What is a welding station? Types, equipment, requirements

Without exception, all welders working in production have a specially equipped workplace, which is also commonly called a welding station. It can be stationary or mobile and is equipped depending on the tasks assigned to the specialist.

General and individual requirements

Regardless of the type of equipment, when organizing a post, sanitary and safety standards are observed:

1. To improve the quality of welding work, provide good lighting. It should be at least 80 lux, but not interfere with the master. The lamps are installed so that no shadows fall on the desktop.
2. Since welding produces vapors and gases harmful to humans, sanitary standards are taken into account when creating ventilation. Thus, exhaust equipment must cover a radius of at least 4 m, the recommended air exchange rate is more than 40 m³ per hour. When organizing a post at home, standard supply and exhaust ventilation is sufficient.
3. If several craftsmen work in a room, then the installation of centralized exhaust units is required, to which all stations are connected. The dampers help regulate the air exchange rate. When working in closed containers (reservoirs, tanks), air is supplied using a mask.
4. When installing single-phase welding units, an oscillator is included in the circuit. For a three-phase device, the presence of a magnetic contactor is required.
5. If metal cutting will be carried out at the workplace, then a separate place will be equipped for storing and using cutting equipment.

Individual requirements are provided for different types of technologies:

1. When organizing a gas welding station, a separate compartment for storing cylinders is equipped. There should be no sources of heat or open flame in the work area.
2. In electrical technology, attention is paid to equipment grounding. A rubber mat is placed near the welding machine. When setting up a post on the street, a canopy is built.
3. When using plasma welding, equipment is provided that quickly removes toxic products of metal combustion from the working area. There should be no flammable liquids or materials in the room.

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Requirements for welding stations

General requirements

Requirements for the organization of welding stations are based on compliance with safety regulations and ensuring comfort in carrying out work. It is important to ensure that all energy consuming installations are grounded. To place them, it is highly advisable to make a base of concrete or brickwork. The post must have everything necessary to store not only tools, but also documentation.

Briefly about the basic requirements. Ventilation is required. The table is made of steel or cast iron. The welder must stand on a rubber mat while working.

For cases where the welder works while sitting, it is necessary to provide a special chair with a non-conductive seat. It should be durable, but light and small so that it can be moved with one hand if necessary. Naturally, the seat should be comfortable, since sometimes a specialist has to work for several hours without a break.

Productive work is impossible without adequate lighting. The brightness should not be excessive, but at the same time, even small details should be well illuminated. As practice shows, 80 Lumens are enough to work. The light source should be placed directly above the table. If this is not possible, then it is permissible to place the lighting device in close proximity to the workplace.

Even if we are talking about multi-station welding, you still need a switch, by turning which you can turn off the electricity supply in an instant. This may be needed in an emergency and to de-energize the area at the end of the working day.

Classification of posts by type of welding

The following types of jobs are distinguished:

1. Gas welding stations. The room for working with such equipment is organized taking into account the technology: the melting of the metal is carried out under the influence of thermal energy released during gas combustion. The workspace is equipped with the most efficient exhaust system. The post is finished with fireproof materials.
2. Electric welding. The space allocated for the welder’s work is organized taking into account the high risk of electric shock.

Workplace safety

Regardless of the type of equipment used, rules must be followed to prevent fire and injury hazards. The main conditions for organizing work areas are the following:

1. Each post is surrounded by protective screens made of fire-resistant materials. The screen cannot be equipped with a closed top part.
2. Wall paneling should not touch the floor. It is recommended to leave a distance of 30 cm.
3. When gas welding, an additional light protection screen with a height of more than 2 m is installed.
4. The walls are sheathed with fireproof materials.
5. It is forbidden to place several welding tables at one station. If such a need arises, install an additional light-protective screen.

