Welding Solutions

The fume plume contains solid particles from the consumables, base metal, and base metal coating. For common mild steel arc welding, depending on the amount and length of exposure to these fumes, most immediate or short term effects are temporary, and include symptoms of burning eyes and skin, dizziness, nausea, and fever. Long-term exposure to welding fumes can lead to siderosis (iron deposits in the lungs) and may affect pulmonary function. Bronchitis and some lung fibrosis have been reported.Some compounds which may be in welding fume, and reported health effects of overexposure are below. See the SDS for the consumable product used for specific information.

• Barium may cause severe stomach pain, slow pulse rate; irregular heartbeat, ringing of the ears, convulsion and muscle spasms. In extreme cases it can cause death.
• Cadmium fumes can be fatal even under brief overexposures, with symptoms much like metal fume fever.
• Chromium and its compounds are on the IARC (International Agency for Research on Cancer) and NTP (National Toxicology Program) lists as posing a cancer risk to humans. Some forms of these metals are known or suspected to cause lung cancer in processes other than welding and asthma has been reported.
• Manganese: Manganese overexposure may affect the central nervous system, resulting in poor coordination, difficulty in speaking, and tremor of arms or legs. This condition is considered irreversible.
• Nickel: Nickel and its compounds are on the IARC (International Agency for Research on Cancer) and NTP (National Toxicology Program) lists as posing a cancer risk to humans.
• Silica: Overexposure can cause severe lung damage (silicosis).
Crystalline silica is present in submerged arc flux.
• Zinc: Overexposure to zinc may cause metal fume fever with
symptoms similar to the common flu.

Your work area has adequate ventilation when there is enough ventilation and/or exhaust to control worker exposure to hazardous materials in the welding fumes and gases so the applicable limits for those materials is not exceeded. See the SDS for the legal limits, the OSHA PEL (Permissible Exposure Limit), and the recommended guideline, the ACGIH TLV (Threshold Limit Value). Confirm that if the worker exposure does not exceed the applicable exposure limit for compounds in the fumes and gases by having an industrial hygienist take and analyze a sample of the breathing air. A respirator may be required if exposure cannot be controlled to the PEL or TLV.

Read the product label and material safety data sheet for the electrode posted in the work place or in the electrode or flux container to see what fumes can be reasonably expected from use of the product and to determine if special ventilation is needed. Know what the base metal is, and determine if these is any paint, plating, or coating that could expose you to toxic fumes and/or gases. Remove it from the metal being welded, if possible.
If you start to feel uncomfortable, dizzy or nauseous, you may be overexposed to fumes and gases, or suffering from oxygen deficiency. Stop welding and get some fresh air immediately. Notify your supervisor and co-workers so the situation can be corrected and other workers can avoid the hazard. Be sure you are following these safe practices, the consumable labeling and SDS and improve the ventilation in your area. Do not continue welding until the situation has been corrected.