Welding workspaces contain multiple hazards that may lead to vision or hearing loss, electrical shocks, burns, and metal fume fever. Proper training and following safety procedures are key to minimizing these dangers, but not every hazard is within a welder’s control. Faulty equipment, poor ventilation, and hazardous fumes can all pose serious risks, which is why the right protective gear and a well-maintained workspace are essential.
What Is Metal Fume Fever?
Some metals used in welding are coated with zinc, cadmium, chromium, copper, fluoride, lead, manganese, or vanadium. During welding, these metals emit vapors that are oxidized in the air and then inhaled by welders. Inhaling these fumes may cause an illness known as metal fume fever, which presents flu-like symptoms in as little as four hours after exposure. Metal fume fever typically resolves on its own, assuming there is no additional exposure to metal fumes.
What Causes Metal Fume Fever?
The most common cause of metal fume fever is zinc oxide, which forms when welding bronze or galvanized steel. Other metal oxides can also contribute to similar health effects, such as those from copper or stainless steel.
Who Is at Risk for Metal Fume Fever?
Welders, cutters, brazers, and solderers are most often diagnosed with metal fume fever. As many as 30% of middle-aged welders report at least one episode of illness during their careers. Welders working in poorly ventilated spaces or handle galvanized materials are particularly vulnerable to this condition.
Signs of Metal Fume Fever
Metal fume fever may cause the following symptoms, many of which overlap with those of other flu-like illnesses:
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Fever
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Coughing and wheezing
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Fatigue
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Metallic taste in mouth
You may feel better on Sundays but start to feel worse again on Mondays or Tuesdays, as the symptoms are cyclical due to repeated exposure during the workweek.
Diagnosing Metal Fume Fever
Metal fume fever is diagnosed by a clinician who will assess you for the symptoms above and ask you about your occupation. Since many of these symptoms overlap with other flu-like illnesses, it is critical you let your physician know you work with metals, as this is an important piece of information for an accurate diagnosis. Your blood may also show elevated zinc levels if you’re suffering from the condition.
Metal Fume Fever Treatment Options
As the underlying cause of metal fume fever is exposure to metal fumes, there is no specific treatment for this condition. The main recommendation is to reduce your exposure to metal fumes that cause the fever. You may request medications to manage symptoms, such as fever reducers, non-steroidal anti-inflammatory drugs (NSAIDs), and aspirin.
Is Metal Fume Fever Dangerous?
Fortunately, metal fume fever is rarely a serious condition and typically resolves in as little as one or two days. Nonetheless, repeated exposure to the fumes that cause metal fume fever may lead to the development of chronic asthma.
What To Do if You Think You Have Metal Fume Fever
If you think you have metal fume fever, remove yourself from the source of the fumes and get some fresh air. If your symptoms are severe enough to disrupt everyday activities, seek medical attention, especially if you have trouble breathing.
Rest and drink fluids until your symptoms go away. If your symptoms don't go away within 48 hours of removing yourself from the source of the fumes, follow up with your doctor to make sure you are not suffering from a more serious condition.
Preventing Metal Fume Fever
Preventing metal fume fever comes down to being aware and taking a few precautions. You should clean coatings used during welding to remove toxic metals, solvents, or paint.
Also make sure you are located away from areas where you might breathe welding fumes and gasses, even working outdoors, if possible. Working in a well-ventilated space is critical to avoiding the inhalation of metal fumes, which you can accomplish by using exhaust ventilation systems, and making sure the exhaust vent is located away from other workers. If this does not provide adequate ventilation, respiratory protection might be necessary.
Other Types of Welding Hazards
Welding is a high-risk profession, and metal fumes are just one of the many hazards metalworkers encounter. Some dangers can be far more serious than metal fume fever and may require medical attention to resolve. According to the U.S. Bureau of Labor Statistics, there were 48 fatal injuries among welding, soldering, and brazing workers in 2020, with six related to harmful substance exposure and 22 linked to contact with objects and equipment.
Physical Hazards
Welding (as well as other metalworking activities like brazing and cutting) involves various physical hazards, several of which may lead to serious long-term injuries, disabilities, or even death.
UV and IR Radiation
When metal particles are heated hot enough, they begin to emit visible light as well as invisible ultraviolet (UV) and infrared (IR) light. UV radiation is emitted from the electric arc during welding and may also reflect off hard, smooth surfaces.
You may suffer from an indoor sunburn if any of your skin is unprotected during welding. Its lower energy means IR light poses much less of a risk than UV light, but it is still possible for it to produce cataracts upon long-term exposure.
