Medical gases are vital for various diagnostic and therapeutic purposes, from powering medical devices to providing anesthesia and breathing support. Storing and handling these gases properly is crucial for minimizing the risks of accidents, injuries and property damage.

Medical gases are stored under high pressure, making them at risk for fire or explosions if not handled appropriately. Some medical gases are toxic, and most canisters are extremely heavy, adding extra risk to incorrect storage and handling.

Due to these potential hazards, healthcare and medical facilities must follow strict medical gas storage standards and safety recommendations. Learn more about gas storage and accessibility considerations in health care facilities below.

Common Hazards of Medical Gas Cylinder Storage

Storing and handling medical gases correctly is key to creating a safer environment. Appropriate processes minimize the risks and hazards that can occur from improper actions. Common but dangerous hazards include: 

Fire hazards: Many medical gases are nonflammable, but other gases are, like ethylene oxide, which is used for sterilization. Oxygen, a common and necessary gas in medicine, is nonflammable but supports combustion. Should oxygen leak, it contributes to a fire hazard.
Physical risks: Gas cylinders are under high pressure, and storing or handling them incorrectly can cause them to rupture or explode. Cylinders are also extremely heavy. If a cylinder ruptures or falls over, it can create serious safety issues.
Asphyxiation and health hazards: Inert gases can displace oxygen if they leak, which can lead to asphyxia. Other medical gases are toxic. Exposure to carbon monoxide, a gas used as an anti-inflammatory agent, can cause death. 

Regulations and Compliance in Medical Gas Storage

The Occupational Safety and Health Administration (OSHA) and the National Fire Protection Association (NFPA) both publish regulations for compliance in medical gas storage.

OSHA Requirements for Medical Gases

The OSHA requirements for storing, using and handling compressed medical gases include the following:

1910.101(a): Cylinders must be inspected visually to determine they are in a safe condition. 
1910.101(b): Compressed gases must be handled, stored and used in accordance with Compressed Gas Association requirements.
1910.101(c): Compressed gas cylinders must have pressure relief devices installed. These devices must be installed and maintained in accordance with guidelines published by the Compressed Gas Association (29 CFR 1910.101(b) and Pamphlet P-1-1965).

Additionally, in regard to surgical suite compressed gases, OSHA states that all cylinders must be in an upright position — whether empty or full — and cylinders must be secured so they do not drop or strike any objects with force. When transporting medical gases, the cylinders must be secured with protective caps and should never be rolled or dragged.  

NFPA Standards

NFPA 99, also referred to as the “Health Care Facilities Code,” is a detailed outline of standards created by the NFPA to minimize the risk of fires, explosions and other related hazards in medical settings. Part of the guidelines and standards focuses specifically on carefully storing and using medical gases.

Some of the basic recommendations outlined in NFPA 99 for health care facilities include:

Clearly labeling and color coding piping systems. 
Storing gases in designated, well-ventilated areas. 
Separating gases accordingly to prevent cross-contamination or other potential hazards. 
Ensuring regular inspections, maintenance and staff training and education.

The NFPA also has requirements to ensure health care facilities adhere to fire codes.

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Best Practices for the Safe Handling and Storage of Medical Gases

These practices can help medical professionals avoid common mistakes when handling and storing medical gas cylinders.

1. Label Gas Cylinders for Identification

Gas canisters, valves, station inlets and outlets, distribution piping, alarm panels, and source equipment should be color-coded and labeled appropriately. There should be a wraparound label on all canisters that identify the gas and other key properties.

The name of the gas must be written in lettering that is at least 2 inches high and be either in white against the proper designated color or written in the correct designated color. The label should clearly indicate the gas is “for medical use.” Other components, like valves, should also be clearly labeled. 

The color codes for medical gases are as follows:

Medical air: Yellow
Carbon dioxide: Gray
Helium: Brown
Nitrogen: Black
Nitrous oxide: Blue
Oxygen: Green
Mixture or blend: Corresponding colors for each gas component in the mixture

2. Store Gas Cylinders Safely and Accessibly

Following medical gas storage standards are crucial for creating a safer environment. Some of the best practices to follow for storing medical gases include: 

Implementing fire-resistant enclosures for cylinder storage and supply systems.
Separating oxidizing gases — storing inert (nonflammable) gases in the enclosures is permissible. 
Ensuring enclosures have the correct vents. 
Installing proper gas monitoring systems and smoke detectors. 

Keep in mind that although they should be enclosed, gases must still be accessible, especially in emergency situations. 

3. Train Staff on Safety Requirements for Gas Cylinders

Training for risk management in health care facilities typically includes education on proper gas cylinder labeling and storage. All medical personnel working with or around gases should receive training and regular refresher courses in handling medical equipment and supply systems correctly.

Staff should also be trained on how to use personal protective equipment (PPE), such as gloves and eye protection, and how to properly inspect and maintain cylinders. Personnel must also be trained in emergency protocol in the event of a gas leak, fire or other hazard.

Get in touch with a Meritus Gas team expert to learn more about finding the right PPE and safety equipment for your team.

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4. Implement Gas Monitoring

One of the most vital elements of storing gases is having reliable and well-maintained gas monitoring and leak detection systems, as well as smoke alarms. There are various types of gas sensors and systems available. Multigas sensors are an effective choice as they can detect a range of gases, including combustible gases and other common medical gases like oxygen and carbon dioxide.

Explore Medical Gas Solutions With Meritus Gas Partners

Following approved methods and safety regulations for storing and handling medical gas is essential for all medical facilities. Regulations and protocols for handling medical gas are in place to help keep staff, patients, visitors and property more secure. 

At Meritus Gas, our partners are reliable and trusted distributors in the industry you can turn to for your medical gas supplies and solutions. Our partners provide quality gas that helps you streamline operations and maintain compliance with government regulations. Our partners also provide PPE and other safety equipment that equips staff to handle and store gas.

To get started, visit one of our branches or contact us for any additional information.

Some gases are highly flammable or combustible. Others are harmful if inhaled or exposed to your skin or eyes. If one thing is certain, it’s that the correct storage of compressed gas cylinders decreases the risk of accidents, damage to property and environmental hazards. Additionally, proper storage methods help maintain the gases’ integrity and ensure their intended use.

While safety is a major concern, adequate gas cylinder storage also prevents contamination. Manufacturing, construction and maintenance industries often use industrial gases in various processes, which means the quality of the gas is critical for optimal performance. Our industrial gas storage guide will show you how to store gas, the ideal storage conditions and how to prolong its life span.

How Do Storage Environments Affect Gases?

When considering the safe storage of gas cylinders in workplaces, consider the ideal storage conditions, as the environment will have an effect on gases, especially when storing specific types.

Impacts of Different Storage Environment Factors

The wrong temperature, humidity and space considerations can alter the quality of stored gases and increase health and safety risks. Gas storage guidelines recommend specific locations for these reasons. Here is how storage factors affect the integrity and hazard of industrial gases:

Temperature: Gas expands at higher temperatures, increasing the pressure in the cylinder. External heat or fire can cause compressed gasses to explode or create another fire source, especially when pressure relief valves release a flammable gas.
Humidity: When water vapor has no way to escape, cylinders can be exposed to dampness, causing valve protection caps to rust or stick. Also, if moisture finds its way into cylinders with open valves, it will result in internal contamination.
Space: If gases are stored indoors or in confined spaces with limited or no ventilation, leaked gases can accumulate. Some gases are denser than air and can cause toxic exposures, asphyxiation and even explosion with ignition sources.

Ideal Conditions for Compressed Gas Cylinders

Gas cylinders need to be stored in well-ventilated, cool and dry areas, preferably far away from possible ignition sources and combustible materials. This will decrease your risk of accumulating gas in case of a leak. Make sure the area is specifically designed for safe gas storage with appropriate fire-rated walls and ventilation.

The storage area’s temperature should be below 100 degrees Fahrenheit — be sure to ask your supplier about the lowest temperatures you can safely store the cylinders.
Keep cylinders as dry as possible.
The storage area should have enough space so cylinders can be grouped together by hazard class and full cylinders can be stored separately from empty cylinders.

Safety Measures for Storing Industrial Gases in Manufacturing Facilities

Every industry uses different types of industrial gases for various purposes, but the types of risks remain the same. Follow these standard procedures to store gas cylinders safely in your facility.

