011 welding and cutting hazard assessment program

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Safety Policy and Procedure

Policy Number 015 Author ized By: The Cianbro Companies Alan Burton

Title: Welding and Cutting Hazard Assessment Program Effective Date: 09/16/95

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1 Status

1.1 Update of existing policy, effective 06/03/11.

2 Purpose

2.1 To provide guidelines and requirements to protect team members from the hazards associatedwith welding, cutting, and burning operations.

3 Applicability

3.1 This policy applies to all subsidiary companies and departments of the Cianbro Companies.

3.2 All organizations are required to comply with the provisions of this policy and procedure. Anydeviation, unless spelled out specifically in the policy, requires the permission of the SafetyDirector or designee.

4 Definitions

4.1 Adequate Ventilation: Used in this policy means any of the following: Local exhaust ventilationis used to capture fumes or in open area with adequate air movement or adequate dilutionventilation with directional air flow away from team member.

4.2 Air Arc (Carbon Arc): A cutting process by which metals are melted by the heat of an arc usinga carbon electrode. Molten metal is forced away from the cut by a blast of forced air.

4.3 Bug-O BUG-O Systems Inc.: A manufacturer of a system of drives, carriages, rails andattachments designed to automate welding guns, cutting torches and other hand held tools.

4.4 Cad Welding: An exothermic (gives off heat) welding process that fuses conductors together toform a molecular bond with a current-carrying capacity equal to that of the conductor. Typicallyused in grounding systems.

4.5 Downdraft Table: A downdraft table is a work station for welding (or grinding and cutting) thatprovides a ventilated table to work on top of. The air and contaminant is drawn down throughthe table and away from the worker.

4.6 Flux: A substance which facilitates welding (and soldering and brazing) by chemically cleaningthe metals to be joined. The primary purpose of flux in welding is to prevent oxidation of thebase and filler materials Note: Flux typically contains fluorides


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4.9 Inadequate Ventilation: As used in this policy means local exhaust ventilation is not being usedor work is inside enclosed spaces with inadequate air movement or any other location withinadequate air movement or the air movement draws the contaminants through breathing zoneof the team member.

4.10 Lance Rod: Thermal lance rod is a cutting tool that utilizes ignited iron (or aluminum ormagnesium) fed with a stream of pressurized oxygen. A steel tube packed with steel rods (and

aluminum or magnesium) is connected to a valved handle assembly fed by an oxygen line andtank. An intensely hot (6k - 10 k degrees Fahrenheit) oxy/steel fueled jet is created at the tip.

4.11 The National Institute for Occupational Safety and Health (NIOSH): Federal agency responsiblefor conducting research and making recommendations for the prevention of work-related injuryand illness. NIOSH is part of the Centers for Disease Control and Prevention (CDC) in theDepartment of Health and Human Services. It is essentially the research arm of OSHA and isresponsible for approving respirators.

4.12 Oxy-Fuel Cutting: A mixture of oxygen and the fuel gas is used to preheat the metal to its

'ignition' temperature which, for steel, is 700°C - 900°C (bright red heat) but well below itsmelting point. A jet of pure oxygen is then directed into the preheated area instigating avigorous exothermic chemical reaction between the oxygen and the metal to form iron oxide orslag. The oxygen jet blows away the slag enabling the jet to pierce through the material andcontinue to cut through the material. Typical fuel gases used are acetylene, propane, MAPP(methylacetylene-propadiene), and propylene.

4.13 Plasma Cutting: Arc cutting process which severs metal by using a constricted arc to melt asmall area of the work. This process can cut all metals that conduct electricity.

4.14 Shielded Metal Arc Welding (SMAW) or (Stick Welding): Arc welding process which melts and joins metals by heating them with an arc, between a covered metal electrode and the work.Shielding gas is obtained from the electrode outer coating, often called flux. Filler metal isprimarily obtained from the electrode core.

4.15 Sub-Arc Submerged Arc Welding: A process by which metals are joined by an arc or arcsbetween a bare metal electrode or electrodes and the work. Shielding is supplied by a granular,fusible material usually brought to the work from a flux hopper.

