for holding the electrode securely
in any position. The welding cable
attaches to this holder through the hollow
insulated handle.
 Two general types of electrode holders are in use:
insulated and non-insulated. The non-insulated
types are not recommended because they are
subject to accidental short circuting if bumped
against the workpiece during welding. For safety
reasons, try to ensure the use of only insulated
stingers on the jobsite.

You require a larger holder when welding with a

machine having a 300-ampere rating than when
Ground Clamp – the ground clamp
welding completes
with the full
a 100-ampere machine. If the holder
electrical circuit so that enough heat will
is too small, beoverheat
it will available for
the welding job. It must be securely fastened to the metal
being welded or to an adjoining workbench or piece metal.

The use if a good ground clamp is essential to producing

quality welds. Without proper grounding, the circuit voltage
fails to produce enough heat for proper welding, and there
is a possibility of damage to the welding machine and
Three (3) basic methods are used to ground
welding machine.
You can fasten the ground calbe
to the workbench with a C-clamp

You may also choose

to attach a spring-
loaded clamp directly
onto the workpiece

The thirdway-bolting or tack-

welding the end of the ground
cable to the welding bench-
creates a permanent common
ground
Electrode – The electrode which come in
several types and sizes-consists of an
internal metal core and an outer coated
called flux which shields the weld. The core
melts into the molten base metal to produce
the metal bond
Cleaning Equipment

Strong welds require good preparation and procedure. The surface area
of the workpiece must be free of all foreign materials such as rust, paint
and oil.
Steel Brush – A steel brush is an
excellent cleaning tool and is an essential
part of the welder’s equipment. After
initial cleaning and a weld bead has been
deposited, the slag cover must be
removed before additional beads are
added.
 The Chipping or Slag Hammer was specifically
designed for this task. The chipping operation is
then followed by more brushing and this cycle is
repeated until the slag has been removed. When
the slag is not removed, the result is porosity in the
weld that weakens the weld joint.

Cleaning can also be accomplished by the use of

power tools or chemical agents. If these items
are used, it is essential that all safety
precautions are followed
Safety Equipment

Arc welding not only produces a brilliant light,

but it also emits ultraviolet and infrared rays
that are very dangerous to your eyes and skin.
Personal safety items include helmets, lenses
and gloves.

The heat of the arc, for instance, will heat all

of the metal being welded. You should always
use Tongs to carry or maneuver the metal
stock.
Another important item that needs to be
covered here is Welding Screens. The
welder not only has to protect himself but he
also must take precautions to project other
people who may be working close by. When
you are welding in the field, you must install
a welding screen around your work area. It
can be an elaborate factory-manufactured
screen or as simple as one constructed on
site from heavy fire-resistant canvas

A concern that is often overlooked is

if you are welding
ventilation. Weldingin produces
a tank or aother
lot ofenclosed
smoke area. Permanent welding
booths should
and fumes thatbe equipped
can with to
be injurious Exhaust
anthe welder,Hood and Fan System for
removal ofto
if allowed smoke and fumes.
accumulate. This is especially
true
Safety in Arc Welding
When arc welding, observe the following general safety practices

1. Wear gloves and eye and face protection. The welder and all observers
must wear welding helmets with a No. 10 or 12 filter lens. A welding cap or
helmet with a hard hat is also recommended for head protection. When
chipping slag or cleaning welds, wear a clear face shield or flip-up liftplate
on the helmet.

2. Avoid electrical shock. Make certain that the electrode holder and all
electrical connections and cables are properly insulated. Check to see that
the welder is properly grounded. Do not dip the electrode holder in water to
cool it because this practice may result in electrical shock.

3. Protect others. For small and practice welding jobs, work in a

partitioned area to protect others from harmful rays. When prepared to
strike the arc, inform all bystanders to cover their eyes.

4. Never weld in a damp area. Stand on a dry board or rubber mat if the
5. Never wear synthetic fiber clothing. Synthetic fibers are highly
flammable. Wearing clothing made from wool or cotton is safer for welding
because of their relatively high flash points.

6. Protect welding cables. Keep the cables from coming in contact with
hot metal and sharp edges. Do not drive over cables. When welding, avoid
wrapping electrode cables around your body.

7. Secure work. Use a welding table with a positioners to hold welds

securely in place. Clamps and vises can be used to hold odd- shaped work or
field work. Securing work will also prevent injury from accidental dropping
of metal on your feet or body.

8. Dispose of electrode stubs properly. Keep a container in the work area

in which to deposit electrode stubs. This prevents burns to shoes or falls due
to stubs rolling underfoot.

9. Prevent burns. Never allow the hot electrode or electrode holder to

touch bare skin. Avoid letting the electrode touch a grounded cable. Remove
10. Do not let the electrode stick. If the electrode sticks, cut off your
gloved hand. the switch, allow the electrode to cool, and then break it loose
with your gloved hand.

11. Use both hands. To reduce fatigue, use both hands for welding.

12. Handle hot metal with pliers or tongs. Submerge hot metal
completely in water to prevent steam burns.

13. Weld in a well-ventilated area. The fumes from lead, zinc, cadmium,
and beryllium are toxic and may cause sickness or death.