Divide full and empty containers: Store empty cylinders the same way you would full and functional cylinders, but keep them separate to avoid confusion.
Categorize gas containers: Divide and store similar gases together, such as flammable, oxidizers and toxic gases.
Keep cylinders away from heat sources: Keep gas containers far away from ignition sources, naked flames, combustible materials and electrical circuits.

Essential Safety Tips and Equipment

If you are someone who works with or handles industrial gas in some form, it is essential to use proper safety equipment. Here are a few essentials to be aware of:

Handle one cylinder at a time: Keep cylinders vertical as much as possible and avoid lifting them by the protective cap or guard.
Wear the right personal protective equipment (PPE): Use PPE like goggles, gloves, protective clothing and safety boots when handling industrial gas cylinders.
Use equipment designed for moving: Move gas cylinders or containers with a hand truck or cart.
Use a crane: If you need to use a crane, place the cylinders on a special platform with proper nets to prevent them from falling.
Secure stored gases: Use chains or straps to secure stored gases to a fixed surface or use a cylinder stand to prevent them from falling or moving.

Necessary Precautions and Safety Checks

If you are ever in doubt, review the gas safety data sheet (SDS) or contact your gas supplier. These are the common necessary precautions to adapt around industrial gas storage. 

Only accept labeled cylinders: Suppliers should provide gas in cylinders and containers with proper identifiable and precautionary labels.
Connect equipment before opening valves: Use the correct valve outlet connection and open the valve slowly facing away from you.
Let trained personnel perform transfilling: Transfilling cylinders can introduce contaminants into the container or cause overpressurization, creating potential safety hazards.
Call the experts: If you find any gas container issues, damages or leaks, immediately notify your gas supplier, as these pose safety hazards. Do not attempt to move these containers until given the go-ahead.

Industrial Gas Storage Compliance Considerations

The role of regulatory compliance is to prioritize the health and safety of employees, employers and their surroundings. Following strict guidelines regarding using, moving and storing gas containers helps mitigate the risks associated with industrial gases.

The Occupational Safety and Health Administration, the Compressed Gas Association, the National Fire Protection Association and the International Code Council are a few regulatory organizations to take note of in the industrial gas industry, with each of them having their own set of regulations.

Compliance with regulations enables organizations to do the following:

Preserve the environment: Some industrial gases are toxic and can cause harm to both people and the environment.
Keep the public safe: Mitigating risks can keep workers and the general public safe from any hazards and accidents.
Uphold an organization’s brand value: Upholding compliance shows an organization’s commitment to well-being, responsible operations and ethical business practices.
Gain a competitive advantage: People appreciate organizations that adhere to regulatory compliances and work with service providers that commit to the safety of their employees and the environment.

For example, since the hazards associated with industrial gases include fires and explosions, toxic gas exposures, oxygen displacement, and high-pressure systems, OSHA has put these gas storage requirements together:

When storing compressed gas cylinders inside buildings, keep them in a well-protected, well-ventilated and dry location that is at least 20 feet away from combustible materials.
Assign storage places away from elevators, stairs and gangways.
Do not keep gas cylinders in unventilated enclosures like lockers or cupboards.
Place and secure valve protection caps on cylinders.
Secure cylinders and use proper equipment when hoisting or transporting them.
Keep cylinders from dropping or being struck.
Cylinders should be secured in a vertical position when transported by powered vehicles.
Do not lift cylinders by their valve protection caps or use bars to pry them loose.
Use suitable cylinder trucks, chains or steadying devices to prevent cylinders from being knocked over during use.
Close the cylinder valve after use or when empty.
Separate oxygen cylinders from fuel-gas cylinders or combustible materials by at least 20 feet or with a noncombustible barrier.

How to Train Employees for the Safe Storage of Industrial Gases

Following regulations and using the correct equipment form only a small part of safe industrial gas storage. Many factors can contribute to gas-related accidents occurring at a workplace — one of them is poor staff training. Gas containers are often big and bulky, and it is easy for them to slip or to accidentally knock them over. That is why many accidents happen when workers try to move gas cylinders.

It is dangerous for gas cylinders to fall over, as cylinders could get punctured or valves may break off at the neck. This could cause compressed gas to rapidly release, resulting in the cylinder launching into the air or spinning out of control. Potential hazards from this occurrence may include:

Airborne cylinders can cause serious injury to people and damage property.
If the released gas is toxic, people could get injured from exposure.
In the case of flammable gas, any ignition or even static electricity can start a fire.

That is why it is essential for employees who will be working with or handling gas cylinders to receive training and know what to do during emergencies. Effective training programs should cover topics related to:

Hazard awareness: Workers should be familiar with the gas suppliers’ SDSs and the chemical properties of the gases the workplace stores.
Safety regulations: All employees need to know the storing requirements under the law and the safe handling procedures.
Safe handling methods: Both full-time employees and contractors should follow the proper handling procedures and know how to use equipment that moves gas containers correctly.
Site safety rules: People who visit or work on the site need to know the safety rules, including movement restrictions and prohibited activities.
Emergency response: Workers should be trained on evacuation and first aid measures and be able to locate first aid equipment and safety showers during emergencies.
PPE: Employees should know which PPE to use, how to use them and how to take care of or dispose of them properly after use.

Maximizing the Life Span of Industrial Gases Through Proper Storage

Another benefit of following regulations is that proper storage conditions can prolong the quality and usefulness of industrial gases. Facilities can implement strategies to extend the life span of the gases they use on-site, taking into account factors like environmental conditions, space constraints and costs associated with storing and disposing of old cylinders.

However, keep in mind that cylinders often degrade after two to three years when stored outdoors. Storing gas cylinders over the long term can increase the risks linked to moving gas containers. In comparison, cylinders containing corrosive gases degrade more quickly and can create regulator and valve problems. These cylinders should not be stored for longer than six months.

Here are tips for maintaining optimal storage conditions to maximize the life span of the industrial gases stored in your facility:

Detect leaks promptly: Inspecting and maintaining gas delivery systems and equipment regularly can help prevent leaks. You can reduce gas wastage by conducting regular visual checks and installing leak detection systems so your supplier can repair the cylinders sooner rather than later.
Maintain storage area: Ensure gas containers are stored in a cool and dry space with proper ventilation, where they will be protected from physical damage and exposure to moisture and contaminants.
Manage gas cylinder inventory: Implement a tracking and inventory management system to keep track of gas cylinders, monitor their usage and place new orders in a timely manner. This approach helps avoid unnecessary downtime and prevents losing cylinders due to expiration.
Train and educate employees: Teaching employees the importance of gas conservation can help create a culture of responsibility and awareness, contributing to the extension of industrial gas life spans.
Collaborate with gas suppliers: Gas suppliers can provide insights, recommendations and technological support to optimize gas usage and extend their life span with customized solutions.

Addressing Common Challenges in Storing and Handling Industrial Gases

Storing and handling industrial gases can present various concerns. Here are some common challenges and proactive measures to mitigate them:

Safety hazards: Industrial gases are often flammable, reactive or toxic and some have asphyxiating properties. These hazards can be minimized with proper staff training, appropriate safety equipment such as PPE for moving and handling gas containers, and regular risk assessments to identify potential hazards and implement mitigation measures.
Storage requirements: Different industrial gases have specific storage requirements to maintain stability and integrity. Ensure storage facilities and equipment align with guidelines from the relevant organizations. Maintain optimal storage conditions and mark containers according to regulatory requirements.
Gas leaks: Gas leaks lead to safety hazards, wastage and product loss. Conduct routine inspections of gas cylinders, valves and connectors to identify and repair leaks or damages. Encourage a culture of safety and responsibility by educating employees to be vigilant and report any irregularities.
Inventory management: Poor inventory management can lead to inadequate stock or expired gas cylinders. One proactive measure is to implement a first-in, first-out approach to reduce expired products. Track and monitor inventory and remove expired gas from storage.

Reach out to Meritus Gas Partners for Industrial Gas Storage Guidance

With decades of experience in the industrial gas industry, we at Meritus Gas Partners have built a national group of safe and reliable gas distributors. We have the knowledge and network to provide you with the highest-quality gas equipment as well as PPE and safety equipment that follow the guidelines of safety organizations.

If you require specialty gas equipment, repairs or guidance and assistance with your industrial gas storage needs, contact Meritus Gas Partners today, and one of our sales representatives will get back to you.

