Ergonomic welding—a contradiction in terms?

What is meant by ergonomics?

Ergonomics has several meanings, one of which is quite literal: the term is derived from the Greek words “ergon” and “nomos”. “Ergon” means work and “nomos” translates as law. The word ergonomics can therefore be translated as “law of work”. Another significant (and practical) definition of the term “ergonomics” is the mutual adaptation of people and their working conditions. Ergonomists try to design the workplace in such a way that it does not impair the physical or mental health of workers. 

The same applies to welding workplaces. “These should be designed to meet the physical requirements of welders and enable predominantly focused work that does not cause fatigue,” emphasizes Peter Fronius, Head of Strategic Product Management Professional Welding Tools. “For example, by taking the height or arm reach of the welders into account. If workplaces do not satisfy ergonomic standards, the likelihood of sickness, injury, and absence through illness increases.” Of course, ergonomic risk factors cannot be eliminated every time and everywhere. This is the case for out-of-position welding, for example, whereby the aim must be to limit the time that the individual spends in the situation insofar as possible.

Risk factors when welding

Most causes of injury are not restricted to specific industries, but result from the movement and behavior patterns of welders. Typical here are repeatedly stretching the body, twisting the spine, being supported by or kneeling on hard surfaces, maintaining the same posture over a longer period of time, or a lack of rest. If such risk factors occur repeatedly (individually or in combination) they can lead to work-related musculoskeletal disorders (MSDs), in other words injuries and diseases that affect muscles, nerves, tendons, ligaments, joints, intervertebral discs, skin, subcutaneous tissue, blood vessels, or bones. In addition to the causes previously mentioned, unfavorable environmental conditions such as extreme temperatures can also contribute to the development of MSDs, while personal risk factors such as physical condition, pre-existing illnesses, or age also come into play.

Work-related musculoskeletal disorders in welders

These disorders usually develop as a result of micro-traumas acting on the body over time and causing conditions such as lumbar slipped discs—the most common herniated discs due to the overall weight of the spine sitting most heavily on the two lower discs. These intervertebral discs consist of flexible, annular cartilage that contains semi-liquid gel. If a welder repeatedly lifts heavy components while adopting an unfavorable posture, this cartilage can degrade and tear over time. This results in the intervertebral disc bulging, pressing on a spinal nerve, and causing severe pain. 

The most common musculoskeletal disorders include back injuries, bursitis, inflammation of the tendon and tendon sheath, carpal tunnel syndrome, and thoracic outlet syndrome. This disorder, which can occur due to compression of nerves, arteries, or large veins in the neck and chest area, is very painful and can be caused by frequent overhead welding.

Ergonomics and welding are not contradictory

Time and again, welders are forced to adopt unfavorable postures for a variety of tasks—frequently over long periods of time. It is often easier for the welder to move around large, heavy components themselves than to move the component into the optimum welding position. Is it therefore paradoxical to talk about ergonomics and welding in the same sentence? Absolutely not. Because despite all the hindrances, there are plenty of ways in which welding companies can design workplaces and work equipment ergonomically. Effort that is generally rewarded by a healthier workforce, better morale, higher productivity, and enhanced product quality. For example, height-adjustable welding tables and stools are tried and tested means of adapting the welding height to the physical requirements of welders.  

Ideal for long seams: welding carriages

“Rather than welding meters of welds by hand in the overhead position, rail-guided welding carriages can often be used. The same applies to longitudinal seams and circumferential welds of large dimensions, which can be joined either with rail-guided carriages or with magnetic welding carriages. If mechanized systems like these are used, professional welders essentially only have to operate the remote control, while standing upright and with no physical exertion required,” explains Christian Neuhofer, Product Manager Fronius Welding Automation.

The compact Fronius FlexTrack 45 Pro can be used in a wide range of applications. Three different rail types are available to suit different requirements. In industries where surface geometries vary, such as shipbuilding or container construction, FlexTrack 45 Pro welding carriages are perfect for all-round use.

Link: FlexTrack 45 Pro (fronius.com)