Welding Fume Health Hazards
What Are the Health Hazards of Welding Fumes?
Welding is essential across manufacturing, construction, transportation, shipbuilding and many other industries. The process can also create airborne contaminants that require careful control.
The health risk is not identical for every welder. It depends on what is being welded, how the welding is performed, the contaminants generated, how much fume reaches the breathing zone and how long exposure continues.
What Are Welding Fumes?
Welding fumes are airborne particles generated during welding and thermal metalworking processes. Intense heat vaporizes small amounts of metal and other materials. As those vapors cool, they condense into extremely small particles that become suspended in the surrounding air.
Welding operations can also generate gases. The exact combination of particles and gases depends heavily on the welding process, electrode or wire, base material, coatings and work environment.
Welding Fume May Contain
- Iron
- Manganese
- Chromium
- Nickel
- Zinc
- Copper
- Lead
- Other metals depending on the application
Welding Can Also Generate
- Carbon monoxide
- Nitrogen oxides
- Ozone
Shielding gases can also create hazards in poorly ventilated areas because they may displace oxygen.
How Are Welders Exposed to Welding Fumes?
Inhalation is one of the primary ways welding fumes enter the body. The welder's breathing zone can be exposed when the fume plume rises from the welding arc and is not adequately captured or ventilated.
Exposure can vary substantially depending on:
Different welding techniques generate different quantities and types of airborne contaminants.
Stainless steel, coated metals and other materials can generate different hazardous components.
Air movement and extraction affect how much fume remains in the worker's breathing zone.
Confined and enclosed spaces can allow contaminants to accumulate more easily.
Longer and more frequent exposure can increase the overall amount of contaminant inhaled.
Extraction near the weld can reduce the amount of fume entering the breathing zone.
What Are the Immediate Effects of Welding Fume Exposure?
The short-term effects of welding fumes depend on the specific contaminants involved and the concentration of exposure.
Possible Symptoms
- Coughing
- Breathing difficulty
- Respiratory irritation
- Chest discomfort
Other Possible Symptoms
- Headache
- Fever
- Chills
- Muscle aches
- Flu-like symptoms
What Is Metal Fume Fever?
Metal fume fever is an acute flu-like illness associated with inhalation of certain freshly formed metal oxides. It is commonly associated with zinc oxide fume, which can be generated when welding galvanized steel.
Symptoms may include:
- Fever
- Chills
- Cough
- Muscle aches
- Breathing difficulty
- General flu-like discomfort
These symptoms should not be treated as an expected or acceptable part of welding. The exposure conditions should be investigated and appropriate controls implemented.
What Can Long-Term Welding Fume Exposure Cause?
Repeated exposure to welding fumes has been associated with several chronic occupational health concerns. The exact risk varies because welding fume composition differs significantly between jobs and materials.
Welding exposure has been associated with chronic respiratory effects including bronchitis.
Occupational studies have associated welding exposure with decreases in pulmonary function.
Exposure to metals such as manganese can affect the central nervous system.
Welding emissions have been associated with acute and chronic respiratory disease.
Welding fumes are classified by IARC as carcinogenic to humans.
Some hazards depend on particular metals such as chromium, nickel, lead or manganese.
Can Welding Fumes Cause Cancer?
Yes. The International Agency for Research on Cancer classifies welding fumes as Group 1, carcinogenic to humans.
This classification applies to welding fumes as an occupational exposure and reinforces the importance of controlling repeated exposure throughout a worker's career.
Learn more in Welding Fume Classified as Carcinogenic to Humans .
Source: IARC Monographs Volume 118
How Can Manganese Affect Welders?
Most welding fumes contain at least a small percentage of manganese. The amount varies depending on the welding wire, rods, flux and base metal.
Inhaled manganese is a particular concern because it can accumulate in the body and affect the lungs, liver, kidneys and central nervous system.
Prolonged exposure to high manganese concentrations can cause a Parkinsonian syndrome known as manganism.
Possible Symptoms
- Tremors
- Slowed movement
- Muscle rigidity
- Poor balance
Other Concerns
- Mood changes
- Changes in reaction time
- Reduced hand-eye coordination
- Short-term memory effects
How Can Welding Fume Exposure Be Reduced?
Welding fume control should focus on reducing the amount of contaminant that reaches the worker's breathing zone. Depending on the application, several control measures may be used together.
| Control | What It Does | Typical Role |
|---|---|---|
| Source capture | Captures fumes close to the welding arc | Limits fume before it spreads |
| General ventilation | Moves and replaces contaminated workplace air | Supports overall room air quality |
| Work practices | Changes how welding work is performed | Can reduce unnecessary exposure |
| Respiratory protection | Protects the individual worker | Used where required by the exposure assessment and applicable rules |
Why Capture Fume at the Source?
Source capture uses local exhaust ventilation to collect contaminated air close to the point where welding fumes are generated.
Capturing fumes before they spread helps reduce the opportunity for contaminants to enter the welder's breathing zone or migrate throughout the wider workplace.
Common solutions include:
What Type of Fume Extractor Should a Shop Use?
There is no single extraction solution for every welding application. The appropriate system depends on the process, welding volume and facility layout.
Important factors include:
- Number of welders
- Hours of welding per day
- Type of welding process
- Metals and coatings involved
- Whether workstations are fixed or mobile
- Size and layout of the facility
- Available space for extraction equipment
Improving Air Quality in an Active Welding Facility
At Skeer System in Berthierville, Quebec, two Plymovent FlexHood systems were installed after the facility identified a need for dedicated welding fume capture.
The project was designed around the welding environment and facility requirements, demonstrating how the appropriate extraction solution depends on the way welding work is actually performed.
Welding Fume Health Questions
Yes. Welding fumes may contain metals and other contaminants associated with respiratory, neurological and other occupational health effects. The actual risk depends on the welding process, material and level of exposure.
Yes. The International Agency for Research on Cancer classifies welding fumes as Group 1, carcinogenic to humans.
Depending on the contaminant and level of exposure, symptoms can include coughing, breathing difficulty, fever, chills, muscle aches and other flu-like symptoms.
Yes. Prolonged exposure to high manganese concentrations can affect the central nervous system and may cause a Parkinsonian syndrome known as manganism.
Exposure control often combines engineering controls such as local exhaust ventilation, appropriate general ventilation, safe work practices and respiratory protection when required. The exact solution should be selected for the welding process and exposure conditions.
Welding Fume Exposure Should Be Controlled
Welding fumes are not simply an unavoidable inconvenience of welding. They are an occupational exposure that can affect worker health.
Understanding the materials being welded, evaluating the work environment and using appropriate ventilation and extraction can help reduce the amount of contaminant reaching workers.
Need Help Controlling Welding Fumes?
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