LITERATURE

1. PPR. Fire regulations in the Russian Federation. Decree of the Government of the Russian Federation of April 25, 2012 No. 390;
2. State Committee of the Russian Federation for Construction and Housing and Communal Sector Resolution No. 80 dated July 23, 2001 On the adoption of building codes and regulations of the Russian Federation “Labor safety in construction. part 1. general requirements”;
3. Ministry of Labor and Social Protection of the Russian Federation Order No. 701n dated November 28, 2013 On approval of the professional standard “WELDER”;
4. SP 12-135-2003. Occupational safety in construction. Industry standard instructions on labor protection" (approved by Resolution of the State Construction Committee of the Russian Federation dated 01/08/2003 No. 2) from the "Construction" information bank;
5. MDS 12-49.2009. Layouts of labor safety instructions for construction workers. Methodological manual" from the information bank "Construction".

Scheme and basic tools

The order in which equipment and fixtures are placed is dictated by the type of welding location.

For mobile post

When creating mobile workplaces, there are no special requirements for space and ventilation. However, basic safety rules should be followed:

1. The trolley for placing devices and tools is equipped with wheels, ensuring ease of transportation. For work, a welding unit with a set of cables is used.
2. The mobile post is equipped with stands on which a canopy is installed in case of bad weather.
3. Tools are placed in special boxes.
4. To protect others from light exposure, portable shields are used.
5. When laying long communication lines, workplaces are equipped in trailers with autonomous generators.

For landline

When equipping a welding station in a workshop, it is necessary to purchase all the necessary equipment for the work. The list can be expanded, but when connecting metal parts you cannot do without:

• welding unit;
• a box for storing electrodes and other auxiliary tools;
• constant current source;
• convenient landing place;
• switch for supplying and disconnecting voltage;
• exhaust chamber;
• baskets, shelves and drawers for storing small tools;
• electric holder.

When placed correctly, all these devices do not take up much space.

Basic equipment

To fully equip a welding station, it is necessary to equip it with electrical equipment, additional equipment and auxiliary means:

• a current source for the formation of a welding arc, which is a welding transformer or inverter;
• current-carrying cables in a reliable braid that can withstand high current strength and constant mechanical stress.
• conductors must have appropriate fastening at the end for connection to terminals, electrode holders and ground;
• gas burners for working with gas welding equipment;
• fixtures and other tools for welding work: clamps, clamps, holders;
• welding table;
• protective equipment: heat-resistant suit, special gloves, welder’s mask, headdress with a lapel.

A distinctive feature of a mobile welding station is that it does not have any boundaries. This is explained by the fact that a specialist needs to constantly move to perform his duties within a certain area: construction site, welding shop, production site, etc.

It is worth paying attention to the fact that this classification relates exclusively to the organization of procedures, but does not in any way regulate the nature of the manipulations performed.

Features of gas welding stations

The following must be present in the work area:

• acetylene supply device;
• oxygen cylinders with a reducer;
• gas supply hoses;
• welding torches.

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When arranging a stationary gas welding station, take into account the following recommendations:

1. The surface of the welding table must be metal.
2. Gas cylinders are placed as far as possible from the workbench. At enterprises, gas is supplied centrally through a pipeline.
3. The post is placed at a distance of at least 10 m from sources of open fire.
4. When working in closed containers, additional means of air supply are installed.

Varieties

There are two types of welding stations: stationary and mobile. Stationary stations are located in the workshop and are designed to work with small parts, since the working surface of welding tables is often limited. Mobile posts can be located both inside the workshop and outside. These can be small frames on wheels into which the equipment is built, or a special cart.

Let's take a closer look at each post type.

Stationary post

Below is a diagram of a stationary type welding station. In most cases, the stationary post is located in a separate cabin without a roof, but with closing screens. The area of ​​such a cabin must be at least 3 m2.

A stationary welding station must be made of non-flammable materials, so the screens are made of polymers, and the frames are made of metal. The height of the cabin itself must be at least 2 meters. The interior walls of the cabin are coated with a fire-resistant compound that does not support combustion.

Each stationary post has not only equipment, but also a welding table. Its size is determined by the nature of the work. If welding is done in a sitting position, then the height of the table should be about 60-70 cm. If in a standing position, it should be from 85 and above. The size of the working surface must be at least 100x100 cm.

A separate requirement is good ventilation for the welding station. Local ventilation during welding can be either natural or forced. Forced ventilation is preferable. Local suction from the welding station is also necessary to quickly remove metal shavings, dust from grinding, etc.