Carbon dioxide (CO2) is an odorless, colorless, non-flammable gas naturally present in the atmosphere at safe levels. However, CO2 can pose a significant health risk when it accumulates in an enclosed space. This can happen when working with dry ice — the solid form of CO2 — or because a CO2 container or pipe leaks in a building with insufficient ventilation.

If you work with CO2, you must be aware of the health risks and how to handle a situation where CO2 levels become too high. This article outlines the symptoms of CO2 exposure, safety regulations, handling guidelines and leak detection tools. We also cover the importance of an emergency response plan and what to do in a CO2 emergency.

CO2 Health Risks

CO2 gas is relatively harmless on its own, but prolonged exposure to high concentrations of CO2 gas or contact with dry ice can result in serious health concerns. Understand the following CO2 health risks and overexposure symptoms to stay safe.

CO2 Gas

The main health risk associated with CO2 gas is asphyxiation. This can happen when there are high concentrations of CO2 in an enclosed space, as the gas will displace the oxygen in the air and make it hard to breathe. Symptoms start with drowsiness, headaches, an increased heart rate, nausea and dizziness. They can progress to difficulty breathing, convulsions, loss of consciousness and death as CO2 levels rise.

Most people will start to see mild CO2 exposure symptoms after a few hours of inhaling air with a CO2 level of 2,000 parts per million (ppm). More severe symptoms occur above 5,000 ppm, and a concentration of 40,000 ppm is immediately dangerous. Moving to an area with clean air will help relieve less severe symptoms.

Dry Ice

Handling dry ice and dry ice containers without the correct protection can result in frostbite. Dry ice freezes at -109 degrees Fahrenheit (-78 degrees Celsius), and frostbite occurs at temperatures below 31 degrees Fahrenheit or -0.55 degrees Celsius. With prolonged exposure, dry ice can cause numbness, burning sensations, blistering and tissue death.

Dry ice also sublimates incredibly fast at room temperature, which can cause rapid asphyxiation if there is insufficient ventilation. Dry ice kept in an enclosed container can also explode if the pressure rises too high. An exploding container can cause damage to the surrounding area and injure people nearby.

CO2 Safety Regulations

Paying close attention to and following industry standards for proper CO2 handling is key. The Occupational Safety and Health Administration (OSHA) sets exposure limits for those working with CO2. The OSHA permissible exposure limit for an eight-hour period is 5,000 ppm. The average CO2 level over that period cannot exceed 5,000 ppm. Always consult with local authorities regarding the safety regulations in your area.

How to Handle Carbon Dioxide Safely

Knowing the safety guidelines and precautions for working with CO2 helps increase safety and reduce risk within the workplace. The Compressed Gas Association (CGA) has created specific guidelines for working with dry ice and CO2 gas you can follow to protect yourself and others.

Training programs: All staff working with or around CO2 and dry ice must receive CO2 safety training. They should understand how to handle CO2 containers, the symptoms of CO2 exposure and how to respond to a leak or health emergency.
Install detectors: Install CO2 detectors in areas exposed to CO2 to warn occupants when levels rise too high. The detectors must have both audible and visual warning cues. Regularly inspect all alarms and equipment to ensure they are working as intended.
Monitoring levels: Always check the CO2 levels before entering a storage area. Only trained staff wearing the correct PPE should enter an area with a high CO2 concentration.
Ventilation: Rooms and vehicles with dry ice and CO2 gas must have sufficient ventilation to prevent CO2 buildup.
Personal protective equipment: Always wear the correct clothing, eye protection and additional gear when handling CO2 containers or entering a CO2 storage room. Use tongs or gloves to move pieces of dry ice and avoid direct skin contact.
Safe storage: Always store gas cylinders securely, upright and away from heat. Keep dry ice in a well-ventilated container that prevents pressure buildup.
Signage: Label all containers, rooms and areas with CO2 exposure risks clearly. Signs and labels should warn users of CO2-related risks and what to do in an emergency.

CO2 Leak Detection Equipment

Active CO2 detection techniques are the most effective way to warn of high CO2 accumulations in a confined space. One common piece of active detection equipment is a CO2 alarm. The alarm includes a CO2 sensing probe installed in the confined space and a control unit on the outside. The control unit displays the CO2 level within the space at all times. It uses both audible and visual indicators to warn of high CO2 levels.

Other leak detection tools, including over-run alarms, nitrogen separators and in-line flow meters for beverage gas monitoring, are available. If you currently use the passive leak detection technique of a ball floating inside a flow meter, we recommend you change to another method. This method is ineffective during busy service times.

Preparing for Emergency Situations Involving CO2

Businesses that use CO2 in their daily operations should prepare an emergency response plan for dangerous CO2 situations. This plan should include emergency numbers, a map of all CO2 systems in the building and escape routes and meetup points. Teach the plan to all staff working with CO2 and have it accessible in work areas. Staff should also be aware of areas where CO2 could accumulate to toxic levels.

If you suspect you currently have a CO2 leak, identify possible confined spaces that may accumulate high concentrations of CO2 or nitrogen. CO2 collects in low-lying and confined areas, so keg coolers, closets, basements and enclosed rooms are dangerous during a leak. Air out any contaminated areas thoroughly before entry. All staff must immediately evacuate the building at the first signs of a leak.

Do not enter the area if you suspect there is a chance of compressed gas accumulation. If you can, shut off the gas supply that feeds the leak without placing a person at risk of entering a confined space. Contact emergency services if you can’t safely shut off the gas supply to the leak or if you think there is a safety concern.

Elevate Your CO2 Safety Standards With Meritus Gas Partners

At Meritus Gas Partners, we understand the importance of CO2 safety as we are a partner of leading industrial carbon dioxide suppliers. Meritus Gas Partners members can offer you industrial-grade, food-grade and beverage-grade CO2 tanks. Each supplier complies with standard safety regulations and has decades of experience helping customers with safety equipment.

All of our distributors have various solutions to help you meet your business’s safety needs. Whether you need a CO2 alarm, gas equipment or PPE, you can head to a Meritus Gas Partner location for assistance. Our partners can advise you on the cost of every leak detection option available and assist with installation if needed.

Contact us today if you have any questions.

Professional welders make the job look easy, but the reality is that welding is a dangerous occupation that comes with health and safety risks. Welders work with compressed gases, electric currents, flammable materials and specialized equipment to complete a job, all of which can pose various hazards, from the possibilities of electric shock, fire and explosions to toxic fume exposure.

Welders can protect themselves and others on a job site by always following safety measures. This ultimate welding safety guide explores safety standards and regulations in welding so that you can maintain a workspace that is as safe as possible.

The Basics of Welding Safety

Welding safety is paramount to prevent accidents, injury and compromised health. A safe welding area also helps welders work efficiently and deliver quality projects.

To mitigate the risks associated with a welding workplace, follow these guidelines:

Welders should always dress in full PPE. 
The work table must be adequately grounded for arc welding, and the area should always be dry. 
All staff should be aware of possible fire hazards, know where fire extinguishers are located and know how to operate them.
Work areas should have an adequate ventilation system, and no fumes should escape the welding area.
Equipment and tools must be well maintained and only qualified staff should use them.
Work areas should be completely free of unnecessary clutter.

Training all staff who would need to enter weld areas is an excellent way to uphold safety standards and regulations in welding. Through continued education programs, workers stay up to date on rules and policies to create a safe welding environment.

Understanding Occupational Safety and Health Administration Guidelines

Understanding OSHA guidelines ensures a safer facility. OSHA has welding safety requirements in place that help protect workers and property and help facilities stay compliant. OSHA’s regulations and requirements cover all aspects of welding and include standards for training, techniques, PPE, fume and gas management and more. 

The most effective way to navigate OSHA’s requirements is to educate facility managers on OSHA standards and conduct regular internal checks.

Identifying Health and Safety Risks in Welding Shops

Risk management assessments provide an excellent foundation for ensuring an overall safer workspace. Without proper risk assessments, facility owners or managers could face liability costs or property loss and welders and staff can face unnecessary risks regarding their health and safety.

A proper assessment helps identify risk management opportunities in welding. Risk assessments should address the following:

The condition of welding, cutting, and brazing tools and equipment and how regularly equipment is maintained. 
Electrical safety.
Fire and explosion safety, including the presence of flammable materials, locations of fire extinguishers and their working condition. 
Optical radiation from infrared or ultraviolet light.
Weld-cleaning practises. 
Welding position and techniques. 
Noise levels. 
Clearly-marked emergency exits. 
Items that pose slipping, tripping and falling hazards in the welding area. 