4.16 Threshold Limit Values TLV® (TLVs): Guidelines, not standards prepared by the AmericanConference of Governmental Industrial Hygienists, Inc (ACGIH) to assist industrial hygienists in

making decisions regarding safe levels of exposure to various hazards found in the workplace. A TLV® reflects the level of airborne exposure that the typical worker can experience withoutan unreasonable risk of disease or injury. Cianbro uses the TLV in situations where it is moreprotective than the OSHA PEL. Some definitions obtained from the Miller ElectricManufacturing Co. website

4.17 Tungsten Inert-Gas Welding (TIG) or Gas Tungsten Arc Welding (GTAW) (HELIARC): Joinsmetals by heating them with a tungsten electrode which should not become part of thecompleted weld. Filler metal is sometimes used and argon inert gas or inert gas mixtures areused for shielding.

5 Policy

5.1 Adequate ventilation is required during welding and cutting operations. If adequate ventilation isnot provided then respiratory protection is required.

6 Responsibilities

6.1 The top Cianbro manager of the job site is responsible for the implementation of this policy on


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7 Welding and Cutting Hazard Assessment Program Index

7.1 Health Effects .........................................................................................................................................3 7.2 Pre-Job Welding and Cutting Hazard Evaluation ................................................................................... 3 7.3 Engineering and Administrative Controls ............................................................................................... 6 7.4 Respiratory Protection ............................................................................................................................ 7 7.5

Exposure Monitoring............................................................................................................................... 7

7.6 Medical Surveillance............................................................................................................................... 8 7.7 Training................................................................................................................................................... 8 7.8 Physical Hazards.................................................................................................................................... 8 7.9 Safety At Home....................................................................................................................................... 9 9.1 Appendix A Minimum Respiratory Protection for Cutting and Welding Processes.............................. 10 9.2 Appendix B Exposure Guidelines for Welding Fumes and Gases.......................................................11 9.3 Appendix C Associated Guidelines for Gases Associated with Welding and Cutting.......................... 12

7.1 Health Effects

Welding, burning, and cutting produce metal fumes and gases that can be hazardous to yourhealth. Breathing in these fumes and gases can and does make people sick. Luckily, a healthybody clears most toxic substances including welding fumes. Still, you can be exposed to toomuch of any fume or have a medical problem that makes you more likely to get sick fromexposure to welding and cutting fumes. The length of time that you are exposed to these gasesand fumes, the type of hot work you do, the work environment, and the protection you use

determine the risks to your health and how you will be affected.

Like most other toxic substances, welding and cutting fumes have “acute” effects that mayoccur as soon as or shortly after you are exposed. Acute effects can include headache, cough,shortness of breath, eye irritation, or metal fume fever. Welding and cutting fumes also have“chronic” effects that may not be noticed for years. These effects may include lung, kidney,bone or joint disease and even cancer. Most acute effects are caused by brief overexposures.These effects almost always go away within a day or two and don’t cause any permanentdamage. Chronic effects from lower exposures over longer periods of time, like lung disease orcancer, are more serious and can sneak up on you before you know it. Any time you think youare having any unexplained symptoms or effects, let your safety specialist know as soon aspossible.

Pay attention to what you weld or cut, where you are welding or cutting, and which process youare using. Be sure to provide for appropriate ventilation and use all required PPE. Remember,the best “treatment” for any toxic exposure is prevention!

7.2 Pre-Job Welding and Cutting Hazard Evaluation

Before starting any task that involves welding, cutting and burning a pre-task hazard analysis isrequired. This should be done as part of the activity planning process and will include bothhealth hazards and physical hazards (see section 7.6). Once the hazards are identified,appropriate engineering and administrative controls and personal protective equipment (PPE)can be selected to keep team member exposure to as low as reasonably practicable. Whendoing a hazard evaluation, make sure to include surrounding workers that could also haveexposure and make provisions to protect them as well. Special precautions and planning are


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What base metals are being worked on?

