Welding Resources and Tips

How to Prevent Heat Stress While Welding

Today’s guest post is by Bill Gardner of Miller Electric:

With summer approaching, heat is on the rise. As a welder, intense heat can be irritating, but the effects of heat stress can also greatly impact productivity, the ability to concentrate, quality of work, and safety.

OSHA recommends various ways to reduce heat exposure and the risk of heat-related illnesses, including engineering controls like air conditioning and ventilation; work practices like water breaks, rest cycles and heat-tolerance build up; employee training and awareness.

The proper selection of PPE also plays a crucial role in preventing the adverse side effects of heat stress. The very nature of welding adds heat to an already warm environment, but the right PPE can improve a welder’s performance by lowering the risks of heat stress.

Miller’s CoolBand™II

The CoolBand II addresses two of the most common causes of heat stress – high heat and limited airflow. A fan is integrated into the helmet’s headgear, providing directional airflow over the head and face to evacuate hot, stagnate air and encourage more rapid sweat evaporation. With the use of the CoolBand II, users can experience temperatures up to 8°F cooler under the welding hood.

Strategically placed air vents also reduce lens fogging, which can be a frustrating side effect of heat and humidity, impacting weld quality due to poor visibility. The CoolBand II features new and improved headgear for increased comfort, and a lightweight Lithium Polymer rechargeable battery that delivers 6 hours of battery life.

Since the slim, balanced design fits seamlessly with most Miller welding helmets*, it is significantly lighter than wearing a cooling vest and will not obstruct range of motion or hinder performance.

William Fries, a welder with Xtreme Fabrication in Kentucky, summed up the CoolBand’s impact when working on an outdoor project in 90 degree heat, “The fact that you have air movement across your face makes all the difference in being able to get the job done.”

The Miller Titanium 9400™ Welding Helmet

The Titanium 9400 welding helmet also has features to help reduce temperatures under the hood. The titanium colored shell reflects radiant heat produced during welding to reduce temperatures under the hood, while an innovative aluminum heat shield protects the auto-darkening lens in high amperage applications. Combined with the CoolBand II, this duo makes a great choice for combating heat stress and can be an effective element for any organization’s Heat Stress Management plan for welding.

Most importantly, remember to stay hydrated and safe under the hood during the hot summer months.

Note: Not compatible with XL Series™, Classic VSi™, Titanium 1600i™ or 9400i™ helmets.

About Today’s Guest Blogger

Bill Gardner is the Business Development Manager/Welding Safety at Miller Electric Mfg. Co. He has worked at Miller for 23 years, and has an extensive background in welding protection.

Find Miller’s Top Welding Supplies on Sale

Visit the Miller Electric page at Baker’s Gas and Welding for the latest promotions and free shipping offers. 

Welding Safety Isn’t Rocket Science

Welding safety isn’t too hard to figure out, but it does require some planning and an investment in the right safety gear. Welders work in a variety of positions and locations, so be sure to review these safety steps to stay safe while welding:

A Stable Work Surface

Before you even strike your first arc, make sure you’re welding on a stable surface that is safe, will support your metal, and provides a steady ground. If you’re working on a welding cart of some sort, make sure the wheels are locked into position and that you’re welding at a safe distance from other machines and materials that could be damaged.

In addition, take note of the floor in your shop. Is it smooth and stable? Are there divots or cracks that could send your table off balance?

Non-Flammable Clothing

Besides not keeping a lighter in your breast pocket, your clothing itself should also be non-flammable material such as cotton. Any kind of synthetic blend will catch a spark and catch on fire much faster than cotton, which can be easily snuffed out. You can pick up welding jackets and aprons that provide more protection while welding, but the most basic place to start is with cotton clothing.

If you’re working in a colder climate, a leather welding jacket will be effective for protecting your skin and keeping you warm while you work.

Besides the natural protection you get from sparks while welding, long sleeves are also important for protecting yourself from harmful UV rays that are emitted while welding. In fact, you can give yourself a particularly nasty sun burn if you don’t take the right safety steps to cover your skin while welding.

Welding Safety Gear

The basics for welding safety include a welding helmet and welding gloves along with a long sleeved shirt, pants, and heavy duty work boots. Most welders prefer auto-darkening welding helmets that make it easy to strike an arc right on target without having to mess with dropping a helmet into position. The higher priced helmets will give you more sensors and faster response time to flashes, protecting your eyes and keeping you on the job.