Working through a risk assessment that covers these points can help you find ways to prevent welding-related accidents.

Common Welding Dangers and Prevention Techniques

Proper welding techniques are vital for preventing accidents, injuries and exposure to toxic fumes.

Preventing Electric Shock in Welding

Various welding techniques use electricity to produce arcs and fuse metals, so understanding arc welding techniques for safety is a top priority. Working with high-voltage equipment leaves the risk of electric shock, which is potentially fatal. Through proper checks and techniques, welders can reduce the risk of electric shock and ensure increased safety during arc welding:

Wear full PPE, including the appropriate eyewear and helmet.
Ensure the capacity and the input power of the outlet are compatible before welding.
Check the condition of all cables.
Make sure you ground metal with an earthing clamp. 
Always work in dry conditions wearing dry PPE.
Never rest your arms or hands on the workpiece once welding starts.
Stand on an insulating mat.
Shut down the welder when you aren’t using it.

Mitigating Risks Associated With Fumes and Gases

OSHA’s safety requirements outline guidelines for proper ventilation and control of hazardous fumes and gas. Adequate ventilation is key in any form of welding — whether using electric arcs or gas welding to bond metals, the process produces smoke that contains toxic fumes and gas byproducts.

Breathing welding fumes can lead to various health complications, including the risk of lung-related diseases, an increased risk of cancer, stomach ulcers, kidney damage, damage to the nervous system and asphyxiation.

All weld areas must have adequate ventilation systems, and workplaces should ensure welds only take place in confined spaces with proper ventilation. Workers or anyone in the weld area should wear respiratory protection where required.

Fire Prevention Measures in Welding

Welds produce incredible heat to bond metals and require the use of flammable materials. Always follow these fire prevention measures in the workspace:

Have working fire extinguishers in the weld area and train staff on how to use the extinguishers.
Keep flammable materials separate from hot work areas and protect them with flame-proof covers.
Use thermal barriers when necessary.
If the floor is combustible, it must be kept wet or protected with flame-proof materials.
Ensure proper ventilation at all times.

Safety Checks for Welding Equipment

Safety during welding often starts with using well-maintained equipment. Working with faulty equipment can easily lead to preventable accidents and injuries.

Follow these checks for arc and gas welding equipment:

Check hoses for defects.
Check gauges and fittings. 
Check shut-off vaults, tip connections and hose couplings on torches.
Check that electric cords, cables and electrical holders are free from defects.

Key Personal Protective Equipment for Welders

One of the most effective ways welders can prevent injury is by wearing the correct personal protective equipment. Through the proper use of PPE, welders can protect themselves from exposure to toxic fumes, burns from UV radiation and hot metals, cuts, shocks, eye injuries and even broken bones from heavy objects accidentally falling.

Essential protection equipment for welders includes:

Welding helmets in the right shade
Welding glasses in the right shade
Work boots
Welding gloves
Welding respirators
Heat-resistant jackets and pants 
Ear muffs
Ear plugs 

Be sure to follow these extra tips to ensure proper PPE use:

Choose sturdy leather gloves that also allow for mobility. 
Ensure welding jackets have snaps, not buttons, for easy removal. 
Quality leather boots are best. Metal can quickly melt through other shoe materials. 
Do not tuck pants into shoes. 
Only weld with the hood down. 
Avoid synthetic clothes.
Wear a respirator. 

Partner With Meritus Gas Partners for Your Welding Safety Needs

At Meritus Gas Partners, we work with reputable distributors in the industry that prioritize safety by offering premium equipment and services that streamline your operations. Our partner businesses provide quality solutions, including welding equipment repair services.

You can rely on professional, efficient and helpful services from a partner near you for all your gas welding supplies. Feel free to visit any of our branches or contact us today to discuss solutions to suit your needs.

Dry ice is very different from the ice we get when water freezes. As solidified carbon dioxide, dry ice has the same chemical formula as carbon dioxide gas — CO2 — just in a different form. Because dry ice is extremely cold, it has many practical uses. 

Medical professionals sometimes use dry ice as an alternative to liquid nitrogen. Doctors can use the substance in minor surgeries to remove skin imperfections and to store various biological samples to keep them fresh. Dry ice is an essential tool in the food industry, seeing use by restaurants, supermarkets and commercial kitchens to meet food storage and preparation regulations. In shipping, dry ice keeps perishables cold and fresh until they reach their destination.  

While dry ice clearly is valuable for many different applications, anyone handling it must do so with care. Working with dry ice without following safety precautions or proper storage guidelines can lead to severe injuries.

This comprehensive guide will cover how to handle dry ice, including the proper ways to store, transport, ventilate and dispose of it. 

Understanding Dry Ice

Dry ice is produced by cooling and pressurizing carbon dioxide gas to get it to solidify. Carbon dioxide gas solidifies at extremely low temperatures. While ice forms at 32°F (0°C) — water’s freezing point — dry ice forms at minus 109.3°F (minus 78.5°C).

Properties and Applications  

Other key properties and characteristics of dry ice include: 

Nontoxic: Carbon dioxide is considered nontoxic, so CO2 gas and dry ice are safe for food-related applications like preserving perishables. Because dry ice is nontoxic, it is also safe for certain medical uses.  
Sublimation: The characteristic fog effect dry ice produces happens due to sublimation — CO2 transitions directly from a solid to a gas without melting and becoming liquid. That means it doesn’t leave a mess behind in the same way as regular ice.
Carbonation: Carbon dioxide forms carbonic acid when it combines with water. Manufacturers can use dry ice to carbonate drinks, giving them their fizziness. 
Nonconductive: Dry ice is nonconductive and therefore safe to use with electrical components. 

CO2’s unique properties make dry ice an ideal substance for a range of different use cases beyond those mentioned here: 

As a freezing and cooling agent for medical supplies, lab samples, pharmaceuticals and food. 
For dry blasting — an eco-friendly, nonabrasive cleaning method. Dry blasting prepares surfaces by removing contaminants and is widely used in manufacturing. 
As a pest control method — temperature drops can help eliminate pests, so placing dry ice in strategic areas like burrows or nests can mitigate an infestation. 

Hazards

Due to some of its extreme properties — like its very low temperature — there are hazards associated with using dry ice:

Frostbite: Temperatures at or below 31°F (minus 0.55C) can lead to frostbite, so there is a high risk of severe frostbite if dry ice comes into direct contact with skin. Dry ice will constrict blood vessels, freeze skin cells and cut off blood supply to the point of contact, potentially leading to irreversible tissue damage with continued exposure.
Asphyxiation risks: Dry ice sublimates, or changes from solid to gas, at temperatures above minus 109 °F. Sublimation can release substantial volumes of CO2, and CO2 displaces oxygen. If the amount of CO2 present in an area becomes too great, it can make breathing difficult and lead to loss of consciousness or death.  
Explosion: Dry ice can release large volumes of CO2 gas and cause high pressure in a closed container. If not stored correctly, the container can explode as the pressure builds. A dry ice explosion can cause serious damage. 

Proper Handling Techniques

The Compressed Gas Association (CGA) works directly with regional, state and federal agencies to promote gas-related safety practices and regulations. The CGA also outlines specific guidelines for handling CO2 according to health and safety standards. Implementing adequate safety measures when handling dry ice is essential to avoiding injury. Observe the following guidelines for dry ice storage, disposal and transport to protect yourself and anyone else in the vicinity. 

Storage and Transportation

Industries use dry ice for storing and transporting goods that need to be kept fresh, including food, pharmaceuticals and biological samples. By law, dry ice is a hazardous material, and anyone handling it must have the correct training to do so. All shipping companies have specific guidelines for transporting hazardous materials. Additionally, the United States Department of Transportation (DOT) has the following Materials of Trade (MOT) regulations in place: 

The CGA Dry Ice Safety Resource Center recommends always checking CO2 concentrations before entering a storage area. 
You must mark packages to show they contain dry ice. 
There is a limit on how much dry ice you can transport at any one time — 440.93 pounds (200 kilograms).
Packages containing dry ice must have a design that allows CO2 gas to escape to prevent pressure buildup and subsequent container explosions. 
Packages with dry ice must be entirely separate from the main cabin of the vehicle. 
You must take measures to secure the package against movement and damage. 
The driver and all occupants of the vehicle must be aware of the presence of dry ice and know MOT regulations.  