Mobile post

The welding station for manual arc welding can be mobile or portable. Often, a mobile welding station can be set up with less effort, since it does not require compliance with many rules. There is no need to organize ventilation, observe the size of the working area, etc.

But what is worth doing is a canopy over the mobile station so that the welder can work in bad weather or under the sun. Also, the mobile post should have comfortable wheels so that even heavy equipment can be transported without much difficulty.

The mobile post must have compartments and niches for storing components. If this is a mobile gas welding station, then there must be space for a gas cylinder. Ventilation of the welding station can be natural, since work in most cases takes place outside.

High-quality ventilation

When arranging the hood, observe the following rules:

1. Install local and general ventilation systems. The first is connected to each workbench if toxic substances are released during welding. Installation of a general hood is required in all cases.
2. Ventilation equipment is equipped with a filter that removes welding aerosols from the air. The equipment removes harmful substances outside the workshop.
3. When welding in a gas environment, air is supplied dispersedly. When using other technologies, directional ventilation is used.

Organization of stations for different types of welding

Since craftsmen use several technologies, work areas are equipped differently. The basic set of tools, safety rules, and equipment grounding remain unchanged. Individual points include:

1. Arrangement of the installation site for gas cylinders and a compressor during argon arc welding with non-consumable electrodes.
2. The use of additional devices for supplying consumables and cutting devices in mechanized welding processes.
3. Use of equipment grounding and neutralizing equipment during electric welding.
4. Installation of a separate screen for a plasma installation. The height of the screen in this case should be at least 220 cm.

Equipment

Since there are several types of welding, the workplace will have to be equipped differently. The only things that remain unchanged are grounding, safety requirements for the welding station, lighting and auxiliary devices for the convenience of the welder.

• Welding with non-consumable electrodes in shielding gases requires organizing a place for gas cylinders or a compressor.
• Mechanized welding or cutting of metals is an additional unit for supplying consumables or cutting tools.
• Using three-phase voltage means installing a contactor of the required size.
• The workplace of an electric welder operating on alternating current is additionally equipped with an oscillator. Its purpose is to stabilize the electric arc.

Equipping a place where a gas or electric welder works is a serious and responsible matter. The basic and important rule here is to ensure maximum safety during welding work. Therefore, systems such as ventilation, grounding and lighting receive increased attention.

Proper provision of a welding station for manual welding is not only reducing the risk of employee illness, but also preserving his health, which is very important. This is an increase in the quality of work, plus a reduction in order completion times.

Create your own post

You can organize your workspace with your own hands. When creating a mobile welding station, additional components are required to carry tools and consumables.

A stationary office does not need such devices.

Collection of tools and materials

When organizing a welder’s workspace you will need:

1. Current supply devices. These include transformers or generators, often operating from a 380 V network.
2. Cylinders with inert or active gas. Large capacity containers are installed at stationary posts.
3. Set of fixing tools. These include vices and clamps.
4. Means for pre-processing of metal parts - cold rolling and rolling devices, pipe benders.
5. Inverters, semi-automatic welding machines for mobile posts.
6. Electrodes, filler wire. It is recommended to purchase different types of materials.

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How to assemble

In the process of creating a welding booth with your own hands, follow the following rules:

1. The recommended length of the working area is 2 m, width – 2.5 m. The ceiling height should be at least 2 m. The upper part of the office should not be closed.
2. To assemble the walls, sheet steel or plywood treated with a non-flammable composition is used.
3. For preliminary preparation and welding of metal parts, a convenient welding table is organized. It can be made stationary or foldable. For assembly, profile pipes and thick steel sheets are used. Tables must be equipped with metal holders that secure the current-carrying cable and grounding wire coming from the power source.
4. Containers for storing electrodes and welding wire are placed on the side of the table. Drawers are installed in which small tools and technical documentation will be stored.
5. Install single or multi-station arc power sources. The first option is preferable when organizing your workspace yourself. In the second case, the use of current-carrying busbars will be required.
6. Install a switch to control the welding current.

