The conditions of welding work strongly vary and are not always completely foreseeable. The welded materials, the coatings, the type of welding work, the welding parameters as well as the ambient conditions all influence the type and quantity of released welding fumes and gases. The compositions and concentration of hazardous and potentially carcinogenic substances in these fumes also vary depending on the welding situation. These potential health hazards do not only concern yourself during welding work but also colleagues performing preparatory and subsequent work, transport materials, perform maintenance or other work in you close vicinity. Therefore, adequate safety measures and air suction and ventilation are always very important.

Things you should know!

Welding fumes and welding gases

During welding work, fumes, smokes and gases are released that may contain hazardous substances. Among these substances can be metal oxides, ultrafine particles, ozone, nitrous gases and carbon monoxide

The air you work in

Inhaling the fumes that are generated during welding can irritate the respiratory tract on short term, but may lead to lung diseases, further impairments of health and can on the long run cause cancer.
Risk management measures are key
Preventing the inhalation with tailored and correct risk reduction measures and consequent use and application of technical equipment are key to minimise exposure.

The hazards vary

Chromium VI and nickel oxide are released when welding Chromium-nickel-alloyed stainless steel. Asbestos may be released when maintenance and repair work is carried out in constructions that were built before national asbestos bans came into force. Polycyclic aromatic hydrocarbons (PAHs) and Benzene can be released when corrosion or colour coatings are heated involuntary due to welding work.

Your employer’s duties to protect you!

Your employer carries the responsibility that you are safe during and after your welding work.

• Hazard and risk assessment: Your employer has to perform and regularly update the risk assessment for you work place and your task. This risk assessment has to take into account UV radiation, flying sparks, risk of fire, confined spaces, inadequate ventilation, and the exposure to hazardous chemicals like Chromium VI or nickel compounds.
• Substitution check: The first thing your employer has to check during the risk assessment is whether the used welding technique can be substituted with another technique or adapted parameters that will lead to a reduced release of hazardous fumes. For MAG welding, the reduction of the active gas content (carbon dioxide and oxygen) in the shielding gas is one possibility. Further, for MAG and MIG welding, adjusting the process control variant (colloquially known as ‘pulsing’) can be used to reduced fume formation. (For further info, take a look here (German))
• Technical and organisational measures: Your workplace has to be designed and equipped to promote and support your safety. In addition to choosing welding techniques, equipment and welding material which support reduced exposure, your employer has to safeguard that a functioning air suction directly at the emission source as well as an adequate general ventilation is in place and welding tasks in confined spaces. For MAG, MIG and TIG welding, using a welding machine with built-in fume extraction is the most efficient way to reduce your exposure.
• Personal protection: Personal protective equipment (PPE) that has to be provided by your employer includes certified welding wear, gloves, eye protection and – if necessary – respiratory protection. The PPE has to fit you, needs to be functioning and regularly maintained and cleaned.
• Training and motivation: Regular instruction from your employer must include a description how to safely weld and motivate you to consequently make use of these procedures. As part of the instruction, you should be informed about potential new hazards, changing working conditions and subsequent safety measures. This will qualify you for welding safely.

Your own duties to support your own and your colleague’s protection!

• Measures that resulted from the risk assessment: You have to adhere to the rules and standards, especially when it comes to the positioning of air suction and ventilation. Equally important are rules regarding the work and workplace organisation and the handling of hazardous substances.
• Technical and organisational measures: Adopt all technical and organisational measure by using the point source air suctions and taking care of sufficient ventilation.. Position yourself so that you are not directly in the path of the welding fumes. Use every means possible to extract the welding fumes at the source. For example, you have to shield the arc by using a welding shield and prevent any work in closed compartments. If possible, unscrew the part to be welded and weld it in a better-ventilated area..
• Check and wear PPE: Before you equip your personal protective gear, you check its functionality and once equipped you only use it in the way the clothes, respiratory protection, gloves and eye protection is foreseen. Protective clothing must fit properly so that, during repetitive tasks, droplets from sparks, for example, cannot collect in the folds.
• Identify risks early and act in a preventive manner: You react instantly when you recognise something is not working properly, like for instance air suction is missing or poor. This is relevant also if you encounter unusual fumes, damaged wires or defeat devices, risky behaviour from colleagues or insufficient safety distance.

Take-home message

The impact of welding fumes, metal particles and dust, gases and other health hazards that can be breathed in are serious. With your active support and consequent adherence to safety measures, health hazards are reduced effectively and safety at your workplace is enhanced. This includes furthermost that you regard applicable safety and hygiene regulations (for eating, drinking and smoking) and obey instructions from your employer. Use hazard-reduced welding techniques and above all take care that air suction at the point source is optimised in addition to good ventilation of the workplace. Always wear mandatory safety gear and instantly report any hazard you observe.

Take care of your health now and for the future by working safely and protected at all times as your safety is your and your employer’s priority!