RISK ASSESSMENT FOR THE CORRIS RAILWAY MAESPOETH WORKSHOPS
ASSESSMENT UNDERTAKEN 1 MAY 2001 by S.G.Wheeler
ACTIVITY UNDERTAKEN: Heat Treatment: welding, Brazing, Bronze welding, Silver soldering. Forging
POTENTIAL RISK/HAZARD / L / S/C / TOTAL LxS/C / CONTROL MEASURES / I
IMMEDIATE REMEDIAL
MEASURES
Explosion
Incorrect handling of gas /oxygen torch.
Gas leaks can result from damaged hoses, loose connections and faulty equipment.
Working on tanks and drums is a high-risk activity!

Spontaneous ignition

Oil, grease and even some textiles can catch fire spontaneously in the presence of high concentrations of oxygen.

Radiant heat burns
Handling hot metals, which may not appear hot (black heat).
Rearranging ceramic blocks or supports if they are still hot from previous use.
Quenching hot metals in a bath of water can produce scalding amounts of steam.
Inadequate control of the direction of the flame and the use of welding rods that are too short.

Toxic

Flux fumes. Copper and zinc oxide fumes can induce “metal fume fever”.
Contact with the flux may irritate skin and eyes.
Products having Cadmium plating must not be heated or welded in this workshop! / 2
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4 / Training on the use of; Valves on cylinders and controls on welding and cutting torches. The system has flash-back arrestors and non-return valves fitted. All connections, regulators, valves and hoses should be checked daily, before use. Full function and safety recorded testing, should take place once a year. All welding equipment should be kept free from oil and grease.
Tanks and drums must be effectively cleaned of flammable residues before work is done and purged with inert gas. Oxygen must never be used to blow dry or cool any thing or blow away dust/debris.
Goggles which, reduce the radiation reaching the eyes, must be worn. These will also protect against spitting of flux or spatter of molten metal.
Leather heat resisting gloves and apron should be worn.
When hot metal is left to cool, a warning notice should be displayed close to it.
Hot metals or blocks should be handled with suitable tongs.
A burning blowpipe must never be put down on the floor or bench: the flame must be shut off first. Hoses should be kept away from the working area to prevent contact with flames, sparks or hot spatter. Combustible materials should be moved well away from welding.
The floor area should be kept clear of any tripping or slipping hazard since anyone carrying a hot object will not be concentrating on the floor.
Local exhaust ventilation is not required provided the operation is carried out in a well-ventilated area.
Powder fluxes should be mixed into a paste with care, so as to minimise dispersion into the air.
Thoroughly wash hands after work or prior to visiting the toilet! / A fire extinguisher of suitable type and a fire blanket should be at hand during welding operations. The type of extinguisher should be chosen according to the nature of the materials, which could be set on fire. (See fire extinguisher information poster for further details)
If minor burns to the skin occur, cool the affected area under a cold running tap for 10 minutes.
If serious burns to the skin occur, send for an ambulance.
Cool the affected area under a running tap for 10 minutes.
Monitor the casualty. Apply a dry dressing to the wound held in place by cotton wool and a bandage or adhesive tape.
Do not apply any form of cream to the wound!
If flux powder or paste is in the eyes, irrigate immediately with water for at least 10 minutes, holding eyelids apart. Obtain medical attention,
If flux swallowed the casualty must go to straight to hospital.
Do not induce vomiting!
Storage of gas cylinders
Gas cylinders ready for use may be kept in the workshop providing that they are valves uppermost and held securely to a wall or bench, or on a cylinder trolley.
When not in use, the equipment should be removed from the workshop and kept in the well-ventilated out side store or to a place agreed with the local Fire Prevention Officer, away from any source of heat and secure from unauthorised persons.
Easy access must be assured at all times in case of fire.
All gas cylinders must be in the out side store when not in use.

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