Occupational Health Hazards Of Welding Fumes

What Are Welding Fumes?

Welding fumes and gases are the result of welding activities and can be extremely harmful to those who inhale them. Welding fumes are created when metal or other materials such as flux or solvents are heated above its boiling point and its vapours condense into very fine particles (solid particulates). Inhaling these fumes can be toxic.

What Are Welding Fumes Composed Of?

Welding fumes normally contain oxides of the materials being welded and of the electrodes being used. If the metal has a coating or paint, these too can become part of the fumes. Welding fumes contain particles from the electrode, the material, and coatings on the being welded. 

What Are the Hazards of Welding Gases?

Electrocution, asphyxiation, UV radiation burns, hearing loss and welding fumes are just a few of the occupational hazards faced by welders. Welding fumes contain their own hazards including: 

• asphyxiation (lack of oxygen)
• fire or explosion
• toxicity

What Are the Contaminants Found in Welding Fumes?

The airborne gases and fumes produced or present during welding can include nitrous oxide, carbon dioxide, carbon monoxide, shielding gases like argon or helium, ozone, as well as metal fumes like manganese and chromium.

Why Are Welding Fumes Dangerous?

Your risk of inhaling welding fumes depends on how toxic and concentrated the fumes are, how long you were breathing in the fumes, and the welding fume dangers associated with the specific materials being welded.

How Do Welding Fumes Harm My Body?

There are health effects for both short-term and long-term exposure to these welding fumes and gases, including potential impacts on overall health.

Health Effects and Short-Term Exposure

Symptoms of short-term exposure to welding fumes in the workplace include eye, nose, and throat irritation, as well as dizziness and nausea. 

Health Effects and Long-Term Exposure

The long-term side effects of inhaling welding fumes in the workplace include:

• Occupational asthma 
• Pneumonia 
• Metal fume fever 
• Reduced lung function 
• Stomach ulcers 
• Kidney damage
• Nervous system damage 
• Prolonged manganese exposure can cause Parkinson’s-like symptoms 
• Cancer of the lungs, larynx, and urinary tract 

Welders are at increased risk of respiratory tract infections from chemical irritation.

Who Needs To Be Concerned About the Occupational Health Hazards of Welding Fumes?

Welders are at the highest risk for occupational exposure to welding gases and fumes, but anyone who works near a welder can also inhale welding fumes, especially in confined spaces or indoors where fumes can’t escape, and hazardous levels can accumulate. In fact, workers who work in enclosed or confined spaces with a welder can have the same level of risk as the welder.

What Factors Influence Worker Exposure to Welding Fumes?

Several factors can influence worker exposure to welding fumes, including: 

• The welding process used 
• The composition of the welding rod 
• The filler metals and base metals employed 
• The type of coatings present 
• The location of the work (open area vs. confined space) 
• The type of ventilation controls in place (mechanical or local) 
• The welder's work practices

How to Mitigate Welding Hazards in the Workplace

Chemscape’s Mike Phibbs along with Michael K. Harris have written a practical field guide to help you communicate more effectively with welding shop and plant personnel.

Use this guide to develop similar exposure groups and learn about local exhaust ventilation, welding fume as an IARC Group 1 carcinogen, and exposure control banding. With several handy color-coded tables and graphics, assessing hazards and managing welding health hazards is easier than ever!  

Supplement traditional industrial hygiene (IH) assessment methods for welding with new control banding approaches.  

Gain a deeper understanding of welding hazards and protect your worker’s health.