Another important safety tip for moving dry ice is not to set the ice directly into empty glass containers or on surfaces like countertops. The extreme difference in temperature can crack the surface or container. 

Avoiding Skin Contact

It’s imperative to avoid direct skin contact when working with dry ice, as it can cause frostbite very quickly. Although a very brief touch may not necessarily cause harm, no amount of contact is considered safe. Touching dry ice, even for just a second, may make skin red and sensitive, just like a hot burn. 

If you maintain contact with dry ice for longer than a second or two, your skin cells will start to freeze and die. Holding on to dry ice without protective gear will cause varying degrees of frostbite. Frostnip, a milder form, is what happens when the skin turns red or purple from brief exposure to extreme cold. Even though frostnip is temporary, it’s best to treat it immediately and see a health care professional to avoid any chance of lasting problems. 

Superficial or surface frostbite requires prompt medical attention. Signs of superficial frostbite include skin feeling warm, pins and needles in the affected area, blue and purple patches that resemble bruising, stinging and swelling, peeling, and blisters. 

The third stage of frostbite is deep, severe damage that affects subcutaneous tissue — the lower, deeper layers of skin. Severe frostbite makes skin completely numb and may make it impossible to move the affected area. Blisters will form and skin will become hard and black. This extensive tissue damage can cause additional complications due to lack of blood supply to the affected tissue, including secondary infections and gangrene. Severe frostbite is a medical emergency requiring urgent care.  

The danger in handling dry ice for even brief periods is that the numbness caused by the cold may prevent you from realizing that frostbite is setting in. Always follow these safety precautions to prevent the chance of dry ice burn: 

Do not handle dry ice with bare hands. Always use tongs, gloves and other insulated tools. 
Wear appropriate personal protective equipment (PPE), including a lab coat and thermally insulated gloves (nitrile exam gloves will not provide sufficient protection). Also, wear safety goggles or a face shield to prevent corneal damage from dry ice accidentally contacting the eyes. In some instances, wearing a respirator may be appropriate. 
Never place dry ice in pockets, even if the clothing is insulated. 
Never ingest dry ice fragments. Dry ice can freeze the tissue in the mouth, throat and stomach, and the buildup of CO2 gas during sublimation can rupture the stomach. 

Ventilation Precautions

When you expose dry ice to room temperature, it sublimates, changing straight from a solid to a gas. Due to the potential dangers of sublimation, you need to take careful measures to ensure your dry ice storage area is suitable for the task. Never store dry ice in an airtight container, as the resulting buildup of gas will likely cause an explosion. Similarly, do not dispose of dry ice by throwing it in a sink, toilet or drain of any kind, as the pipes may freeze or burst. 

There is also the risk of asphyxiation as dry ice sublimates and displaces oxygen in the air. Exposure to large volumes of CO2 gas lowers the amount of oxygen in the body, which causes hypoxia. Symptoms of hypoxia include difficulty breathing, rapid heartbeat, restlessness, confusion and bluish skin. 

To prevent explosions or asphyxiation, label all containers to show they contain dry ice, ensure that they are not airtight and store them in a space with ample ventilation. Do not store dry ice in confined areas like walk-in refrigerators. Only use packaging that has been designed specifically for holding dry ice, like a specially made cooler or insulated container. You can use Styrofoam coolers, as they are insulated but not airtight.

If you are storing large quantities of dry ice, consider monitoring oxygen levels in the area as an added safety measure.   

Safe Disposal

Having a safe dry ice disposal method is just as important as using safe handling practices. Dry ice will sublimate when you discard it, so you want to have a proper space for it to do so safely, such as an inaccessible outdoor area. You can take these steps to keep everyone in the vicinity safe:

Handle sublimating gas with the same care as solid dry ice. Only trained individuals in full PPE should dispose of dry ice. 
Keep dry ice on a suitable surface like Styrofoam or hard plastic while it sublimates. 
Let the ice sublimate in a well-ventilated area well away from children, pets and uninformed adults. Keep the area off-limits if you can. 
If your disposal area is indoors, open windows and doors to allow for proper ventilation.
Allow the ice sufficient time to sublimate completely — you’ll want to wait at least 24 hours before checking it. You may need to wait longer depending on the volume of ice you have. 
Do not spend extended periods of time in the same area as the sublimating ice. Wear a respirator if there is a risk of extended exposure. 

FAQs

Where Can You Obtain Dry Ice? 

You can obtain dry ice from industrial gas suppliers, companies that supply welding industries and relevant regional suppliers. Some grocery stores may also carry dry ice. Depending on the supplier, orders can be collected directly or delivered regionally. If shipped, the dry ice will be transported in insulated packaging and in accordance with MOT regulations.

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How Long Does Dry Ice Last? 

The size of the block of dry ice you get and how you store it are some of the factors affecting how long it lasts. If you leave a small- to medium-sized block of dry ice out at room temperature, it will likely sublimate within three to five hours. However, you can keep your dry ice for longer by storing it in an insulated cooler (with sufficient venting). If you store two blocks of dry ice in a regular-sized Styrofoam cooler, it can last for around 24 hours. A large quantity of dry ice properly stored in a sizeable, thick Styrofoam cooler may last three to four days. 

What Are Some Common Mistakes When Handling Dry Ice? 

Some common mistakes when handling dry ice include not wearing appropriate PPE, storing it in a freezer or in a tightly sealed container, ordering more dry ice than what you need and disposing of it incorrectly. Another common error is purchasing the ice too far in advance, which results in it starting to sublimate before it can be used. For that reason, you should always aim to receive or collect a dry ice order only a few hours before you need it. 

Connect With Meritus Gas Partners for Gas Services

Following the proper procedures and recommendations for handling dry ice is a good business practice. By training staff, supplying PPE and emphasizing the significance of safe practices for using this substance, you can mitigate risks and protect your staff. You can also contact your local gas supplier to discuss your needs regarding dry ice. A knowledgeable supplier will be able to fill your order as well as provide the guidance you need to transport and handle it. 

At Meritus Gas Partners, our partners are reputable distributors in the industry that you can trust for your gas needs and welding supplies. Our partner businesses offer premium gas and welding solutions that empower you to improve your operations. 

You can visit any of our affiliated branches or contact us today with any questions for our expert team. We’ll connect you with efficient and helpful services, supplies and equipment from a partner near you.

Gas leak prevention and detection are crucial for safety and compliance across many industries, including welding, chemical industries, utilities and semiconductor fabrication. Since gas leaks can lead to various health risks, injuries and fatalities, having prevention and detection measures in place is critical.

Having standard practices to identify potential hazards, monitor for leaks, evaluate the severity of leaks, and respond to emergency situations accordingly is essential to a safer and more compliant workspace.

Gas Leak Preventive Measures

Taking proactive measures to prevent gas leaks is the first step to creating a safer work environment. Gas leaks can occur due to worn-out, damaged, or malfunctioning appliances or pipelines, corroded pipes or cylinders, poor installation and/or maintenance, a lack of training, or human error.

You may do the following to combat these causes and have effective preventive measures in place:

Ensure regular maintenance of equipment.
Schedule system upgrades for enhanced safety.
Providing the right PPE and safety equipment.
Conduct regular safety audits, both internally and externally, so that you comply with OSHA compressed gas and equipment safety standards.
Keep staff up to date with safety and skills training. In an environment where staff work with compressed gas, ensure they get proper and regular training for safely handling gas cylinders.

Effective Gas Leak Detection Solutions

There are many gas leak detection methods and devices you can incorporate into your workplace.

Gas Leak Sensors

Gas leak sensors are one of the most effective safety devices you can install. Different types of sensors include:

Catalytic bead sensors: These sensors can detect combustible gases.
Infrared (IR) gas sensors: IR gas sensors are commonly used to detect carbon dioxide and hydrocarbons by measuring the absorption of infrared radiation from these gases.
Electrochemical sensors: These sensors are designed to detect toxic gases like chlorine, hydrogen sulfide and carbon monoxide based on chemical interactions with these gases, which produce an electrical signal that indicates the level of the gas.
Photoionization detectors: These devices can detect volatile organic compounds (VOCs) and gases using ultraviolet light.
Multigas sensors: Multigas sensors can detect a range of gases and vapors, including combustible gases like methane and propane, toxic gases like formaldehyde and carbon monoxide, VOCs, and other gases like oxygen and carbon dioxide.

