Air Carbon Arc Gouging
Air carbon arc gouging melts metal with an electric arc from a carbon electrode and blows it away with a jet of compressed air. It is used to remove welds, cut out defects, prepare joints and cut metal. It is fast and powerful, and it throws a spray of molten metal many feet, makes extreme noise and heavy fumes, and starts fires.
- Welders
- Boilermakers
- Shipyard & Steel Workers
- Fabricators & Repair Crews
How it works
- A special gouging torch holds a copper-coated carbon-graphite electrode and has air jets that blow along the electrode.
- An arc between the electrode and the metal melts it, and the air stream blows molten metal out of the groove.
- It needs a welding power supply (usually DC), compressed air at the pressure the torch requires and appropriate leads. See Welding Leads & Cable Care and Stick, MIG & TIG Welding.
Main hazards
- Molten metal spray: sparks and slag are thrown far and burn skin, clothing and eyes. They can ignite combustibles at a distance and fall through floors and gaps. See Sparks & Fire Risk.
- Noise: gouging commonly exceeds 100 dB. See Noise.
- Fumes and smoke: heavy metal fumes and carbon particles, especially with coated, painted or galvanized metal, stainless steel or cadmium and lead coatings. See Galvanized Metal Fume Fever.
- Arc light: intense ultraviolet and infrared light burns eyes and skin. See Welding Helmets.
- Electric shock from the power supply and damaged leads.
- Compressed air hazards: hose whip and blowing debris.
- Fire and explosion in the presence of flammables and in confined spaces. See Hot Work Permits.
- Hot metal and carbon stubs that burn on contact.
Safe gouging
- Get a hot work permit, clear or protect combustibles within the required distance (commonly 35 feet), cover openings, and post a fire watch during and after the work. See Hot Work in Occupied Buildings.
- Wear flame-resistant clothing, leather jacket or sleeves and apron, leather gloves, high-top leather boots (with pant legs over boots), a welding helmet with the right shade lens (often darker than for welding), a hood or cap, and ear protection (plugs and muffs together if needed). See Welding Leathers and Flame-Resistant Clothing.
- Use ventilation and local exhaust, and a respirator suitable for the fume when needed. Remove paint and coatings where possible. See Ventilation and Respiratory Protection.
- Set the air pressure and amperage to the electrode maker's recommendations. Keep air hoses and leads from kinks and damage, and use whip checks on high-pressure connections.
- Gouge away from your body and away from others. Control the direction of the spray with the torch angle, and place fire-resistant shields or blankets around the area.
- Warn nearby workers, and screen the area to protect others from light and sparks. See Welding Screens.
- Handle hot electrode stubs carefully and put them in a metal container.
- In confined spaces, treat gouging as a high-risk activity requiring an entry permit, ventilation, atmospheric monitoring and a rescue plan. See Confined Spaces.
- Turn off the power, close the air valve and check the work area for smoldering fires before leaving.
Carbon arc gouging checklist
- A hot work permit, fire watch and shields or blankets are in place
- I wear FR clothing, leathers, a dark-lens helmet and double hearing protection
- Ventilation or a respirator controls fumes, and coatings are considered
- Air pressure, amperage and hoses are set and in good condition
- I gouge away from my body and others and check for fires afterward
Standards & references
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