ANSI Z49.1-2021: Welding Safety Standard

Electric arc welding generates extreme heat—up to 10,000°F (5,537°C)—which rivals the temperature of the Sun’s surface. This intense heat creates a plasma arc, a superheated and ionized gas used to melt and fuse metals together, forming strong, permanent bonds. Electric welding is essential in modern manufacturing and fabrication, with applications ranging from World War I battleship construction to fine metal sculptures and everyday infrastructure. To assure safety in such high-temperature environments, the ANSI Z49.1-2021: Standard for Safety In Welding, Cutting, And Allied Processes provides comprehensive guidelines on arc welding safety, including protective equipment, ventilation, and hazard prevention.

Understanding Welding: Techniques and Everyday Uses

Welding refers to the joining together of metal pieces, thermoplastic, or wood via heating the surfaces to the point of melting by using a blowtorch, electric arch, or other means, and then fusing the surfaces together by pressing or hammering. Welding is predominantly done with metals like steel and is the most efficient way to permanently join metals together. Skyscrapers, barbeques, coffeepots, railroads, and more require welding.  

What Is ANSI Z49.1-2021?

ANSI Z49.1-2021 emphasizes oxygen gas and arc welding processes and provides some coverage about resistance and high energy beam welding, brazing, and soldering. This American National Standard contains precautionary information about the protection of personnel and the general area, ventilation, fire prevention and protection, and confined spaces.

Key Safety Requirements (Personnel, Property Protection)

The overall purpose of ANSI Z49.1-2021 is to provide safety protection of:

1. Persons from injury and illness.
2. Property (including equipment) from damage by fire and explosions arising from welding, cutting, and allied processes.

How Does ANSI Z49.1-2021 Relate to OSHA?

ANSI Z49.1-2021 and OSHA are both important in promoting safety in welding and cutting operations, but they serve different roles.

• ANSI Z49.1-2021 provides best-practice safety guidelines for welding and cutting and is seen as the industry benchmark for welding and cutting safety. By showing adherence to the recognized safety practices in this standard, employees can prepare for inspections and defend against citations.
• OSHA sets and enforces legal safety requirements. As such, OSHA inspectors may use ANSI Z49.1-2021 as a reference when evaluating whether an employer is providing a safe workplace.

In sum, ANSI Z49.1-2021 is often used to comply with or exceed OSHA standards and can be helpful in demonstrating a commitment to safety in the workplace.

Industries That Rely on Welding

Welding is vital to the U.S. economy as over 50% of the United States’ gross national product is related to welding. Welders belong to the following groups:

• Repair services:  includes the maintenance and repair of automobiles or electrical machinery
• Mining, oil extraction, and gas: involves the drilling and extracting oil and gas or mining of ores, stone, sand, and gravel
• Metal industries: include steel mills, iron and steel foundries, smelting and refining plants (usually involves maintenance and repair of equipment)
• Electrical and electronic Equipment companies: includes work on electric generators, battery chargers, household appliances, etc.
• Public administration: hires welders to perform maintenance welding done on utilities, bridges, government armories and bases, etc.
• Wholesale and retail establishments: consist of auto and agricultural equipment dealerships, metal service centers, and scrap yards
• Artists and sculptors: have a large impact on the public as they have designed and constructed fountains, sculptures, playgrounds, and more in neighborhoods around the world (e.g., St. Louis Arch, Chicago Picasso, The Grand Canyon Skywalk, and Yankee Stadium).

Unimate: The Robot That Revolutionized Welding and Manufacturing

There are even robots that perform welding. In 1961, General Motor’s Unimate, the very first industrial robot, was a single-arm unit designed to perform spot welds, and it revolutionized the world of manufacturing. The Unimate weighed over 4,000 pounds (over two tons) and did its work, which consisted of taking die casting from machine and performed welding on auto bodies, from step-by-step commands stored in an attached magnetic drum.

The development of robotic welding not only enhanced productivity but also aligned with the goals of ANSI Z49.1-2021, which emphasizes minimizing hazards in welding and allied processes. By removing human workers from direct exposure to welding fumes, heat, and sparks, automation like the Unimate helped lay the groundwork for safer industrial environments in accordance with national safety standards. Today, the Unimate can be found in the Robot Hall of Fame, housed in the Carnegie Science Center.

ANSI Z49.1-2021 Requirements for Welders and PPE

ANSI Z49.1-2021 defines a “Welder” and “welding operator” as a person who operates any electric or oxyfuel gas welding or cutting equipment, or allied processes. The standard states welders shall wear welding goggles, gloves welding helmet, welding faceshield over spectacles, protective clothing, and/or goggles during all oxyfuel gas welding and cutting and submerged arc welding operations. This equipment is important for eye and face protection from hazards like arc rays, spatter, and weld sparks that may strike against a welder’s helmet.

ANSI Z49.1-2021 does not pertain to the design or manufacture of equipment, such as piping systems, station outlet equipment, bulk gas supply systems, and building electrical installation.

Where Did Welding Begin? – Ancient Egypt

While welding did not become the process that we recognize today until the late 1800s, welding existed in some form since the Bronze Age (~4000 BC -1300 BC). Archaeologists have found the oldest examples of welding in Egypt and the eastern Mediterranean. Some of the oldest examples of welding can be seen in Egypt’s ancient pyramids, where hieroglyphs depict welders at work.

Early Welding Techniques from the Bronze Age

Here is a timeline of pivotal welding moments during the Bronze Age:

• 4000 BC: Ancient Egypt began welding with copper, which was the only welded metal at this time.
• 3500 BC: Tin was used in welding.
• 3000 – 2000 BC: Bronze and gold were used in welding, and gold boxes with pressure welded joints were discovered in Egyptian pyramids. Humans started welding metal into kitchen utensils, farming tools, hunting tools, arms, and jewelry pieces. Ancient Egyptians and Sumerians converted iron ore into sponge iron using heat generated from charcoal in a process known as pressure welding.
• 1300 BC: The Egyptians began soldering, blowing pipe, and joining pieces of metal together.

Over time as welding improved metals like tin, gold, bronze, iron, and steel welds gradually were incorporated throughout the Bronze Age. Since then, welding has evolved to include modern techniques that are rooted in safety and allow for enhanced performance. With the development of modern welding processes, safety became a critical concern, leading to formalized standards like ANSI Z49.1-2021.

Where to Find ANSI Z49.1-2021

ANSI Z49.1-2021 is developed by the American Welding Society (AWS).

Please direct any technical questions relating to this American National Standard to the developer. You can find the contact information for all standard developing organizations (SDOs) here: Who to Contact for Standards Related Questions.

ANSI Z49.1-2021: Standard for Safety In Welding, Cutting, And Allied Processes is available in the ANSI Webstore and in the following Standards Packages:

• ANSI Z49.1 / ANSI Z136.1 / ANSI/ISEA Z87.1 – Welding and Lasers Face Protection Package
• AWS A3.0M/A3.0 / AWS A2.4 / ANSI Z49.1 – Welding Safety Terms and Symbols Package