Choosing the right welding gloves will boil down to weighing how much flexibility you need and how much protection you need from heat. Some welding gloves also provide protection along your wrists with a “gauntlet” design that is great for stick welding or MIG welding out of position where sparks can fall down your arms.

A Dry Area

It’s commonsense that water and welding could lead to a life-ending jolt of electricity, but many welders underestimate how much water it could take to cause that shock. It really doesn’t take much. A puddle at the wrong spot and at the wrong time could prove particularly deadly to an unsuspecting welder.

Properly Stored Gas and Oxygen Cylinders

Besides keeping your shielding gas and oxygen cylinders away from sparks, they need to kept in safe, upright positions that will ensure they don’t bang around or get dented. A dent and a spark could mean a huge explosion.

If you’re working with oxy-acetylene, you’ll have plenty of safety concerns since it’s an extremely volatile gas. While it’s an effective way to cut metal, you’ll need to spend time making sure that your cylinders are securely stored and have proper regulators and valves in place.

If you have smaller cylinders of cutting gas in your tool box, take them out immediately, as they could be punctured at any time, and the last thing you want is an exploding tool box that will send all kinds of metal scraps into your workplace.

Welding with Sufficient Ventilation

Welding can give off fumes and when you weld with a MIG or TIG welder, you’ll most likely use Argon as your shielding gas. When you replace Oxygen with Argon, you’ll be unable to breathe and will pose a hazard to yourself and to anyone else who enters the room after you. Whether you use a fan in the window or use a ventilation system, make sure there is a steady flow of air in your workspace.

You can also pick up screens that you can set up in your garage so that you can weld with the door open.

A Workspace Free from Flammable Materials

Whether a fire breaks out while you’re welding or after you’re welding, taking stock of your location is a critical part of welding safety. Are there other welders working nearby? Are there cardboard boxes or piles of sawdust that could catch fire if a spark hits them? Many welding fires are caused hours after the welder is done—often in the middle of the night. Sparks from welding sit in piles of sawdust and slowly smolder into flames and cause unexpected and costly fires.

Learn more about welding safety at Baker’s Gas and Welding.

Welding Jackets: Miller’s Latest in Welder Protection

Today’s guest post about welding jackets is by Eric Sommers of Miller Electric:

Not all welding projects are alike, and choosing the correct welding jacket for your specific application requires taking a number of other factors into account. One may be tempted to purchase solely on cost but as we all have experienced, you end up getting what you pay for in the end.

One of the first factors that should be considered when selecting a jacket is: “What does the application need?” A welder doing predominantly MIG welding would have different needs than someone doing TIG welding. You should also consider product durability, material type, comfort, laundering and disposal requirements.

Below I’ll discuss the two most common materials used in welding environments — flame-resistant cotton and leather — and how each fabric performs according to the factors we mentioned above. Also mentioned is a new material called WeldX™ that combines the benefits of both cotton and leather (see Miller's video demonstration on WeldX™).

Flame Resistant Cotton Welding Jackets

Flame resistant (FR) cotton is very popular because it is relatively inexpensive, lightweight (about 9 ounces per square yard) and breathable. An FR cotton garment often provides the ideal combination of protection, cost and operator comfort in applications where sparks and spatter are relatively mild, ambient heat is of a concern and washability is important.

FR fabrics are treated with a chemical that “off-gasses” when it comes in contact with flames, molten metal or other intense heat sources. This off-gassing process deprives the area of the oxygen that would be required to cause combustion. Although most FR cotton fabrics will not start on fire, they can be charred when exposed to sparks, spatter and molten metal. This exposure causes susceptibility to future burn through.

Two elements to consider when purchasing an FR cotton jacket are: 1. the quality of the cotton fabric and 2. the flame retardant application process. A higher quality, thicker base cotton will provide improved comfort and durability over the life of the garment.

Flame retardant processes may vary depending on the manufacturer. High quality control standards are needed to ensure that chemicals are applied consistently to garments, resulting in safe, reliable products that protect workers. The Miller Indura Cloth Jacket, made of Indura^® cotton, is treated domestically in the United States and guarantees the material’s flame resistance for the life of the garment, regardless of launderings. All other non-Indura® garments only maintain their flame resistance through a specified number of launderings.

Also to consider is how the FR chemicals are applied to the jacket. Some companies use a technique of spraying the FR chemical topically which is cost effective, but leaves the garment feeling more stiff and scratchy. The other process is sewing the already FR treated thread into the jacket, making it more comfortable to wear.

