Welder

Induction Required

This equipment requires an induction prior to use. For your own safety and to avoid damage to the equipment do not attempt to use it until you have been inducted.

Burn Hazard

Welding generates heat, resulting in workpieces and equipment which may be very hot. This may pose a burn hazard to the user or those around them, take care during and after use.

Fire

The welding process generates sparks and embers which can start fires. Steps must be taken to prevent fires - see safety notes below.

Risk of permanent damage to eyesight

The welding process generates intensely bright light, which can cause lasting eyesight damage.

PPE Required

This equipment requires the use of eye protection and appropriate clothing.

Please note, this is a work in progress. Please do not use the welder until inducted - thanks, Ollie

Avoiding fire and fumes

Before commencing any welding, ensure the hot works area is clear from flammable items. Do not weld if there are strong, potentially flammable fumes in the space
Do not weld items which could be flammable. No not weld vehicles
Do not weld items which contain surface finishes, which could release flammable or hazardous fumes such as painted or galvanised surfaces.
Keeping workpieces clean can help to minimise sparks and will result in a better weld
Make yourself aware of firefighting equipment in the space (eg, fire extinguishers, just outside of the hot works area. Familiarise yourself with where they are, and how you would operate them.
Have a bucket of sand next to the welding bench, which can quickly and safely extinguish minor flames with minimal cleanup
The roller shutter doors must remain open during welding operations, and kept open until fumes have cleared
Fume extraction must be used at all times, and kept on until fumes have cleared. Check fume extractor has not been used for general extraction or hoovering - open the top and ensure there are no flammable items inside (eg sawdust)
After welding, you MUST remain in the space for at least 1 hour, checking the area for smouldering items or fires. This is non-negotiable - if you cannot wait the hour, do not weld

Avoiding burns

Welded parts will be hot, but heat can be minimised by welding intermittently, with short welds. Quench as required, but being careful of steam release.
Wear appropriate welding gloves / gauntlets. Check their condition before welding. The Hackspace has gloves, but you may wish to bring your own
Ensure you are sufficiently protected from sparks. Cotton (or other appropriate fireproof material) overalls or a top made from fireproof, burn resistant material with long sleeves should be worn. Such PPE is provided, and will be pointed out in the induction
It is possible to get sunburn from welding, from the emitted UV light. You must wear a welding hood or use an appropriate visor.
Make care when handling welded items, or torch components. Even with gauntlets there is a potential for burns
Think about other members – don’t leave hot items lying around.

Avoiding damage to eyesight

Position the mobile welding guard such that it completely shields all uninvolved parties from arcing. This includes, but not limited to, members of public outside the hackspace, hackspace members and road users.
Do not attempt to remove, prop up, or otherwise overcome the fixed welding curtain.
Appropriate welding masks/shields/goggles must be used by all parties within the hot works area
Prior to welding, with the isolator switch turned on, ensure the beacon lights are flashing. These warn other users that welding is being carried out

PPE

The following PPE must be used

Gauntlets
Fire-proof long sleeve clothing (e.g. overalls)
Welding hood or mask. There are three hanging up, just outside the hot works area. Link to manual https://www.clarkeservice.co.uk/manuals/welding_accessories/PG4_Headshield_Iss_3.pdf
Closed footwear

These are the minimum requirements. You may also need additional PPE for other related tasks, such as eye protection when using an angle grinder.

The welder is stored on the lower shelf of the welding table, in the hot works area, next to the roller shutter doors. Also on the table are a few welding accessories such as a pair of MIG pliers and a chipping hammer

The Hackspace welder is a Clarke MIG160EN, with an adjustable welding current between 30 and 150 Amps. This is enough to weld 5mm mild steel, and to blow holes through thinner stuff.

Link to manual - https://www.clarkeservice.co.uk/manuals/mig_welders/MIG160EN_Mig_Welder_REV_8.pdf

Fume extractor

Gas vs Gasless welding

The welder is designed for both gas MIG and Gasless welding, however in the Hackspace all welding shall be the gasless type. This uses wire with a flux core to prevent oxidisation and contamination of the weld pool. Whilst the welder can operate as a standard MIG (ie with Gas) the Hackspace does permit compressed cylinders. The risk assessment for the welding has not considered the use of shielding gas, so for the foreseeable, all welding shall be gasless

Welder - work in progress