Being as comfortable as possible contributes to welding operator safety and productivity — and it’s a factor that can impact the quality of the finished weld. There are numerous issues that play a role in welding operator comfort, including the heat generated by the welding process, the repetitive motions and, at times, cumbersome equipment. These challenges can take a toll, resulting in aches, fatigue and physical and mental stress for welding operators. There are some steps, however, to help reduce the impact of these factors. These include choosing the right equipment for the job, utilizing tools and accessories designed to improve operator comfort, and following some best practices that promote proper operator form.
|Choosing a GMAW gun that meets the needs of the application — and in some cases customizing the gun — is a critical way to impact welding operator comfort so he or she can achieve the best results.|
Selecting the right gas metal arc welding (GMAW) gun
Promoting operator comfort can lessen the chance of injuries associated with repetitive movement, as well as reduce overall fatigue. Choosing a GMAW gun that meets the needs of the application — and in some cases customizing the gun — is a critical way to impact welding operator comfort so he or she can achieve the best results. A gun’s trigger, handle, neck and power cable design all help determine how long a welding operator can comfortably weld without experiencing fatigue or stress. The application’s weld joint geometry also plays a role in welding operator comfort, and it impacts what components to choose for optimal joint access. Here are some issues to consider in GMAW gun selection that can impact comfort, as well as quality and productivity:
|Because welding applications differ for every welding operator, customizable GMAW guns can be a good option to gain greater comfort.|
Consider gun balance
Different welding guns can offer different “balance,” which refers to the feel and ease of movement experienced when the welding operator holds the gun. For example, a heavier gun that is balanced properly can lessen operator fatigue compared to a heavier gun that is not balanced properly. A gun that is properly balanced will feel natural in the operator’s hands and be easy to maneuver. When a gun is not balanced correctly, it might feel more unwieldy or uncomfortable to use. This can make a difference in operator comfort and productivity.
Customize for the job
Because welding applications differ for every welding operator, customizable GMAW guns can be a good option to gain greater comfort. Poor welding operator comfort can directly impact productivity and efficiency.
Some gun manufacturers offer online resources to help welding operators configure a GMAW gun for the exact specifications of the job. This helps ensure the gun is suited to operator preferences and the needs of the application — for greater comfort and productivity. For example, most welding operators do not make huge, sweeping movements when using a GMAW gun. Instead, they tend to use more minute, delicate maneuvering of the gun. Some configurations allow users to choose an option available for fume extraction guns — for example, a ball and socket swivel design that helps the vacuum hose to move separately from the handle. This improves flexibility and reduces the wrist fatigue for the welding operator.
Use correct positioning and form
Utilizing proper weld position and form are additional ways that welding operators can maximize comfort on the job. Repetitive strain or prolonged uncomfortable postures can result in operator injury — or even the need for costly and time-consuming rework due to poor quality welds. Whenever possible, place the workpiece flat and move it into the most comfortable position. It’s also important to maintain a clean working environment. In some cases, a fume extraction gun paired with the proper portable fume extraction system can be a viable option to replace wearing a powered air purifying respirator and lessen the amount of equipment the welding operator must wear. To maintain compliance and safety, it’s always a good idea to consult an industrial hygienist to be certain that’s an appropriate step. In addition, operator comfort can be maximized by using stable posture and avoiding awkward body positioning, and by not working in one position for long periods. When welding in a seated position, operators should also have the workpiece slightly below elbow level. When the application requires standing for long periods, use a foot rest.
Having the right equipment, choosing equipment or accessories that are easy to operate and promote operator comfort, and utilizing proper welding technique and form are all important steps toward achieving a comfortable, safe work environment for welding operators. Lightweight welding guns with appropriate handle and neck designs for the job and for the operator can help achieve safe and productive results. The reduction of heat stress, wrist and neck fatigue and repetitive motions can also help decrease overall physical and mental stress for welding operators. To achieve optimal results, consider the numerous options available in tailoring a GMAW gun that is right for the application and operator preference.
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