Noise Exposure
As exposure to loud noises may damage the nerves and hairs in your ears, OSHA requires employers to take measures to protect and educate employees working on activities that reach high noise levels. Some welding activities and machines generate noise levels up to 120 decibels, with air compressors, metal angle grinders, and plasma cutters being some of the main culprits.
Electrical Shocks
Welders may suffer a shock from touching an electrically “hot” metal part or electrode, as this completes a circuit between the electrode, power supply, and grounded metal. Some factors that increase the risk of electrical shock include working with wet hands, gloves, or clothing or touching a lead or other electrically “hot” component while your hand or body is touching grounded metal.
Chemical Hazards
Although laymen may think of it as a simple melting process, welding involves a series of chemical reactions. These reactions may produce toxic byproducts.
Fume and Gas Emissions
As noted earlier, when metals are heated above their boiling point during welding, they form gasses that are oxidized. If inhaled, these fumes may lead to metal fume fever. Welding, especially oxyacetylene welding, may also produce other toxic gasses, such as nitrogen dioxide, which damages mucus membranes.
Exposure to Toxic Metals
Many metals involved in welding activities pose much more serious hazards than metal fume fever, including cancer. Other issues related to metal exposure include:
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Lung diseases, such as pulmonary fibrosis and asthma caused by the inhalation of metals like beryllium as well as iron oxides
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Skin irritation (such as contact dermatitis) caused by exposure to nickel, chromium, and other metals
Thermal Hazards
The temperature of the electric arcs during welding may reach temperatures of 10,000 degrees Fahrenheit (~5500 degrees Celsius). Therefore, it should come as no surprise that thermal hazards are one of the main safety concerns during welding.
Burns and Fires
Welding should not be performed near any flammable substances, such as solvents or paints. Note that hydraulic lines may contain flammable liquids and fuel lines are flammable.
Explosions
Although the odds are relatively low, there is a risk that the gasses generated during welding may reach explosive levels. Welding should also not be performed in areas where large amounts of airborne dust may accumulate, as this also poses the risk of an explosion.
Ergonomic Hazards
While the safety hazards above relate to broader workplace conditions, ergonomic hazards refer to using pieces of equipment in a way that causes strain on the body.
Repetitive Motion Injuries
Welding involves many repetitive motions, but the repeated use of the same body part, especially if the repeated motion is performed too quickly or for too long — causes wear and tear that may lead to injuries over time. Repeated wear is especially problematic when the welder applies more force, as a longer recovery time is needed.
Improper Posture Risks
Improper posture such as overextending your arms, squatting, or straining your neck, may lead to injuries. When welding, make sure you are comfortable and stable. It may help to position the welding item flat at a comfortable height, such as between waist and elbow height. Avoid working in the same posture for a long time, as this puts strain on the same body parts. Proper ergonomics have benefits beyond comfort and may even increase your productivity.
Health Risks Associated with Welding
Welding comes with several health risks that every welder needs to understand to stay safe on the job. From respiratory issues caused by inhaling harmful gases to long-term effects like lung diseases and skin cancer, being aware of these hazards is important for protecting your health.
Respiratory Issues
When there is inadequate ventilation, the welder may inhale gasses produced during welding. If the amount inhaled is high enough or the exposure to the fumes is long enough, a variety of respiratory issues may develop, including metal fume fever as well as welder’s lung and occupational asthma.
Eye Inflammation
UV radiation emitted during welding activities may damage the eyes, such as by giving your cornea a sunburn, which leads to the condition known as “arc eye”. Ultraviolet radiation has also been implicated in causing melanoma of the eye, with welders being at a high risk.
Lung Diseases
Long-term exposure to steel welding fumes has been implicated in the development of pulmonary fibrosis as well as chronic bronchitis. As the IARC classifies welding fumes as carcinogenic to humans, it should come as no surprise that a meta-analysis found that exposure to welding fumes increases a welder’s risk of lung cancer.
Skin Cancer
As noted earlier, welding produces bright light, a portion of which is UV light, which causes sunburn and corneal burns, just like the UV light emitted by the sun. Although the link between UV light produced by welding and ocular melanoma has been established, it is unclear whether UV light also causes skin cancer. However, studies have shown that welders have a higher risk of basal cell carcinoma on their necks when exposed to UV light for more than 30 years.
Personal Protective Equipment (PPE)
The right personal protective equipment (PPE) is important for welders to protect themselves and stay safe from potential hazards on the job.
Eye and Face Protection
Everyone near welding activities should wear adequate protection, as many surfaces reflect UV and IR light. In addition, small metal debris poses a threat to the eyes during welding. The most appropriate face and eye protection depend on the type of metal working activity you are performing. OSHA has specific regulations to make sure employees are wearing the correct filter shade during welding, brazing, and soldering activities.