Base Metal Contaminant GeneratedCarbon (Mild) SteelStainless Steel

Galvanized AluminumExotic metals

Iron oxide, manganeseIron oxide, hexavalent chromium, nickel, ozone gas, manganese

Iron oxide, zinc oxide, manganese Aluminum, ozoneBeryllium, titanium (examples)

Iron, Zinc, Aluminum – have relatively high exposure limits. If welding outdoors, naturalventilation and limiting actual welding time during the day should suffice for controllingexposures. For indoor welding or confined spaces, available mechanical or natural ventilationwill need to be reviewed on a case-by-case basis along with daily duration of welding. Ifrespirators are required, any “100” efficiency particulate respirator should be adequate

(assuming sufficient oxygen is present).

Chromium, Nickel, Cadmium - are suspect human carcinogens, have very low recommendedexposure limits and therefore will require more careful planning in regards to ventilation. Thereis a new OSHA standard for Hexavalent chromium with a very low permissible exposure limit(5.0 ug/m3). Limiting the amount of welding time per day is not allowed as a control option forcadmium or chromium. If respirators are required, “100” efficiency respirators and possibly airsupplied respirators should be used. See 29CFR1926.1127 for cadmium specific regulationsand 29CFR1926.1126 the hexavalent chromium standard.

Note: Working with stainless steel is much more dangerous than working with galvanized steelbecause the hexavalent chromium and nickel in stainless have serious long term health effectswhile the zinc from galvanized causes metal fume fever but has no known long term healtheffects.

Manganese - Manganese is a highly reactive gray-white metal resembling iron, and addingmanganese to steel increases its hardness, stiffness and strength. Manganese is a majorcomponent of welding fumes, particularly those from mild steel welds using shielded metal arcwelding (SMAW). Mild steel is the most common steel used in industry, and SMAW is the most

common type of commercial welding, but manganese exposures can result from other types ofwelding as well.

Exotic Metals - contact Safety Department for consultation.

7.2.1 What type of welding process is being used?

Welding Process Contaminant Generated

Flame cuttingGas metal arc welding (MIG)Gas tungsten arc welding (heli-arc or TIG)Plasma cuttingCarbon arc (air arc) cuttingFlux cored arc weldingShielded metal arc welding (stick)Cad WeldingLance rod cutting

Carbon monoxide, oxides of nitrogenUV radiation, ozone, CO if CO2 gas is used, lowoxygen, manganeseUV radiation, ozone, oxides of nitrogenOzone, oxides of nitrogen, noise, low oxygenNoise, iron oxide, copperBarium, iron oxide, aluminum, magnesiumUV radiation, fluorides, manganeseCopper oxide, aluminum, fluorides, heat (exothermicreaction)


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Noise - Exposure to excessive noise may cause noise induced hearing loss. All weldingoperations should be reviewed for noise exposure. Plasma arc, arc air gouging, andmetal spraying will almost always require use of hearing protection devices.

Low oxygen - Oxygen deficiency (less than 19.5%) is possible whenever gas shieldsare use in confined spaces, or areas with poor ventilation. Note: Improper use ofoxygen in a confined space can produce an oxygen-enriched atmosphere - a seriousfire and explosion hazard.

Oxygen Enrichment – Oxygen present at levels higher than 21% makes flammable andcombustible materials burn violently when ignited.

Aluminum, magnesium, and copper fume – may cause metal fume fever and irritationof the respiratory tract. Aluminum and magnesium have relatively high exposure limitswhile copper fume has a relatively low exposure limit of 0.2 mg/m3.

UV Radiation - See Section 7.6

7.2.2 What is in the welding rod or filler rod being used?

MSDS must be reviewed to determine what components (e.g. filler metals, fluxes) maybe in the welding rod being used. Hazards and controls will vary with the specific rodused. Some rods will be copper coated (e.g. gas metal arc). Excessive exposure tocopper may cause metal fume fever. Other rods contain manganese. Fluoride fluxesmay cause irritation to the eyes, nose and throat.