14. Do not carry matches or lighters, and do not allow bystanders to

smoke. Before welding, make sure the welding area is free of other
flammables (gas, grease, etc.).
Using Fire Extinguishers
Using Fire Extinguishers

Fire can have devastating consequences on a business and poses a

serious risk to the safety and welfare of workers. It is one event for which
a workplace should have a fixed action plan in place. This plan should
include a fire drill and escape routes. In the event of a fire, preparation is
the key to survival

When it comes to fire in the workplace, there can be a number of causes

and depending on the nature of your business, a fire can start because:
- Electrical office machinery may overheat and catch fire
- Grease on a cooking appliance may ignite
- Discarded paper and paper materials might catch fire from a
cigarette butt
- Arsonists set fire to waste material next to the premises

If a fire occurs at your workplace, it is important for you and anyone else
on the premises, such as customers and employees, to leave as quickly as
possible. Remember that smoke rises, so the best approach may be to
crawl low where it will be easier to breathe. If it is still possible to get
You should have designated fire point locations and exits in the
workplace. Fire point locations should be easily recognizable and clearly
visible. Color coding and/or using illuminated exit signs can achieve this.

In most parts of the country, commercial establishments are required to

have manual fire alarm call points, fire instruction notices, fire evacuation
plans and various types of fire fighting appliances, depending on the type
of fire likely to occur.

Keeping fire equipment at pre-agreed "fire points" provides workers with

easy access to fire fighting equipment or facilities, and also makes routine
servicing of the equipment much easier.

Where special risks are involved-like in the case of electrical work shops,
kitchens and storage areas for flammable substances suitable fire fighting
equipment should be positioned nearby.

Fire Point Locations

The following should be considered for the location of fire points:

 - Prominent locations not more than 30 meters apart

- Several fire points, each with a few appliances. rather than

concentrating all fire fighting equipment at only one location

- As near as possible to fire exit doors and, along main fire escape
routes (Do not obstruct fire points or escape routes in any way.)

- In some cases, it may be appropriate to combine the fire point

with other equipment e.g., emergency chemical spillage kit, first aid
equipment, emergency breathing apparatus, etc.

Fire Prevention

The arc welder is capable of producing temperatures in excess of 10,000

degrees Fahrenheit. Therefore, it is important that the workplace be made
fire-safe. This can be accomplished by using metal sheets or fire resistant
curtains as fire barriers.

The floor should be concrete or made from other fire-resistant material.

should be filled to prevent sparks and hot metal from entering.

When work cannot be moved to a fire-safe area, then the area should be
made safe by removing or protecting combustibles from ignition sources.

In certain welding situations it may be necessary to ask someone to watch

for fires that could go undetected until the welder has finished the job.

Suitable fire extinguishing aids such as buckets of sand or a dry chemical

extinguisher should be readily available.

What Kind of Extinguisher?

It is important to make sure you have the correct kind of extinguisher

because not all extinguishers work on all types of fires. Extinguishers that
are rated "ABC" are effective on most types of fire:
- Class A fires, (ones that leave an ash), involving ordinary
combustibles such as wood, paper, trash, clothing, etc.

- Class B fires, (ones that boil), involving flammable liquids such as

gasoline or grease.

- Class C fires (ones that involve a current) are energized electrical

fires.

You must select an appropriate extinguisher for the type of fire you hope
to extinguish. There are three (3) basic classifications for fire
extinguishers:
Keep extinguishers along the escape route, and near likely sources of fire.
Keep them out of reach of children. Do not locate might not be able to
reach it. extinguishers too close to where a fire may be likely to develop;
you might not be able to reach it.

How to use a Fire Extinguisher Properly

Fire extinguishers are useful tools for putting out certain kinds of small
fires. Firefighters stress, however, that their value is limited to small fires
that are not spreading rapidly. With or without an extinguisher, the most
important safety tip in the event of fire is to get out of the burning
building.

Parts of Fire Extinguisher

Use an extinguisher only if:

1. You have first called the Fire Department

2. The fire is small and not spreading
3. The fire is not between you and your exit
4. You know the extinguisher is the correct type for what’s burning
5. The extinguisher is in working order
6. You know how to use it. It’s too late to read the instruction when the
fire is burning

To operate the extinguisher properly, remember to PASS:

By doing things right, you and your co-workers
will commit yourselves to safety on the job and
everyone will benefit. Accidents occur in many
ways but most often can be traced back to one
of two basic factors: ignorance or
carelessness. You must always be concerned
with your own safety and with the safety of
others around you.
Surprise! May Exam 

Module Assessment
Module Assessment

1. Which of the following is NOT a type of arc welding power supply?

a. Rectifier
b. Transformer
c. Alternator
d. Generator

2. The purpose of the ground clamp is to:

3. The flux of an electrode

a. form a gas
b. creates slag
c. forms a shield for the weld
d. all of the above
4. The best material to use for protective clothing, footwear and gloves is:
a. nylon
b. leather
c. polypropylene
d. dacron

5. The darkest and most protective lens available for welding purposes is:
a. Shade 5
b. Shade 7
c. Shade 14
d. Shade 20

6. The ground clamp should be attached to:

a. non-conductive block of wood
b. the project or worktable
c. a properly grounded bolt mounted on the floor
d. the electrode
7. When the voltage setting is too low, the weld:
a. spatters and undercuts
b. digs a deep crater
c. leaves the weld puddle exposed to oxidizing air
d. provides poor penetration with a high, narrow head

8. Fire extinguishers for welding areas should be suitable for:

a. Class A fires
b. Class B fires
c. Class C fires
d. all of the above

9. What does the acronym PASS mean in relation to Fire Extinguishers?

10. Identify at least (3) pieces of protective clothing and briefly discuss each

11. Identify at least (3) pieces of welding equipment and briefly discuss their
uses
12.

15.

13.

14.
Thank you Gar
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