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Ergonomics for Welders

 In my work I often conduct ergonomic risk assessments on welders, who regularly indicate that they suffer from neck and shoulder pains. Managers and co-workers react surprised, as the job does not seem to be very stressful to the untrained eye. If one is to expect problems, it should surely be a result from the static posture of the wrist and/or from the negative results from static standing? But if one looks at the welder’s head posture combined with the helmet, one can start to understand the problem.

welding

The weight of a welder’s helmet, especially the older models, is considerable. The welding itself nearly always happens at some awkward angle, which means the welder’s head, with helmet, is nearly always at a forward tilted angle. The neck and shoulder muscles then need to counteract the weight of the head and the weight of the helmet, which causes increased strain on these muscles. As a welder needs to concentrate on the weld, he doesn’t alternate this posture often, which results in reduced blood flow and a build up of waste products in the muscles. As a result, early fatigue is a given, which subsequently may bring a reduction in the quality of the weld. And that brings us to the main problem, duration. In South Africa, a welder can sometimes assume these welding postures for up to 8-12 hours a day, depending on the nature of the shift. In the long term, these long duration (static) postures may even cause permanent damage to the spinal column.


Welders have not traditionally had the attention they deserve with regards to the musculoskeletal risks associated with their work, and I believe their physical complaints are not treated with the urgency they deserve. The problem is also one of economics; South Africa, with it skills shortage in the trades, can ill afford lower productivity or absenteeism from this group of workers in our economy.

But what can we do to minimise this risk? There is not a single solution, but rather a collection of small changes in equipment, work layout and behaviour which should improve the situation:

  • -          Use the lightest possible welding helmet.
  • -          Do not “nod” the helmet down over the face, or rather use an auto dimming helmet.
  • -          Optimise the workstation, to ensure that the work piece is at an optimal position; this can be achieved by using positioners, for example. If the work piece is large and placed on the floor, try and place it on a, in height adjustable, turn table and use stools and knee protection. This will assist in reducing the necessity to assume a forward flexed posture of the head, and decrease reach to the work piece.
  • -          Take regular breaks, and perform stretching exercises during these breaks.

As welders perform different duties in different companies and are often part of the maintenance team, it is important not to overlook the maintenance team when conducting an ergonomics assessment and identify these possible risks. If the welder is able to conduct their tasks in a more “comfortable” position, and get the job done quicker, shut down times of machinery can also be reduced. 

Last modified on Monday, 15 February 2016 11:47
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