Arc welder dies when using an
old barrel for a worktable.
A 38-year-old male arc welder died during an explosion at a rural construction company, while he was repairing a large garbage truck. The victim was making some heavy brackets for the back of the dumptruck, using a wire welder and an old metal 55-gal barrel as a worktable. Apparently the heat or sparks from the welding ignited residual vapors and/or material in the barrel, causing it to explode. The explosion blew the lid off the barrel, which hit the man in the face, and it started a fire in the immediate area. An employee heard the explosion and saw the building on fire near the back of the garbage truck. The victim was found unconscious and not breathing, with exploded portions of the drum falling about him. Secondary multiple explosions and fires began immediately and it was impossible to rescue the man. The fire increased rapidly and involved propane and acetylene tanks in the establishment. Fire investigation failed to reveal what substance was in the barrel. Than victim may have burned through the lid of the barrel while welding, or had attached the grounding clamp to the barrel, causing the explosion. The welder died from severe head injuries.

#1: Welders must be suitably trained in the safe operation of their equipment and process.

-- Welding sparks may travel up to 35 feet! Combustibles must be moved or covered with a fireproof blanket.

-- Coiled welding cable must be kept in good repair and spread out when being used.

-- A separate electrical connection should be used to ground items being welded.

-- Ground leads must be firmly attached and checked before welding is started.

 

#2: Welding should not be done on used drums until they have been thoroughly cleaned.

-- Even a small amount of residual oil or gasoline, when mixed with enough air, becomes deadly.

-- All flammable materials must be removed, including greases, tars, acids, or other substances
which produce a flammable or toxic vapor when heated.

 

#3: Employers should designate a competent person to conduct frequent and regular site safety inspections.

-- Regular inspections demonstrate the employer is committed to a company's safety program.

-- Unscheduled inspections should also be conducted, to review jobsite materials and equipment.