7.2.3 Are there any coatings or cleaning solvents residue on the object to be welded?

Coating or Solvent ContaminantPaint primers or coatings

Plating or corrosion protectionPolyurethanes, isocyanate based paintsMarine coatings, anti-foulingChlorinated solvents

Anti-spatter (may contain chlorinated solvents)Residue from previous contents

Lead, Cadmium, Zinc, HexavalentChromium (lead chromates, zinc chromates)CadmiumVariety of organic pollutants (e.g.diisocyanates)Mercury, tin

Decomposition products (e.g. phosgenegas)Refer to MSDS

Varies, refer to MSDS

Note: Preferred control method is to remove coating or solvent prior to welding.

Lead, Cadmium and Chromium - For lead see Cianbro’s Workplace Lead and OtherHeavy Metals Safety Policy and Procedure and 29CFR1926.62 for lead specificregulations. For hexavalent chromium see 29CFR1926.1126 and for cadmium see29CFR1926.1127. Cadmium plating on bolts and nuts is common in high corrosionareas.

Chlorinated solvents (e.g. trichloroethylene, perchloroethylene) - Chlorinateddecomposition products (e.g. phosgene) especially common with high UV producingwelding


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Anti-spatter compounds - May contain chlorinated solvents.

Residue from previous contents - Know what material was present in the tank or linebefore beginning hot work. Refer to the MSDS.

If caustic was present, it may leave traces of mercury in the metal due to the processused to manufacture the caustic.

Paper mill stock lines may contain hydrogen due to anaerobic bacteria called Clostridia:There have been several reported cases of explosions in the literature attributed tohydrogen. The anaerobic condition required is most likely to be present duringshutdown conditions. Ventilation of stock lines and tanks can control this hazard.Hydrogen may show up as a reading of carbon monoxide and LEL on a multigasmonitor. It can be tested for using colorimetric (detector) tubes.

7.3 Engineering and Administrative Controls

7.3.1 Once the hazards are identified, determine what controls will reduce or eliminate therisks. The most effective way to protect you from the hazards associated with hot workis to substitute less hazardous materials or methods, make physical changes in thework environment, and use administrative controls (safe work practices). Below aresome engineering and administrative controls that should be considered for each task.

• Spec areas to be welded on new material to be left bare of coatings.

• Spec bolt-up connections rather than welds.

• Use mechanically guided welding processes (e.g. Bug-O) so welder can stay backaway from the plume.

• Use welding guns that capture the fume. These units are highly recommended forall work using wire feeders. They control the contaminants at the point ofgeneration.

• Use general ventilation (air movers to blow or exhaust the fumes away from you)making sure the fumes are not drawn through your breathing zone or exposingother workers. As a rule of thumb, visible welding fume should clear within 30seconds of the welding stopping or it is probably not adequate.

• Use local exhaust ventilation positioned 4”-6” from the work to remove fumes and

gases at their source. This is the most effective form of ventilation and should beused whenever possible, especially in fab areas and fixed locations.

• Stay out of the plume! Make sure you position yourself so the plume does not passthrough your breathing zone. Also, pay attention to other welders as they may noteven realize that they are in the plume.

• Move the work into open areas if possible. Do not work in confined or enclosedspaces if it is not necessary.

• Use mechanical means rather than hot work (sawcut grating rather than burning tosize or rivet bust rather than burn rivets off, etc.). There is a circular saw available

that cuts grating, angle, pipe, etc. up to 2 inches thick as easily as cutting plywood.• Limit the length of time you weld during a shift. Sampling results should be used to

determine safe lengths of time to weld.

• Use long-handled torches.

• Remove all coatings and residues from the pieces to be welded. For paint andother preservative coatings remove at least 4 inches back from the point of heatgeneration Far enough back that the operation does not raise the temperature of


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7.3.2 Is the Ventilation Adequate or Poor?

Adequate Ventilation: The following situations would be considered adequateventilation.

