Metal offers special advantages for some applications, but requires care and proper equipment to handle safely.  Below are some of the hazards normally encountered when working with metal.

  • Metal is hard to cut.
    • Manual hacksaws are suitable only for small, thin stock.
    • Cutoff wheels on angle grinders can be dangerous
      • They throw off metal shards and abrasive grit.
      • They can bind and shatter, sending fragments back towards the user.
      • They generate heat and noise.
    • Powered band saws are better
      • They make more accurate cuts 
      • They operate at slow speeds
      • They cannot explode and create shrapnel
      • They can cut thicker stock
    • Plasma cutters excel for some cuts
      • Sheet metal of all thicknesses
      • Irregular shapes
      • Thick stock up to 1/2 inch
      • Hardened steel, but may ruin the temper
  • Welding emits harmful energy and other substances
    • Arc emits UV radiation
      • Can cause sunburns on exposed skin
      • Will permanently damage eyes if not properly shielded
      • Need to protect onlookers from exposed arc light
    • Noisy environment
      • High frequency operation can be annoying
      • Fans on welder and water cooler 
      • Wear ear protection
    • Metal gets hot
      • Use welding pliers and protect hands
        • Stick welding might be worse with spattering
      • Hands can get hot from torch and welded metal
      • Preheating welded parts might make environment uncomfortable
    • Flux can emit toxic fumes
      • Stick welding -- some rods worse than others
      • Flux cored metal wire also hazardous
    • Argon shielding gas may accumulate
      • Heavier than air
      • Need good ventilation
      • Too much turbulence may compromise shielding and quality of weld
    • Sparks from some processes may ignite flammable materials
      • Clothing
      • Debris
      • Flammable gases and vapors
  • Metal is heavy
    • Need adequate supports when cutting and welding
    • Need lifting machinery for heavy stock and parts
    • May need to build armatures to hold pieces in alignment
  • Machines and work must be properly grounded
    • Eliminate shock hazard
    • Ensure continuity for continuous arc
Last modified: Tuesday, 18 June 2024, 6:47 PM