Device in stages

A welding room can be set up in a garage, at a production site, or at a technical inspection station. In this case, the following scheme of work is used:

1. Choose a place. It is recommended to locate the post away from flammable liquids, materials and gases.
2. Assembling the cabin. From the floor to the bottom edge of the walls, leave gaps of 5 cm for ventilation. When working with inert gases, this distance is increased to 30 cm. Ventilation meshes are installed. A tarpaulin or plastic non-flammable screen is hung at the entrance.
3. Mount a table with a tabletop. Provides the ability to adjust the height of the racks and the area of ​​the tabletop.
4. Install lighting fixtures.
5. The cabin walls are painted with light gray paint that absorbs ultraviolet rays. Choose paint compositions based on titanium or zinc.
6. Install a forced-type exhaust system. Connect the equipment to a centralized air exchange system.
7. The floor is poured with concrete. Brick can be used to form flooring.
8. Install a switch for emergency shutdown of welding machines.

At the last stage, connect the equipment to power sources.

The procedure for issuing permits and permits for hot work.

It is recommended to carry out fire hazardous work during daylight hours, i.e. during the day (except for force majeure and accidents) and with the participation of specialists with special training and relevant documents (certificates, certificates, certificates) confirming their qualifications.

Previously, the head of the unit or the head of the team (shop, department, section) must prescribe an exact plan for future work, equipment must be installed in explosive areas to secure the facility, power supplies have been turned off, devices and installations that pose a threat to life and health during the work process have been stopped, and signs indicating the boundaries of dangerous zones have been installed.

All specialists associated with the work must undergo appropriate targeted training, be provided with fire protection equipment, tools must be checked, and the workplace must be prepared.

Only after all these measures have been ensured is a permit issued to carry out fire hazardous hot work.

Admission rules

According to paragraph 437 of the Fire Regulations in the Russian Federation, for carrying out hot work (fire heating of bitumen, gas and electric welding work, gas and electric cutting work, gasoline and kerosene cutting work, soldering work, cutting metal with a mechanized tool) in temporary places (except for construction sites and private households), the head of the organization or the person responsible for fire safety issues a work permit to perform hot work in the form provided in Appendix No. 4 (it is below). The permit is filled out either on a regular A4 sheet or on the company’s letterhead in two copies. One of them is transferred to the work manager, the second to the employee who is responsible for fire safety at the enterprise.

A work permit for hot work is a permit document that clearly states the facility where the work will be carried out, its name, information about the specialists receiving access to it, the persons in charge, as well as the fire safety measures taken at the workplace.

Instructions for filling out the work permit for hot work

• In the upper right part of the document the full name of the enterprise whose employees carry out hot work, as well as the structural unit to which they belong, is indicated.
• In the upper left part, information about the head of the enterprise is entered, as well as the date of registration of the permit. Here, after the final completion of the document, the director will have to sign.
• Below in the center of the line is the name of the document.
• Then, in separate paragraphs, it is written down to whom the permit was issued (i.e., the person responsible for carrying out the work), for what kind of work, as well as information about the object (here you must indicate the name of the object and its actual address).
• The fourth paragraph contains information about the performers: here you need to indicate their profession, qualifications, and the date of the last training completed. Each participant in the work must sign opposite his/her name.

The following paragraphs of the permit relate directly to the hot work being carried out .

• First you need to indicate their start and end times (hours, minutes), then the fire safety measures taken (in detail).
• Further, it should be noted that hot work, as well as measures taken to ensure fire safety, have been agreed upon with the responsible services of the facility - here it is necessary to indicate a specific person, his position, surname, initials, and the date of approval.
• Finally, in the last paragraph of this part of the work permit, we similarly note the employee responsible for preparing the workplace for the implementation of assigned labor tasks.
• According to the rules, a work permit must be issued for all types of work separately for one day shift.
• If the work is not completed within the period established by the permit, then in paragraph 9 you need to make an entry indicating until what time they are extended (but not more than for one work shift). The next paragraph should include a note about agreeing to extend the permit for hot work.
• If changes are made to the composition of the performing team (some workers are replaced by others, or someone is simply excluded or added), this should be noted in a special table.
• After all the work is completed, the fact of completion of the work, the date and time are recorded, and the signature of the person in charge is affixed. After final registration, the work permit is submitted to the head of the enterprise for approval and signature.