• Local exhaust ventilation is used to capture fumes (must be positioned within oneto two duct diameters of the work) or

•

Work is in an open area with adequate air movement or• There is adequate dilution ventilation with directional airflow away from teammember (the fume cannot be drawn through the team member’s breathing zone) or

• Fume capture guns are used.

Poor Ventilation: The following situations would be considered poor ventilation.

• Local exhaust ventilation is not used and

• The work is inside enclosed spaces with poor air movement or

• The air movement draws the contaminant(s) through the breathing zone of theteam member.

If you are not sure if you have an adequate or a poor ventilation situation, then considerit poor ventilation. If adequate ventilation can not be provided, respirators are required.

7.4 Respiratory Protection

If adequate ventilation cannot be provided, all jobs will require a respirator until air samplingproves otherwise! If a respirator is required you must follow the requirements of29CFR1910.134 and Cianbro’s Respiratory Protection Program Safety Policy and Procedure.

Respirators are a last resort and should be used only when feasible engineering andadministrative controls are not enough. Refer to Appendix A of this Safety Policy andProcedure for minimum respiratory protection requirements for the most common hot workactivities. Respiratory protection is almost always required when welding in a confined space.

7.5 Exposure Monitoring

OSHA has limits for exposure to the metals, gases, and fumes during welding. However someof these limits are out of date and may not protect you enough. Other more protective published

limits may be used like the ACGIH Threshold Limit Values. These more protective suggestedlimits should be used in most cases to better protect the health of our team members. NIOSHhas reported that the levels of sickness and death are higher than expected in welders, evenwhen the exposures are below the current OSHA PEL’s for the many individual components ofwelding emissions. NIOSH also says welding fumes may cause cancer. Therefore it is veryimportant to keep exposure to welding fumes as low as possible.

When deciding what to sample or monitor for the safety specialist needs to be involved and willuse the information obtained in the pre-job hazard evaluation required in Section 7.2 of thisSafety Policy and Procedure. Sampling is the only way to know whether or not our teammembers are being protected from the airborne hazards associated with the welding process.

7.5.1 Metals

The metals will be sampled using the same procedure as for lead and multiple metalcontaminants can be tested from a single sample. Typical sampling would includemanganese for mild steel and hexavalent chromium for stainless steel Hexavalent


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7.5.2 Gases

Gases can usually be monitored using direct reading instruments such as multi-gasmonitors and detector tubes. These should be used to determine if ventilation and othercontrols are adequate and to determine if further monitoring should be done. Todetermine actual team member exposure however, personal air sampling needs to bedone using either passive monitors or a sample pump and appropriate collection mediasuch as cassettes or charcoal tubes. Contact the Manager of Health and EnvironmentalHazards, the Scott Lawson Group,Travelers Laboratory, or other approved laboratory to obtain the correct samplingmedia and method. Reference Appendix C for exposure limits.

7.6 Medical Surveillance

Any team member who performs welding or cutting for Cianbro is required to fill out the weldingand cutting section of the periodic medical questionnaire. Cianbro’s Medical Director will use

this information along with other information (like the PFT results every third year) to determinethe need for a welding physical and/or other medical testing. Reference the welding/cuttingportion of the periodic medical questionnaire in Appendix B. If there are any symptoms possiblycaused by exposure to welding processes report it to your supervisor and safety specialist.Symptoms can be very similar to many other types of illnesses so it is important to report them.The job site will contact Occupational Medical Consulting as soon as possible to help determinethe proper care and to recommend specialty evaluation. Cianbro’s Medical Director will makerecommendations for medical removal from the welding environmental, PPE, and other actionsto reduce ill effects from exposure as necessary.

7.7 Training

Team members who perform welding or operate and maintain oxygen/fuel gas equipment forCianbro must be trained initially and annually in the contents of this Safety Policy andProcedure and the content of applicable OSHA standards. Team members in charge ofoxygen/fuel gas supply equipment must be trained and deemed competent to do so. Inaddition, the OSHA Hazard Communication standard 29CFR 1926.59 requires team membersto be trained in the hazards of the materials that they may come into contact with. To meet thisrequirement, the results of the pre-job welding and cutting hazard assessment must be coveredwith the crew as part of the activity plan review.