Respiratory Protection
Although OSHA requires sufficient mechanical ventilation for locations where welding, cutting, and heating activities are performed, additional respiratory protection may be necessary. OSHA requires employers to provide their workers with a NIOSH-certified respirator that is appropriate for the type of welding they are performing. It also requires employers to provide several different models and sizes to ensure each employee has a respirator that fits.
Protective Clothing
In addition to a helmet and respiratory protection, welders should wear clothing that protects them from sparks and slag. OSHA states that leather clothing (provided it is free of flammable oils) is an acceptable form of protecting clothing. In addition to fire-resistant clothing, welders should wear insulating gloves and sleeves to prevent electrical shocks.
Ventilation and Exhaust Systems
OSHA requires all exhaust and ventilation systems to operate continuously while work is being performed. It also requires that the exhaust system continue to operate after work has ended because dust may accumulate in the air. Continuous operation removes this dust from the air to prevent harmful exposure to workers.
Safe Work Practices
Proper Training and Certification
Although various regulations are in place to protect workers from factors in the workplace beyond their control, a key component of safety is employee training to understand the risks and hazards of welding. Several entities offer welding certifications:
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AWS offers several online courses to equip metalworkers with the knowledge they need to work safely.
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The American Bureau of Shipping offers services to witness tests and qualifications, for companies that need verification.
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The American Petroleum Institute offers a welding inspection and metallurgy certification.
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The American Society of Mechanical Engineers offers training courses for welders.
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State Departments of Transportation, such as in Georgia and Massachusetts, offer certifications to confirm a welder is certified for a specific process.
Regular Equipment Checks and Maintenance
Proper maintenance of equipment is critical to ensuring worker safety. If a worker notices that a piece of equipment is defective, OSHA requires work to be terminated until qualified personnel have repaired the machine. Some things to look out for when checking equipment include:
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Grounding
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Supply connections and conductors
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Leaks
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Machine hookups
Regulatory Standards and Guidelines
Following compliance standards and maintaining a safe working environment is key to keeping welders safe on the job.
OSHA Regulations
OSHA has several regulations related to welding, brazing, cutting, and soldering activities. Some important ones include those related to:
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General requirements for welding, cutting, and brazing, including guidelines for fire hazards
ANSI and AWS Standards
ANSI standards provide information related to oxygen gas and arc welding processes to protect welders from injuries and illnesses and to prevent equipment from being damaged or destroyed by fires or explosions caused by welding. They also provide many standards related to the PPE welders should wear when working.
The American Welding Society (AWS) is a non-profit that develops standards to maintain worker safety when welders are fabricating quality materials. Their standards and guidebooks are categorized according to the type of welding as well as the specific materials.
International Guidelines
Several countries outside the U.S. also have regulations, standards, and guidelines to ensure worker safety and the quality of work.
Canada
The Canadian Standards Association (CSA) Group governs welding in Canada for standards that cover welding procedures, weld quality, and qualifications for welders. The Canadian Welding Bureau Group (CWB) certifies companies, inspectors, and welding consumables.
EU
ISO 3834-1:2021 sets quality standards for welding products. The European qualification standards for welders are defined by EN ISO 9606 and EN 287-1.
UK
Relevant UK standards for welding include the British Standard, European British Standard European Standard, and the International Standards Organisation (ISO).
FAQ
How can I reduce my exposure to harmful welding fumes?
Ensure you are working in a well-ventilated area that has active air circulation. Also, make sure you are wearing a well-fitted respirator that protects against the specific fumes you may encounter.
What are OSHA's key regulations for welding safety?
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OSHA Regulation 1910.252 is a general document covering regulations for welding, cutting, and brazing, including guidelines for fire hazards.
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OSHA Regulation 1926.353 covers ventilation standards.
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OSHA Regulation 1910.133 covers eye and face protection.
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OSHA Regulation 1926.57 stipulates exhaust and ventilation requirements.
How often should I check welding equipment for safety reasons?
OSHA does not specify a frequency for welding equipment inspections, but it does require qualified personnel to perform such inspections. In addition, you must maintain a record of certification. This record should include the inspection date, the inspector’s signature, and the serial number or identifier of the equipment.
What PPE is mandatory for welding?
The specific PPE you need depends on the welding activity — there’s no one-size-fits-all answer. ANSI and OSHA provide general guidance for selecting appropriate PPE.
Gloves - Gloves need to be appropriate for the chemicals a worker might encounter during welding. They should also be electrically insulating and non-flammable.
Eye protection - Eye protection should protect against the specific hazards each welder will encounter but remain comfortable and not interfere with any other PPE.
Protective clothing - Clothing should be made of a non-flammable material and should not be coated in anything that might catch on fire.
Featured photo courtesy of Rob Lambert // Unsplash
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