One of the most important considerations when choosing gas leak sensors is looking for systems that offer real-time monitoring and automated alerts, allowing you to respond to potentially hazardous situations immediately. Additionally, make sure the system you select aligns with any relevant regulations.

Other Leak Detection Options

Other leak detection tools include over-run alarms on green air supply nitrogen separators and in-line flow meters for beverage gas monitoring.

As always, active monitoring alarms are far superior to passive leak detection methods. If you currently have this type of passive leak detection (which you can identify as a tiny floating ball inside a plastic tube), be aware that it can be ineffective during busy service times.

We recommend active gas level monitoring over passive leak detection to our customers. At Meritus Gas, we can advise you on the cost and supply of available leak detection options.

Emergency Protocols and Leak Response Plans

Creating a comprehensive gas leak emergency protocol and response plan is crucial for compliance and safety. An ideal plan will include the following:

The first port of call in an emergency.
Who to contact during emergencies.
The role of each team member in the plan.

In the event of a gas leak, be aware of any possible confined spaces that may accumulate high gas concentrations. Depending on your industry and facilities, these may include keg coolers, closets, basements, and enclosed rooms. Do not enter that area if you suspect there is any chance of an accumulation of any type of compressed gas.

If you can, shut off the gas supply feeding the leak without putting a person at risk of entering a confined space. If you cannot safely shut off the gas supply to the leak and think there is a safety concern, contact your local fire department for assistance. 

Who Should You Call During a Serious Gas Leak?

If you think you have a serious safety situation, call 911 immediately and request your local fire department respond. You can then call your local Meritus Gas Partners distributor to advise us of the situation and to receive further assistance and instructions.

Get Leak Detection From a Meritus Gas Partner Near You

Following safety protocols and having the right gas leak monitoring systems in place are vital safety practices for any company. By equipping your staff and having an emergency response plan, you can reduce potential risks and make your workspace a safer place for all.

At Meritus Gas Partners, our partners are trusted gas distributors who will gladly assist you in purchasing a gas leak alarm. Whether you’re planning on installing the alarm yourself or you would like our certified beverage technicians to perform the work, we are your partner in providing your employees with a safer work environment.

Visit any of our affiliated branches or reach out to us today with any questions for further assistance from our expert team.

Anyone involved in welding practices, whether a small independent fabricator or someone who works for a welding-intensive company, must know fundamental welding safety tips. In general, it’s essential to use safety equipment for welding, abide by OSHA welding safety regulations and purchase equipment and supplies from reputable gas and welding manufacturing brands to ensure a healthy and safe work environment for welders.

Below are eight safety tips for welding that will help equip welders with best practices to avoid hazards and establish safer workspaces.

The Importance of Welding Shop Safety

According to OSHA, welders are at risk of various safety hazards while on the job. The American Welding Society also maintains a comprehensive fact sheet detailing welding health and safety concerns. Thankfully, most of these concerns are entirely avoidable or require standard safety protocols to mitigate potential danger.

By fostering welding best practices, such as supplying and ensuring welders wear safety equipment for welding, employers can help protect welders from the five most common welding safety hazards:

Physical harm: Welders are at risk of a range of physical dangers that can cause cuts, burns, eye injuries and more. 
Welder’s flash: The dangers of welder’s flash, or arc-eye, can lead to temporary or permanent blindness. 
Welding fumes: Without proper ventilation or respirators, welders are at risk of respiratory issues and diseases.
Electrocution: To avoid minor and significant electric shock, welders must ensure equipment is adequately grounded and take precautions.
Fire and combustion: Welders work with several flammable materials while welding, and not adhering to welding best practices may lead to fire and explosions.

Welding Industry Safety Standards

OSHA document 29 CFR 1910 Subpart Q breaks down OSHA welding safety and procedural requirements, including various topics that pertain to welding best practices. Furthermore, the American National Standards Institute (ANSI) outlines a spectrum of welding safety standards, including general welding safety standards, arc welding safety standards and more. The level and manner of implementation depend on the type of welding and the company’s context.

Top 8 Welding Safety Tips and Best Practices

Welders should hold themselves and others accountable to uphold health and safety standards and maintain an optimal working environment. The following is a breakdown of the top welding safety tips every welder and welding employer should know and implement.

1. Training and Education

There is always a need for skilled welders. This is particularly true considering the current welder shortage in the United States. There are various avenues for welders to learn how to weld and acquire positions in multiple industries. Although a person can learn to weld without formal training, obtaining proper certification or accreditation is best before looking for work.

Being properly certified may lead to more and improved job opportunities. Further, education, which is part of certification, helps welders stay updated on safety regulations and best practices. This means engaging in ongoing learning programs that offer refreshers and insights into the latest safety practices and welding techniques.

Before using unfamiliar or new machinery and equipment, it’s vital to understand the proper procedures. Although laborious, studying the user manuals, warning labels and safety guidelines is a welding best practice. If a welder or their employer feels that further training is needed before using the welding equipment or consumables, that’s a chance to expand workplace knowledge and safety.

2. Personal Protective Equipment (PPE)

What’s the essential safety equipment for welders to avoid injury? In order to help prevent potential physical injuries and diseases, welders should always dress in flame-resistant clothing and other PPE and safety equipment for welding as outlined in OSHA Standard 1910 Subpart I, which discusses all relevant requirements for welding operations. 

Types of essential PPE and safety equipment for welding include:

Eye and face protection: To avoid welder’s flash or arc eye, welders must wear a welding helmet with a face shield, welding goggles or welding safety glasses, depending on the project.
Hand and foot protection: Welders handle various materials and welding equipment. Therefore, welders should wear application-specific gloves that are heat-resistant and non-conductive to protect their hands and lower arms. Welders should also wear steel-tipped high-top leather shoes with rubber soles. For industry and area-specific use, welders may want slip-resistant and electrical hazard shoes.
Head protection: A welding hood, head cover or welding cap is ideal for protecting a welder’s head, neck and ears from sparks that can cause severe burn damage to sensitive areas.
Ear protection: According to OSHA Standard 1910.95 on occupational noise exposure, if someone is exposed to an average noise level of 85dB for eight hours or more, they must wear adequate hearing protection. Therefore, welders should wear ear plugs or welding ear muffs.
Heat, fire and radiation protection: Welders need to wear flame-resistant clothing or outerwear, without cuffs or pockets, that covers their entire body, including legs and arms.
Electrocution protection: Besides other PPE recommendations, welders should wear insulated and non-conductive clothing to protect themselves from electric shock.
Respiratory protection: OSHA Standard 1910.134 outlines respiratory protection requirements and highlights the importance of fume extraction systems, welder respirators and the required types and standards.

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3. Work Area Preparation

A cluttered workspace can lead to injuries on duty from welders tripping and falling — or worse, welding fires and explosions. Welding sparks can travel several feet, so keeping the workspace free of any potentially flammable substances or materials is vital. Ensure only the necessary tools and equipment are out while everything else is packed away.

Welders should also make sure their work areas are clean before working. This step is crucial and can help prevent welders from slipping, keep equipment and materials cleaner, allow welders to avoid contaminated welds and reduce potential fire hazards.

Additionally, welders should make a practice of taking in their surroundings and identifying all relevant equipment locations and potential hazards. Welding equipment should be adequately secured where possible to avoid accidental movement. Knowing where everything is and what the potential dangers are allows a welder to work more productively, organize the work area better and make safety-related decisions.

Finally, before working, welders should ensure ventilation systems are operating and there is sufficient airflow. It’s also crucial to be aware of any drafts or wind, which can carry sparks further than expected and be a fire hazard.

4. Fire Safety Measures

The welding process produces several heat sources that can easily ignite flammable materials. These heat sources include:

Torch flames
Sparks
Spatter
Hot slag 

Clearing the work area of any flammable materials is one of the welding best practices. Before beginning work, welders should take inventory of their environments and note the locations of fire protection as outlined in OSHA Standard 1910 Subpart L, which includes:

Fire extinguishers
Sand buckets
Fire blankets
Emergency exits
Fire alarms

Another OSHA welding safety component is understanding and following fire emergency procedures, as outlined in OSHA Standard 1910 Subpart E. It’s imperative that welders are aware of and trained in the company or premises’ emergency procedures before welding work commences.