7.8 Physical Hazards

7.8.1 Radiation – arc welding produces three types of radiation:

• UV radiation burns exposed skin much like an sunburn and affects the cornea ofthe eye which causes “flashburn” that feels like sand in the eye.

• Visible radiation produces an intense light from the arc that can damage the retinaof the eye.

• IR radiation generates intense heat that can cause burns when sparks and spatterfly off the welding process or hot metal and sparks blow out from the cuttingprocess. Burns can also occur when touching hot work pieces or equipment.

For eye protection, use lens shade as recommended by OSHA 29CFR1926.102 TableE-2. Welding helmets are considered secondary eye protection and must be used withprimary protection (e g safety glasses side shields and UV protection) Other workers


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7.8.2 Electrical Shock

Inadequate grounding of equipment, worn or damaged leads, lack of proper gloves andworking in wet conditions can lead to electrical shock. Electrical shock from weldingand cutting equipment can kill, cause severe burns, or result in serious injury form fallscaused by the shock. Equipment and sometimes the work piece should be grounded.Use a separate connection to ground the equipment or work piece to the earth. Clothesand work surfaces should be dry. If the work area is wet you must eliminate the hazardby moving out of the wet area, protecting from dripping, raising the work up out of thewet, etc.

7.8.3 Fire and explosion can result from welding or cutting close to combustible materials,from leakage of welding or cutting gases through poorly fitting or leaking hoses, fromvapors given off by flammable liquids too close to the work (the vapors can travel untilthey encounter a source of ignition and then flash back), from welding on tanks orcontainers that have held flammable or combustible materials. To reduce the risk from

fire and explosive wear flame retardant clothing (gauntlet gloves, wool or tight weavecotton or leather long sleeved shirt, coveralls without cuffs), inspect the work area andremove or protect all combustibles prior to starting, use a trained fire watch, haveappropriate extinguishing media available. Report any equipment defects or otherpotential hazards to your supervisor. Remove any defective equipment from serviceimmediately and either replace it or have it repaired by a qualified person. Use a hotwork permit when appropriate to ensure the area is safe for hot work. Refer toCianbro’s Watch for Fire, Smoke, and Sparks Safety Policy and Procedure foradditional information and for a Hot Work Permit form.

Never carry a butane lighter when doing hot work; sparks or slag may cause it toexplode.

7.8.4 Heat stress must be considered due to the protective clothing worn and the heatgenerated from the welding process especially when there are high ambienttemperatures (indoors or out doors), work in confined spaces, or spaces withinadequate ventilation. Follow Cianbro’s Exposure to Heat and Cold Safety Policy andProcedure.

7.8.5 Noise is a hazard in the welding environment because of the process (air arc andplasma arc cutting are very noisy for example), the power source, other equipment inthe area, and other operations going on like grinding. If engineering or administrativecontrols like shielding the noise source or separating operations by distance or timedon’t reduce the hazard to an acceptable level, then appropriate hearing protectionmust be used. Refer to Cianbro’s Hearing Conservation Program Safety Policy andProcedure.

7.9 Safety At Home

Welding and other hot work provides the same hazards whether you are at home or at workother than possibly length of exposure. Please follow the guidelines contained in this policy tohelp recognize and control hazards associated with welding and other hot work performedoutside of work.


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Policy: 015 Welding and Cutting Hazard Rev. 06/03/11 Page 11 Assessment Program

9.2 Appendix B Exposure Guidelines for Welding Fumes and Gases

Exposure Guidelines for Welding Fumes and Gases

8-Hour Time-Weighted Average (TWA)Exposure LimitMaterial (Fumes)

OSHA PEL

1

(mg/m3) TLV

2

(mg/m3)

Potential Effects and Symptoms From Overexposure3

Aluminum 5 (respirable) 5 Skin irritation, respiratory system irritation, pulmonary fibrosis

