Ergonomics in Welding

What You Will Learn: How to identify Work-Related Musculoskeletal

Disorders (WMSD’s) in welding jobs

Propose solutions for hazardous exposures

Find further information about ergonomics in welding operations

Common Hazards

Common hazards found in welding are: Inhaling metals fumes

Eye exposure to welding arc light

Foreign objects in eyes

Burns

Noise

WMSD HazardsWelding also includes musculoskeletal disorder (WMSD) hazards such as:Awkward body postures

Lifting heavy equipment or materials

Static postures for prolonged periods

Awkward postures of the wrist

By Nature of Injury

Sprains account for more than 1/3 of the compensable claims among welders in the State of Washington.

Some of those could be caused by hazardous WMSD exposures.

WA State-funded compensable claims 1994-2004Welders, Cutters, Solderers

Hearing loss11%

I ll-Def Symptoms

9%

Neural5%

Other13%

Sprains32%

Contussion/Cut/

Scratches 16%

Fracture/Dislocation

14%

WA State-funded compensable claims 1994-2004Welders, Cutters, Solderers

Other15%

Ears11%

Back/ Neck/Shoulder

28%

Hand / Arm 26%

Foot/Leg

20%

By Body PartThe back, neck and shoulder together with the arm and hand regions make up more than one half of the injuries among welders in Washington State.

Preventive efforts should therefore focus on those body parts among welders at your workplace.

Welding is a strenuous occupation involving work in awkward postures and handling heavy equipment, usually with a high degree of sustained stress to arm and shoulders.

Absences due to injury or illness and the transfer of welders to other tasks

Overtime for replacement workers. Welders are skilled employees

High employee turnover

Increased training and supervisory time

Reduced productivity and quality

Consequences of a poor working environment

Rigorous manual precision requirements– High degree of uniformity

Awkward and static postures– Difficult work position

Heavy lifting, difficult material handling– Heavy objects, heavy welding equipment

Repetition– High work intensity

OFTEN, MORE THAN 1 RISK FACTOR IS PRESENT

WMDS hazards most common in welding

Duration (how long?)

Frequency (how often?)

Intensity (how hard?)

Hazard Elements

Working in front

Working at ground level

Working above the shoulders

Working at ground level, precision work

Working at ground level, confined space

Working above shoulders, confined space

Common postures adopted in welding

Torso twistingAwkward postures in weldingSevere torso flexion

Kneeling, squatting

Bent wrists

Neck flexion/extension

Shoulder flexion/abduction (separation)

Awkward Postures

To simplify the welding tasks for the welder and reduce the physical load during the work

Automate physically demanding or repetitive jobs

Expand the work content of welders (provide flexibility between jobs)

– (Multi-skilled workers who are able to perform different tasks within a group)

The goal of a healthy work environment

Often cost, ease of maintenance, space considerations drive the design of the workplace

When hazards can’t be engineered out, using best practices is a good alternative

Examples of good design: providing opportunities for work station adjustments, providing different types of tools, using good planning to eliminate unnecessary work

The Real World

Ergonomic Solutions for Welding

Heavy Lifting

Use:• Manipulators• Lighter weight

welding equipment• Lighter weight cables

with low stiffness• Cable supporting

balancers• Overhead hoists• Lifting and turning

tables

Awkward Postures

• Position work between waist and shoulder when possible

• Provide lifting tables• Use motorized

positioning devices• Use welding guns with

swivels and designed for use in both hands

• Try work stools

Team Lifting

Team lifting helps reduce heavy, awkward lifting of equipment and materials.

AFTER

From: SIMA San Diego Ergonomics Program

BEFORE

Tables

This picture shows the worker with considerable bending over at the waist

AFTER

From: Shipyard Ergonomics, 2003

BEFORE

Because the work is on a table, the worker doesn’t have to bend over as far

Pre-Assembly

Pre-assembly and material handling equipment helps reduce unnecessary lifting or any other kind of manual material handling

Ergonomic improvements

This rotational clamp for pipe helps reduce awkward postures for the neck, shoulders and arms.

Ergonomic improvements

Use wheeled tables for welding work and to transport stock and jobs. This reduces lifting and carrying of heavy materials.

Ergonomic improvements

Welding leads on pulleys help reduce heavy and awkward lifting, and minimize static postures.

Ergonomic improvements

Robotic automation is a feasible solution to highly repetitive motion with the arms and hands. May also reduce the exposure to fumes.

Not implementing some or all these ergonomics guidelines may result in the following…

Possible Consequences

•Occur when the physical demands of work cause wear and tear on the body.

•Involve soft tissues such as muscles, tendons, ligaments, joints, nerves, blood vessels.

They are cumulative (occur over time and not a result of a single incident):

Work-related musculoskeletal disorders

Work-related musculoskeletal disorders

•Broken bones•Cuts•Slips•Falls•Trips•Motor vehicle accidents•Being struck by or caught with objects

They are not acute injuries such as:

Back injuries Shoulder pain/loss of range of motion Tendinitis/Bursitis Reduced muscle strength Carpal tunnel syndrome White finger Knee joint diseases

Common disorders among welders

The Ergonomics Cycle

The ergonomics cycle shows an organized way to start your ergonomics effort.

EmployeeInvolvement

Evaluateprogress

Management Support

ProblemIdentification

SolutionImplementation

Address Injuries

Training

SHARPSafety & Health Assessment &

Research for Prevention

Credits The technical contents of this slideshow are based upon the presentation developed by Ninica Howard, MS, CPE, research ergonomist with the SHARP program at the Washington state Dept. of Labor and Industries.

More resources

NIOSH’s Ergonomic Interventions in the Building, Repair, and Dismantling of Ships

SHARP Program

Easy Ergonomics. A practical approach for improving the workplace OR OSHA & CAL OSHA Services. www.cbs.state.or.us/osha/pdf/pubs/3347.pdf

On WMSD hazardous exposures visit the DOSH webpage at:www.lni.wa.gov/Safety/Topics/Ergonomics

Example Template of an accident prevention program :www.lni.wa.gov/Safety/Basics/Programs/Accident

Ideas to reduce hazardous exposures can be found at the Ergonomics Ideas Bank

You may also write us at:ergonomics@LNI.WA.GOV

Thank you

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