5. Electrical Safety

There are two types of electrocution that may occur during welding:

Primary voltage shock: This shock usually delivers between 220 and 480 volts but can be as high as 600 volts. It occurs when a welder touches any part of the energized welder, including the welding or electrode circuit.
Secondary voltage shock: This is a more common form of shock and delivers between 20 and 100 volts, which is typically less severe but can still lead to death in certain instances. This occurs when a welder touches a part of either the welding or electrode circuit with one body part while another makes contact with a piece of grounded metal — usually the metal they’re welding.

Welders should always take specific measures to alleviate and eliminate all potential electrical risks, including:

Receiving training
Wearing properly insulated PPE
Keeping everything dry
Inspecting equipment
Maintaining equipment
Maintaining insulation
Properly grounding welding equipment
Using ground-fault circuit interrupters
Following manufacturer-instructions

6. Hazardous Materials and Substances

The primary hazardous materials and substances that welders store and use are two-part and three-part welding mixtures made up of a combination of gases. If compressed canisters are not managed appropriately, they pose significant risks. Apart from fire and explosion risk, gas cylinders can also become projectiles if mishandled or damaged.

Therefore, companies and welders should safely handle and store flammable gases and liquids. Several detailed requirements and guidelines for hazardous materials are listed in OSHA Standard 1910 Subpart H and are worth consulting. In general, these are some welding safety tips and best practices that are in line with OSHA welding safety:

Proper welding mixture storage and handling: All welders need to know how to safely handle and store gas cylinders and potentially transport them. For instance, cylinders should be stored upright in a cool and dry place, preferably in racks, stands or cages. Use carts or trolleys when moving canisters — never roll or drag them.
Storage and work area ventilation: Welders should keep cylinders in well-ventilated areas to minimize fire risk and gas inhalation in the event of a leak.
Gas cylinders and heat sources: During storage or use, gas cylinders should be kept away from any heat sources, including welding arcs, furnaces and heat-generating equipment. It is also wise to keep welding gas cylinders away from other flammable materials to prevent the spread of potential fires.
Valve protection caps: When storing welding gas or when it is not in use, always use valve protection caps to prevent accidental gas release and to protect the valve from damage.
Gas cylinder pressure regulators: When connecting gas cylinders to welding equipment, always check the valve first and use a pressure regulator to control the gas flow and regulate the pressure to avoid sudden or excessive releases.
Safety Data Sheet (SDS): The OSHA Hazard Communication Standard requires that chemical manufacturers provide an SDS — previously a Material Safety Data Sheet. Welders who handle hazardous chemicals must familiarize themselves with the OSHA Safety Data Sheet brief to gain a better understanding of SDS contents and meaning.

7. Welding Fume Extraction

The fumes and smoke emitted during welding pose health hazards to welders, especially in confined spaces. The type of gases and fumes will vary depending on the type of welding and the materials being used and welded.

When welders are overexposed to various welding gases and potentially harmful fumes, they risk short-term effects, including irritated eyes, nose, and throat, dizziness, and nausea. Serious health problems, including respiratory illnesses, cancer and neurological effects, are also possible.

Thankfully, there are viable options and procedures for managing weld fumes. Some control measures for welding fumes and gases include:

Choosing alternative and less harmful materials
Wearing appropriate PPE, such as respirators
Ensuring the work area is well-ventilated
Installing fume extraction systems such as exhaust hoods or exhaust systems
Going for regular health checkups for early health issue detection

8. Safe Handling of Welding Equipment

Apart from receiving the appropriate training and being familiar with welding equipment, a welder should also improve their safety by:

Operating equipment according to manufacturer’s instructions: Even if a welder is highly experienced, they must examine the operating manuals containing user instructions and safety information. Furthermore, following stipulated procedures is advisable if a welder wishes to maximize machine potential. It is also crucial that everyone who uses the equipment is familiar with the manual contents. Keeping the manual readily available is a good idea so welders can quickly refresh their memories.
Regularly inspecting and maintaining equipment: Any experienced welder knows that regularly checking and maintaining equipment is a welding best practice. Welders should ensure equipment is free of wear and tear and potential damages. If a welder suspects any faults, they should have the welding gear inspected before operating. Although it takes a few extra moments, it is wise to do preliminary inspections before every use, including safety equipment for welding.
Properly storing and securing welding tools and materials: Although it can be tempting to leave equipment out for the following day and not clean and pack it away, a simple welding safety tip is to store and secure it properly. Welding tools, equipment, materials and PPE gear should all get cleaned and packed away after use. This minimizes the chance of items getting damaged, stolen or tampered with and helps ensure everything remains in good working order.

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Elevate Your Welding With Meritus Gas Partners

By following these welding safety tips and adhering to welding best practices and requirements set by OSHA and other relevant organizations, welders can mitigate risks and maintain safe work areas. Receiving adequate training, wearing PPE, maintaining equipment, executing safety protocols and using premium welding and gas supplies boosts welder safety and confidence.

Meritus Gas Partners works with a team of independently operated distributors that provide a range of supplies and services for various high-precision industries, including welding. To learn how we and our trusted partners can assist you with welding safety, supplies, equipment and more, contact us or visit one of our branches near you.

Welding is an important practice in industries like construction and manufacturing. However, it comes with various hazards that can impact the health and safety of welders and others nearby. Dangerous compressed gases can explode or leak when handled incorrectly. Gases can be chemical and mechanical hazards and can be flammable, explosive, acidic, corrosive, reactive and poisonous, depending on the environment they’re in and how people handle them.

In this guide, we provide you with all the information you need for handling dangerous gases in the best way possible, from gaining the appropriate training on how to handle, store and secure dangerous gases to attaining leak detection systems and implementing an emergency plan. Learn essential safety tips for dealing with hazardous gases below.

1. Proper Training and Education

One of the most critical safety tips for handling dangerous gases is attaining the correct training for it. This includes completing a laboratory training program, knowing the various hazardous materials and risks of processes, and working according to a hazard control plan. Knowing how to handle dangerous gases is important because all gases have unique properties to consider in terms of handling, storage and use.

Four factors to consider when evaluating properties include:

Toxicity: Some gases, such as carbon monoxide, chlorine and ammonia, can be toxic when absorbed through the skin or inhaled. This makes it essential to use the correct personal protective equipment. It’s equally important to create proper ventilation to prevent the accumulation of toxic gases in the work environment.
Pressure: Because compressed gases are stored at high pressure, gas cylinders can easily become a hazard when handled incorrectly or damaged. This makes it essential to transport and store cylinders safely and securely.
Flammability: Highly flammable gases that catch fire when coming into contact with heat or a spark include propane, hydrogen and acetylene. To prevent explosions and fires, avoid heat and open flames, use spark-resistant tools and have proper ventilation.
Reactivity: Reactive gases are gases such as chlorine, oxygen and fluorine that react to other gases or materials to create a hazardous outcome. You can prevent these gases from coming into contact with each other by storing them separately.

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2. Personal Protective Equipment

Personal protective equipment (PPE) plays an essential role in ensuring safety while working with compressed gases. All gases are different, meaning welders may need varying PPE. Some PPE workers need to use when working with or around dangerous gases include:

Protective gloves: Specialized gloves protect your hands from exposure to hazardous materials and gases. The type of gloves workers wear largely depends on the product label and safety data sheet. Some gases may cause extreme temperatures, while others are hazardous chemicals.
Foot protection: The appropriate footwear will protect workers from exposure to dangerous gases and materials that may harm or burn the skin.
Eye protection: Toxic and corrosive gases can cause severe eye damage and irritation, making it imperative to wear the appropriate eye protection, such as a face shield or goggles. 
Respiratory protection and ventilation equipment: Respiratory protection can help protect workers from inhaling dangerous gases. Some protection equipment a welder may wear includes a respirator, mask or another device that filters out harmful fumes or lowers the concentration of gases in the air. The type used will depend on the type of gas, amount of gas in the air and ventilation levels in the work environment.