Leather Welding Jackets

Because of its density — roughly 30 ounces per square yard — leather has long been considered the best protective material for welding applications. The relative thickness of leather prevents heat from penetrating through the garment and also provides excellent abrasion and puncture resistance. Leather is the best option where there is high amperage, high sparks and spatter prevalent.

There are many different types, cuts and grades of leather designed for welding applications — all of which can impact the product’s quality and cost, as well as the welder’s comfort and mobility.

The top layer of an animal’s hide is the strongest portion and is referred to as grain leather. Because of its strength, grain leather can be made much thinner than the under portions of the hide, which in turn allows it to be lighter and more comfortable. Grain leather, because of its smoothness, tends to repel sparks and spatter making them ideal for welding applications. See the Miller Arc Armor Leather Welding Jacket for an example.

Another type of leather used in welding jackets is called split leather and is made from the under portions of the hide. Split leather has more of a suede look and feel. While less expensive, this type of leather is also heavier, thicker, and more susceptible to catch sparks and spatter and absorb dirt/oil.

Leather is the heaviest and most insulating material available. A typical, full leather welding jacket can weigh upwards of 8 lbs., which can increase welder fatigue. In environments where the ambient temperature can pose heat stress dangers, a leather jacket can compound those dangers by increasing the welder’s internal heat due to its lack of breathability. Another disadvantage of leather is that it becomes stiffer and less pliable over time due to repeated launderings and exposure to intense heat.

One further consideration to bear in mind is that because chromium is used during the tanning process, special disposal requirements might apply to leather garments, resulting in additional complexities.

WeldX™ Welding Jackets

Recognizing the weight and heat stress drawbacks of leather and the protective and durability limitations of FR cotton, Miller sought out a fabric that provides the benefits of both these industry staples but not their disadvantages. The result is the introduction of an exclusive new type of material to the welding industry: WeldX™.

This jacket uses CarbonX material and a proprietary compound to increase its ability to shed sparks, spatter and other flaming or molten materials. The unique coating is embedded into the individual CarbonX fibers instead of applied to the fabric topically, which enhances the material’s flexibility.

Flame resistance is inherent to WeldX – laundering will not degrade its performance over time. It also weighs approximately 60 percent less than most leathers and has micropores in the fabric that together increase breathability and comfort for the welder, while reducing the potential for heat stress-related injuries.

Visit the Miller Arc Armor Welding Jackets page at Baker’s Gas and Welding.

 

About Today’s Guest Blogger

Eric Sommers, Product Specialist, Helmets
Miller Electric Mfg. Co. An ITW Company

Eric Sommers has been with Miller for six years and most of his career has been spent with the Miller welding helmet line.  He also had been the product specialist for Miller’s respiratory category.

The Best Gloves for Stick Welding

Today’s guest post is by Mark Williams of John Tillman Co.

Trying to decide which Stick welding glove is right for you? When selecting a stick welding glove there are four important things to consider:

• What type of leather will work best for your project?
• How is it lined?
• What additional features are important to me?
• How much am I willing to spend?

Types of Stick Welding Glove Leather

Top Grain is the leather from the top layer of the hide and is the toughest and longest lasting. Because the surface of the leather is smooth, sparks and spatter generally roll off easier than with split leathers discussed below. These leathers are generally found in premium priced welding gloves. Top grain leathers are available in elkskin, cowhide, and pigskin. Elkskin is the softest and best for heat resistance; it also doesn’t harden as quickly due to its fiber structure. Cowhide is the toughest and most durable, and in many cases an “affordable” alternative to elkskin. Pigskin is naturally breathable and the best option for those who work in wet and oily welding conditions.

Cowhide Split Leather is the most popular and most affordable leather for stick welding gloves. Split leather comes in three grades: side, select shoulder, and standard shoulder. Side split comes from the side of the cow and has the least muscle fatigue, thereby making it the strongest. Select shoulder split comes from the shoulder of the cow. It’s not as strong as side split but is taken from the best of the shoulder area. Standard shoulder split is used for economy oriented welding glove models.

Lining- Insulation/Dexterity for Stick Welding Gloves

Wool lining offers the most heat protection for stick welding gloves. It’s designed for both higher heat and colder weather applications. Due to its thickness, dexterity is limited, and it is typically more expensive than other linings.

