Welding is a crucial industrial process. The nature of welding brings with it inherent risks, with electrical shock standing out as a significant danger. In this blog post, we’ll explore vital measures to prevent electric shock during welding operations. We’ll focus on the importance of understanding electrical hazards and implementing proper safety protocols.

Welding and Electricity:

Popular welding methods like MIG, TIG, or Stick have electric arc processes. What this means is that that they utilise electricity to create arcs for joining metal structures. Welding machines, acting as power supplies, transform high electrical power into welding power. While household voltages may be 120V or 240V, the internal welding equipment voltage can go as high as 575V, posing serious risks to welders.

Electric Shock Hazard in Welding:

Electric shock in welding occurs when there’s contact with an electrically hot electrode or metal part, completing a circuit between the electrode, power supply, and grounded metal. This can cause in injuries such as spasms, burns, muscle paralysis, or even death. The severity of each depends on factors like voltage, current, exposure duration, and the current’s path through the body.

Primary Voltage Shock:

This severe condition involves getting shocked by primary (input) voltage, usually ranging from 115 to 600 volts. This shock occurs once you touch a damaged lead or electrically hot component inside the welder while your body or hand is on the welder case or other grounded metal. Even when the welder is turned off, the risk persists. This is because of the electricity lingering in the equipment, emphasising the need for proper grounding. Due to the severe risk of electric shock at high volts, most cases are now grounded. So once the issue occurs, the problems blow the fuse rather than electrocuting you.

Secondary Voltage Shock:

This is more common and occurs at lower voltages (20-100 volts). Secondary voltage shock happens when completing a circuit between the electrode, welder, and grounded metal. Simply put, you get shocked if you touch the electrode and grounded piece at the same time. Though less risky, it remains a concern, especially for novice welders.

Can Electric Shock in Welding Be Deadly?

Yes, electric shock in welding can be fatal. However, factors like voltage, current, and resistance determine the severity of the shock. Even small shocks can prove lethal. Particularly in wet environments or with wet welding gear. Understanding the risks and taking preventive measures is crucial.

Which Welding Process Poses the Highest Electric Shock Risk?

Among manual arc welding operations, Stick/Arc welding is considered the riskiest. This is because the live electrical circuit starts immediately when turning on the welder. Accidental contact with the electrode and ground during Stick welding poses a higher risk of electric shock.

AC vs. DC Current:

While both AC and DC can cause electric shock, AC is considered 3-5 times more dangerous than DC at the same voltage. AC’s alternating nature increases the likelihood of prolonged exposure. Which then potentially lead to severe consequences, including atrial fibrillation. Atrial fibrillation occurs when the alternating current alternates from the positive to the negative side of the cycle, which causes tetany in the body. Tetany is an involuntary muscle cramp or spasm that makes it difficult for a shocked welder to release the current source, prolonging the exposure length. Once alternating current hits the heart, it interferes with the natural pacemaker. This condition can cause stroke or death in case of electric shock.

Preventing Electrical Shock in Welding:

Several precautions can significantly reduce the risk of electrical shock during welding:

1. Check the welder’s capacity:

Before you even start welding, make sure that the welder’s capacity is compatible with the input power of your outlet. 110 or 220V, 50-60 Hz, AC or DC must match to ensure safe welding

2. Inspect cables for insulation and connections:

Make sure all your cables, either lead, ground cable, or electrode holder cable, and connections are well insulated and in good condition. Bare insulation or frayed wires are close connections to the live circuit, so you want to make sure to repair them.

3. Ensure the electrode holder has tight insulation:

The electrode holder with loose insulation can easily shock you.

4. Ground the work effectively:

Make sure you ground the metal to be welded to a good electrical ground.

5. Change electrodes with care:

Most stick welders experience electric shocks when changing stick electrode with bare hands or wet welding gloves.

6. Keep yourself and your gear dry:

Dry gloves and skin have significantly higher resistance, so the risks of shock are minimal. Even if you get shocked, you won’t even notice it, so make sure you wear dry gloves.

7. Stay away from water and wet surfaces:

Electrical equipment and water don’t mix very well. So whenever possible, try to stay away from puddles, moisture, or wet surfaces when welding.

8. Avoid direct contact with the electrical circuit:

The welding starts once the circuit is closed between the electrode, welder, and base metal. Direct contact with live parts of the circuit will lead your body into it and cause shocks. So do not rest your body, arms, or legs on the workpiece.

9. Insulate yourself from the work and welding ground:

Electric shock in welding will occur only when you touch both sides of the circuit simultaneously. But if you are well insulated and touch only one side of it, you won’t be shocked.

10. Use appropriate personal protective equipment (PPE):

If you have to weld in wet conditions, make sure you wear rubber gloves, rubber boots, and rubber pads. Since rubber can get damaged due to heat of arc and molten metal, wear the rubber gloves underneath the welding gloves.

11. Consider using an insulating mat:

If you are welding on top of the steel or other conductive material, make sure you place a mat to insulate yourself from the electrode or metal parts.

12. Keep the welder close for quick reaction:

In case of an accident, you must cut the connection quickly, so keeping your welder close will help you react fast and turn it off.

13. Unplug the welder when not in use: 

Most parts and internal components in the welding transformer stay “hot” even if you turn off the welder. So if you check or maintain the machine, make sure you unplug it completely.

14. Shut down the welder when taking breaks or finishing work:

Stick/Arc welders become electrically hot as soon as you turn them on. So once you are finished or just taking a break, make sure you turn them off. Detach the remaining welding electrode and keep it away from others.

Final Thoughts:

While welding presents inherent dangers, understanding the risks associated with electrical shock and adopting preventive measures can significantly minimise the likelihood of accidents. Proper training, awareness, and adherence to safety protocols are crucial. Especially for ensuring the well-being of welders and those working alongside you.