Arsenic 0.01 0.01 Respiratory irritation, lung cancer, dermatitis

Beryllium 0.0020.005 (C)

40.002 Lung disease (berylliosis), lung cancer, eye irritation

Cadmium 0.005 0.0020.01 STEL

5Respiratory irritation, lung congestion, abdominal pain, kidney damage,yellow ring on teeth

Chromium II & III Compounds and metal 0.5 0.5 Lung disease, nasal irritation, sensitization, eye irritation

Chromium VI compounds (insoluble) 0.005 0.01 Lung cancer, nasal irritation and perforation, liver and kidney effects

Cobalt 0.1 0.02 Lung disease, wheezing, hypersensitivity, asthma, cardiovascular system effects, eye irritation

Copper 0.1 0.2 Metal fume fever, respiratory irritation, skin and hair discoloration

Fluorides 2.5 2.5 Respiratory irritation, mottling tooth enamel, bone changes, kidney effects

Iron oxide 10 5 Siderosis (pigmentation of the lung)

Lead 0.05 0.05 Central nervous system effects, lead poisoning, reproductive system effects

Magnesium oxide fume 15 10 Metal fume fever, eye and nose irritation

Manganese fume 5(C)4

0.2 Nervous system effects(Parkinson’s), pneumonia, reproductive system effects, metal fume fever

Mercury 0.1(C)4

0.025 CNS effects, kidney and reproductive effects, eye irritant, cough, chest pain

Molybdenum 5 5 Respiratory irritation, liver and kidney effects

Nickel 1 0.2 Asthma, congestion, lung disease, carcinogen, sensitization

Tin 5 (respirable) 2 Stannosis-benign lung disease

Titanium dioxide 5 (respirable) 10 Lung fibrosis, potential carcinogen

Vanadium 0.05 0.05 Respiratory irritation, bronchitis, emphysema, pneumonia, green tongue, cough

Zinc oxide fume 5 (respirable) 5 Metal fume fever, cough, chest pain

Welding fumes – not otherwise classified 5 (respirable) 5 Depends on components of fume, metal fume fever, irritation, cough, pulmonary edema


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Policy: 015 Welding and Cutting Hazard Rev. 06/03/11 Page 12 Assessment Program

9.3 Appendix C Associated Guidelines for Gases Associated with Welding and Cutting

Exposure Guidelines for Gases Assoc iated with Welding and Cutting

Material (gases) PEL (ppm) TLV (ppm) Potential Effects and Symptoms From Overexposure3

Argon None None Simple asphyxiant

Carbon dioxide 5000 30000 STEL5

Mild narcotic effects, respiratory effects, headaches

Carbon monoxide 50 25 Headaches, drowsiness, asphyxiation, anoxia

Hydrogen chloride 5(C)4

5(C)4

Strong irritation, dermatitis

Hydrogen fluoride 3 3(C)4

Skin, eye, respiratory irritations, bone effects

Nitric oxide 25 25 Cyanotic effects, anoxia, eyes and skin irritation

Nitrogen dioxide 5(C)4 35 STEL

5Eye, nose, throat irritant, chronic bronchitis, lung congestion, chest pain,cough

Ozone 0.1 Light work 0.1Moderate 0.08Heavy 0.05

Any work 0.2

Respiratory irritation, lung congestion, bronchitis, headache, dry throat, premature aging

Phosgene 0.1 0.1 Lung congestion, chronic lung changes, anoxia, eye irritation

1 OSHA Permissible Exposure Limit (PEL) as listed in 29CFR 1926.55 and accompanying standards as of 2/1/2000.

2Threshold Limit Value (TLV) as published in the 2000 TLV and BEI booklet by the American Conference of GovernmentalIndustrialHygienists (advisory guidelines only).

3Primary reference sources: 1997 NIOSH Pocket Guide to Chemical Hazards and the TLV Basis-Critical Effects as publishedin the 2000 TLV and BEI booklet

2.

4 Ceiling Limit, not to be exceeded without respirator use.

5

Short Term Exposure Limit.

011 welding and cutting hazard assessment program

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