Cotton/foam lining consists of a cotton layer for moisture absorption, laminated to a foam layer for heat protection. Dexterity is still somewhat limited, but it’s usually the most popular choice for medium to higher heat stick welding applications because of its excellent value.

Cotton lining is the thinnest and its key feature is moisture absorption and to maximize dexterity.

Additional Stick Welding Glove Features

Kevlar® stitching compared to cotton stitching is one of the most important features for a welding glove. Kevlar® thread resists heat and is significantly stronger than standard cotton thread. This can be vital in maintaining the life of the glove. When sparks and spatter land on the stitching, cotton will burn immediately; Kevlar® will resist these elements, lasting longer.

A reinforced thumb area is designed to protect the glove from the wear and tear of handling torches and welding guns. Thumb straps can be single or double reinforced.

A pull strap is a small but convenient feature. This added piece of leather is sewn onto the base of the wrist, on the palm side of the glove, allowing an extra “pull point” when putting the glove on. It also gives the user an extra layer of leather to protect the glove while dragging a welding gun.

Welted fingers protect the stitching against burning and abrasion, lengthening the life of the glove.

How Much Should I Spend on Stick Welding Gloves?

Super premium gloves are typically made from top grain hides, lined with wool or cotton/foam, and loaded with key features, making them high quality gloves. These would be the highest price typically costing $15 and up.

Premium gloves are just a step under super premium gloves. They are made from side split leather and usually contain additional features. Many of these models can be found from $11-$15.

Standard gloves can vary in their insulation type and features, but generally they’re made of shoulder split leather. Pricing on these models runs between $8-$10.

Economy gloves are made with a budget in mind, so they are made of shoulder split leather, lined with cotton, use cotton thread, and stripped of most additional features. These welding gloves are typically priced in the $5-$7 range.

 

About Today’s Guest Blogger

Mark Williams, VP of Marketing John Tillman Co.

Mark Williams has been John Tillman Co.’s  V. P. of Marketing for the past 12 years.  During this time he has been involved in product development, product testing, key end user field application work, as well as distributor salesperson product training.

Find the best-selling Tillman welding gloves at Baker’s Gas and Welding.

Learn more about choosing welding gloves.

New Ways of Looking at Safety for Welders

Sometimes we take safety for granted. Employers may regularly remind us of safety protocol. We read Fire Prevention for Welders. OSHA books may be handed to us. NFPA codes may be recited, but sometimes it's the simplest visual cues that do the trick to really improve our working conditions.

Charles Duhigg wrote a book called, "The Power of Habit." In his book he recounts the experience of Alcoa's CEO introduction. Paul O'Neill focused on worker safety. He addressed first of all where the nearest emergency exits were. Sure he could've pointed out his plans for the company, the earnings forecast, or his own qualifications, but he didn't.

This was in 1987 and despite investors suggesting selling off Alcoa stocks, O'Neill soon became one of the best CEOs in modern history (according to Bloomberg Businessweek). The focus on safety and proper procedure brought down costs, improved productivity and quality.

"The Power of Habit" addresses the habit loop. When there is a cue, especially a short, vivid cue – we change our habits and are appropriately rewarded. In the early 1900s Pepsodent turned our attention to feeling a film on our teeth and we were rewarded with better teeth.

Febreeze found that people didn't know they had smelly homes, but when they marketed the product to make your home smell nice after cleaning, sales took off. Precisely timed coupons, reminders, and irresistible come-ons, cue us to the products we are craving.

Individuals too can tweak behavior or habits, by tricking ourselves. You learned recently why nutrition and fitness are important to welders. Maybe you've heard the suggestion to leave running shoes by your bed so you exercise every day. The same principles can be applied to creating good habits in welding.

Find a visual cue or reminder to take a fresh look at safety. This may be as simple as leaving your work shoes at the shop. When you get to work and don your safety gear, you make a deliberate mental connection to the fact that you are in a different environment, one that requires constant attention and taking a regular inventory of your surroundings.

Obvious shut off tags, locks, and codes make communicating the state of potentially hazardous equipment clear to others with just a glance. This is crucial where multiple people are working in the same area, where it may be loud or otherwise impractical to verbally inform everyone of a machine's state.

If you own a blacksmithing, ironworks, manufacturing, or welding related business, properly addressing the processes, procedures, and safety habits of your employees will lead to a safer, more productive, and more profitable workplace.

What visual or physical cues work on you? Have you broken from a bad habit or started a good one with a similar technique? Please share in the comments below.