Welding processes expose welders to fumes inhalation from fusion between several metals. These fumes are mostly invisible and can contain dusts, gas and vapors. Continous exposure to fumes is a major risk for welders but also for anyone working nearby because fumes spread easily. Those particules are so small they can enter to the pulmonary alveoli and cause serious illnesses.
Learn more with this article about:
- Risks related to welding fumes
- Regulations
- How to protect from them
1– What are the risks?
Risks change according to gas and dusts composition, concentration and exposure time. Since 2017, the Agency for Research on Cancer (IARC) classify welding fumes as carcinogenic. Besides, welding fumes include many others risks that can be acute risks (short-term exposure) and chronic risks (long-term exposure).
Acute effects can be:
- Irritation of the eyes, nose and throat: Gases and fine particles in welding fume can cause dryness of the throat, tickling, coughing or a tight chest. The effects tend to be short lived.
- Pulmonary oedema: Extreme exposure to ozone can cause pulmonary oedema (fluid on the lungs).
- Poisoning/ asphyxia: Inhaling welding fumes can lead to poisoning, a condition in which you become weak and develop anemia (a low red blood cell count).
- Metal fume fever, is an illness caused primarily by exposure to certain fumes. Workers breathe in fumes from chemicals such as, which are created by heating or welding certain metals, particularly galvanized steel. The symptoms are nonspecific but are generally flu-like including fever, chills, nausea, headache, fatigue, muscle aches, joint pains, shortness of breath, chest pain, and cough.
Chronic effects can be:
- Chronic bronchitis is chronic inflammation and irritation of the bronchial tree.
- Pneumoconiosis (siderosis or welder's lung) is an occupational illness. Pneumoconiosis diseases are all caused by the inhalation of welding fumes which is retained in the lungs. In the case of Welder’s Lung, the disease results from the inhalation of iron particles. For example, if a welder is dealing with metals containing iron, than he or she might breathe in these particles which are often emitted in the welding fumes.
- Central nervous system or digestive system involvement: The nervous system, kidneys, digestive system and mental capacity may be affected due to the exposure to lead, manganese or cadmium oxides.
- Skin or mucous lesions: Repeated or prolonged overexposure can damage the mucous membranes of the nasal passages and cause ulcers to form. In some cases the damage is so severe that the septum (the wall separating the nasal passages) develops a hole. Skin exposure to hexavalent chromium over prolonged periods can cause ulcers to form. Some workers develop an allergic sensitization to chromium. In sensitized workers, contact with even very tiny amounts can cause a serious skin rash.
2- Regulations
Several countries have an occupational exposure limit (OEL) for welding fumes of 5 mg/m3 and a similar OEL for respirable dust. In the US, the exposure limits is of 5mg/m3. In the UK, there is no such limit. Given the accumulating evidence of serious health effects from welding fumes <5 mg/m3, adequate protection of workers, including a stricter health-based OEL, is urgently needed.
3 – How to protect against welding fumes?
As seen previously, some countries have introduced regulations to limit welding fumes exposure. There are differents measures depending on the processes and materials used, but also on the workplace, it’s important to choose tailored measures to your company’s needs. Depending on the country, companies have to provides to welders information about the risks to health and precautions to be taken. Here’s a summary of measures to take.
A) Use lower-emission metal joining processes
The most efficient measure to limit welding fumes exposure is to choose a less emissive welding process.
B) Reduce welding fumes emitted
The release of hazardous substances can be reduced by various measures:
- Use of lower-emission processes, e.g. through automation, or submerged arc welding.
- Use of optimised process parameters, e.g. through digitally controlled process variants.
- Use of other filler materials or gases, e.g. by reducing the CO2 content in the shielding gas or changing the filler metal. 80% of welding fumes are created by filler metal, it’s important to choose wisely.
- Remove grease and all surface coatings before welding. Paint and resin coatings may release toxic components when heated.
C) Extract welding fumes at source
They are many fumes extraction systems according to your needs. Whatever your issue, you can choose a extraction at source. Here are a few examples: welding extraction torch, extraction slit nozzles, extraction arm, extraction table or hood, etc. Find out our article about differents extractions systems.
In addition to these systems, we recommend:
- Wear a ventilated welding helmet (this type of helmet can filter the air and is a good complementary equipment to welding fumes extraction system).
- Clean up work surfaces and extract with a cyclone cleaners to avoid stirring up to particles
- Set up a hall ventilation, to set the air in motion and filters it, while at the same time bringing in new air from outside.
To set up an extraction system according to your company’s needs, our ENGMAR experts offers you to make a complete on-site analysis (welding process used, workshop layout, number of welders and workstations, welders constraints, budget…)
Following to this audit, we advise you a tailored solution to provide the best health protection. We also provide additional services, including solutions installation, employee training along with maintenance and after-sales services.
Want to protect welders’ health but don’t know where to start? We’re here to help you find the solution that suits your needs.