Welders are in the business of fusing metal or thermoplastic parts using heat and pressure. They work in one of the most dangerous occupations and within some of the most hazardous industries. When things go wrong, severe and sometimes deadly injuries can result.
Welding is a type of job known as ‘hot work’ because performing the work can produce flames or sparks. Welding can expose a worker to a significant risk of injury if equipment fails or appropriate safety procedures are not followed.
When welding injuries occur on the job, a worker’s employer is usually responsible for paying the worker’s medical expenses and compensating the worker for lost earnings. The severity of a welding injury often depends on the conditions under which a welder is working. The more dangerous the working conditions, the greater the likelihood of severe injury.
Injury Risks Faced by Welders
Though the environment in which welding is performed can undoubtedly increase the risk of injury, the welding process’s most common injury risks encountered by welders are by-products. Arc welding is the most common way of fusing pieces. The light emitted from arc welding contains ultraviolet radiation (UVR). Like the sun, the ultraviolet radiation from welding can burn exposed skin and eyes. Prolonged exposure can lead to developing cancer.
Welding also emits chemicals into the air. As the metal piece and the metal filler are being melted to be fused, a smoke containing harmful metals and gases is produced. Breathing the fume is toxic, and prolonged exposure can result in respiratory issues, internal organ damage, and cancer. Some gases reduce available oxygen and can create a suffocation hazard if ventilation is poor.
Most Dangerous Welding Jobs
The environment where welding is performed can elevate the risk of accidents and injury. Performing welding in the following environments is more dangerous for workers because of the conditions under which the work is done.
Underwater Welding
Underwater welding is one of the most dangerous jobs.
An underwater welder is both a welder and a diver. Underwater welding is necessary to maintain and repair submerged marine structures – like offshore oil rigs and pipelines. Underwater welders use electricity and rely on safety equipment to remain alive underwater. They may be exposed to electrocution, explosions, hazardous materials, and drowning.
Welding in the Oil and Gas Industry
Workers in the oil and gas industry know the danger of sparks and flames where flammable liquids and gases are present. Welders may work in confined spaces where ventilation is inadequate and are at risk for injury from fires, explosions, and exposure to toxic substances.
Construction Welding
Welders in the construction industry are responsible for ensuring the structural integrity of large building projects such as bridges and skyscrapers.
Welders working on construction sites work in dangerous locations and are at risk of many construction injuries.
Welders can work at significant heights and in confined spaces. An electric shock while working hundreds of feet off the ground could result in a fatal fall.
Pipeline Welding
Pipeline welders work on the network of pipes that carry fuel and water to cities and towns across the country. They may have to work in remote locations and under unfavorable environmental conditions. Pipeline welders face risks similar to welders in the oil and gas industry.
Most Common Welding Injuries
Most Common Welding InjuriesMany of the most common welding injuries occur because appropriate safety precautions were not taken or recommended safety gear was not worn.
- Burns – The ultraviolet radiation emitted during welding can burn exposed skin and is particularly harmful to the eyes.
- Electric shock – Shocks happen when a welder touches two metal objects that have a voltage difference between them.
- Metal and gas fume toxicity—Short–term exposure can cause Irritation to the eyes, nose, and throat. Long-term exposure can damage the lungs, liver, and nervous system and cause cancer of the larynx, lungs, and urinary tract.
Welder’s Flash or Arc Eye
A common type of burn injury experienced by welders is photokeratitis, which is medically known as photokeratitis. It can occur when the cornea and the membrane covering the whites of the eyes (conjunctiva) are exposed to an intense flash of ultraviolet radiation from the welder’s torch.
The painful condition, also known as arc eye, may present up to 12 hours after exposure. Symptoms may also include eye redness, tearing, irritation, vision impairment, and light sensitivity.
The injury from a single exposure will typically heal in a few days without lasting damage. However, repeated exposure can result in the development of cataracts and, in some cases, a rare cancer known as ocular melanoma.
Welding Injuries Caused by Explosions in Texas
Welding Injuries Caused by Explosions in TexasRecent welding accidents in Texas demonstrate just how crucial it is to ensure there are no flammable substances near where welding occurs.
In May 2023, a Houston welder was severely injured when the tank he was welding exploded, sending him flying through the air and leaving him unconscious. Though the tank was supposed to be free of any flammable materials, the company delivering it had not made sure it was clean.
In 2022, the U.S. Chemical and Hazard Safety Investigation Board (CSB) determined Sunoco Oil did not have adequate safety procedures regarding hot work on equipment containing flammable substances after investigating a 2016 flash fire and explosion that injured seven workers.
The workers had been welding a section of pipe that contained residual crude oil when some vapors ignited, causing the explosion.
How Welding Injuries Can Be Prevented
Welding is a dangerous occupation. Yet most injuries are preventable if the appropriate safety regulations are followed. The Texas Department of Insurance offers safety tips to help welders avoid injury on the job.
- Always wear appropriate, fire-resistant clothing, including leather gloves, a leather apron, and hard-toed shoes to prevent burns.
- Always wear goggles and welding helmets with dark, UV-filtering faceplates to protect your eyes.
- If working in confined spaces, ensure adequate ventilation directs the airflow at the face of the welder to minimize the accumulation of toxic chemicals.
- Use a respirator to keep from inhaling toxic chemicals and particulates.
- To prevent fires and explosions, keep work areas clear of flammable clutter and gases.
Of course, welders also need to be aware of additional dangers created by welding in certain environments and take precautions as necessary.
What To Do if You Are Injured in a Welding Accident at Work
The Pearland law offices of J.D. Silva & Associates represent welders and other workers injured on the job in the Houston area. Our work injury attorneys thoroughly investigate work injuries and identify all responsible parties so we can pursue the maximum available compensation for our clients.
If you have been injured in a welding or other accident at work, contact J.D. Silva & Associates for a free consultation.