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3. Gas Cylinder Handling

When dealing with cylinders, it’s crucial to understand the best practices for handling them and keeping them organized in the workplace. The correct personnel must stamp and stencil each cylinder to identify the contents. These labels will help distinguish whether the gas is toxic, flammable or corrosive. If the supplier sends an unidentified gas cylinder, you must send it back for them to identify. It’s also best to avoid identifying them by color or the interchangeable label on the cylinder cap.

Further, you should maintain and implement the following practices:

Proper cylinder handling: Dragging and dropping gas cylinders can often lead to an explosion, leak or damage to the valve or cylinder cap. Instead, roll and tilt the cylinder using its bottom edges or use a cylinder cart according to the size and weight of the cylinder. To prevent injury or strain, use the correct lifting practices, such as closing the cylinder valve before moving the cylinder and lifting the cylinder while keeping your back straight and knees bent.
Storage: Compressed gas cylinders must stay in a well-ventilated area away from direct sunlight and heat. You should also ensure they remain in upright positions and are stored away from emergency exits.
Securing: When transporting dangerous gas, use a strap or chain to secure it to the cart. You should also ensure the rack or stand supports the container’s weight and size.

4. Leak Detection and Monitoring

Long exposure to dangerous gases can cause neurological and physical damage or result in fatality. Leak detectors can help reduce the chances of this happening by clearing the welders’ breathing space of hazardous gases.

Gas detectors can sense carbon monoxide and other gases without taste, odor or color in their natural states. An approved leak-detection fluid or non-detergent soap solution can also help detect leaks from a regulator or hose.

You can regularly monitor gas levels during welding processes by installing a fixed gas detection system.

5. Ventilation and Airflow

When exposed to hot surfaces or flames, compressed gases easily explode or cause fires. This possibility makes it essential for those who handle dangerous gases to understand the correct safety measures and store them in cool, dry and well-ventilated spaces. Additionally, workspaces as a whole should be well-ventilated to protect employees.

Another important factor is to establish your emergency contact numbers. A local exhaust ventilation system is most effective for high-intensity welding activities and dispersing highly toxic gases. This system removes contaminated air through devices like filters, hoods, fans and ducts. Natural ventilation systems use fans and blowers for low-intensity welding activities and mainly rely on airflow through vents, doors and windows.

An effective ventilation system is especially important because when airflow goes in the wrong direction, it can create backflow, causing an increased gas density in the workspace. This event can also happen even with an exhaust fan, making it essential to conduct regular maintenance.

Here are some best practices for welders to follow:

Position the ventilation system close to the welding station.
Wear adequate personal protective equipment.
Turn on the system before you begin welding.
Avoid blocking the airflow.
Keep the system on until the air is clear of gases.
Clean and inspect the ventilation system regularly.
Document the system’s performance and maintenance.

6. Emergency Preparedness 

It’s important to put an emergency procedure in place to reduce injuries, accidents and fatalities in the workplace. This procedure should involve establishing exactly what constitutes an emergency and what workers should do in the event of an emergency. You can improve emergency preparedness by:

Establishing potential hazards: Do a hazard assessment to identify and record the different types of gases, their properties and any risks associated with them. Encourage workers to understand and abide by these assessments.
Creating an emergency response plan: Outline the steps workers should take when noticing a gas leak. Steps will include turning off the cylinder valve if possible, evacuating via the route and assembly point you establish, contacting emergency services, and preventing others from entering the hazardous area.
Training employees: Train workers to become familiar with the emergency procedures you create. This training will help them understand the signs of a gas leak and know exactly how to respond. It may help to carry out regular drills to ensure everyone knows what to do in a real event.
Encouraging the use of PPE: Wearing personal protective equipment is an essential step in preventing accidents and injuries while working with compressed gases.
Reviewing and updating the plan regularly: Always ensure your emergency plan is up-to-date and reflects workplace and regulation modifications and any changes to the types of gases used. Another important factor is to establish your emergency contact numbers, which is likely your local emergency services.

Additionally, an individual emergency procedure a worker may follow includes: 

Remove the contaminated clothes.
Wash with soap and water if the gas made contact with their skin.
Flush the exposed area with water or eye wash for 15 minutes if the gas made contact with their eyes.

In the case of gas inhalation, individuals should leave the facility immediately to go outside and call for emergency services. Then, they should document the incident according to procedures.

7. Proper Storage and Handling Procedures

Determining compressed gas compatibility is an essential part of maintaining dangerous gas safety. You can do this by reviewing manufacturer instructions and consulting with a safety professional.

In most cases, you’ll need to store incompatible gases in separate, well-ventilated storage areas with proper labeling and handling instructions attached. Storing gases away from heat sources like direct sunlight, heaters and furnaces is important because heat can make gases expand in the cylinder, increasing the pressure and causing the cylinder to burst.

At the same time, you should separate incompatible gas cylinders because they can react dangerously when you store them together. You can use proper signage by labeling the storage area and cabinet to ensure workers know the potential risks and how to handle these gases properly. Workers can also use the appropriate handling equipment and tools, such as fittings, connectors and the correct handling instructions.

8. Proper Disposal of Gas Containers 

Improper disposal of containers for dangerous gases can easily endanger the environment. Some proper disposal regulations for empty or expired gas containers you should follow include:

Replace the cylinder cap and move the cylinder to the storage area.
Label the cylinder properly.
Return the cylinder to the supplier. If you are unable to return the empty cylinder to the gas vendor, you can contact your local waste management authorities to assist you with disposal.

Handle the cylinder with care since residual pressure can be dangerous. Avoid refilling and mixing gases, as this could cause an explosion.

9. Continuous Monitoring and Review

The most important aspect of maintaining these safety tips for dangerous gases is consistently monitoring gas handling practices, regularly reviewing and updating safety protocols, and encouraging workers to report any safety concerns. Regular safety inspections and equipment checks can also ensure all tools, such as detectors, gas appliances and containment vessels, function properly.

This is especially important because you need working equipment with uncompromised functionalities to keep workers safe during emergencies. Gas monitoring systems should have the following functionalities to improve dangerous gas safety:

Toxic gas alarms set to the permissible exposure limit
Visible and audible alarms in the gas use location, gas supply area and outside the gas use room
Connection to the emergency power source
A visible and audible alarm that is distinct from other alarms to indicate a specific meaning and the required action from the correct personnel
Enclosure or lock to protect the control switch and power connection for system operation
Alarm status and gas concentration identification panel outside the gas room

Improve Hazardous Gas Safety With Meritus Gas Partners  

Hazardous compressed gases require careful attention and compliance with strict safety rules. They require workers to have skilled training to handle gases appropriately, wear personal protective equipment, and take crucial precautions, such as leak detection and gas monitoring systems, to ensure everyone’s safety.

That’s why we recommend a proactive approach to dangerous gas safety to prevent accidents and promote a safe working environment. With an experienced gas supplier like Meritus Gas Partners, you can be sure to receive trusted information about safe gas handling and storage. We also provide qualified representatives to assist you with the supply of compressed gases and customized solutions to improve safety.

If you’re interested in working with one of our partners for your welding needs, we encourage you to contact a local distributor today.

Did you know that the right gas supply solution can maximize efficiency and eliminate safety concerns? Located in Alabaster, Alabama, E-BOX is one of the largest independently-owned and operated manufacturers of electrical enclosures products in the southeast. E-BOX contacted Atlas to enhance the efficiency of its facility, which supplies a wide range of enclosures to electrical distributors across the country.

The Challenge

To supply nitrogen to its laser machines, E-BOX was changing 12 pack cylinders out 2 to 3 times a day. This was not only time consuming, but moving the cylinders with a forklift was also a safety concern.

The Solution

Atlas recommended installing a bulk tank of E-BOX’s nitrogen mix to eliminate the hassle of moving the cylinders throughout the day. This gas supply solution minimized the facility’s downtime and maximized their production efficiency.

“With the solution that Atlas provided for us, we have measurably less downtime from running out of gas,” said Anthony Madrid with E-Box. “We never have to worry if we will run out of gas anymore because they keep a close eye on our tank and simply refill it when we get low. The purity of the gas that comes from the bulk tank helps to cut maintenance cost in our laser cutting application.”

When you work with Atlas, you can count on us to be a partner that provides customized solutions for maximizing your business’s efficiency.

“My experience with Atlas has been fantastic,” Madrid said. “Top-notch customer service. They really want to help you succeed.”

With decades of experience in gas and welding applications, we are confident we can be your trusted partner. Request a solution from us today!