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Reducing the Risk of Welding Fume Inhalation

Date: 31-10-2018

The risks of welding fumes

Welders face hazards whenever they carry out their tasks. The most noticeable part of the risk factors is inhaling harmful fumes. The recent reclassification of welding fume as carcinogenic to humans by the International Agency for the Research on Cancer (IARC) gives proof to this.¹

As welding professionals, you need to understand that the chemicals in the fumes are dependent on the base material, the consumable you are using and if the metal has a coating. It is crucial for us to discuss the risks of inhaling welding fumes, emphasizing the importance of safety and knowing the right equipment. 

Here are some factors to consider in minimising the dangers of welding fume inhalation at your workplace.

The risks and hazards of welding fumes

Welding fumes are a complex mixture of chemicals and metallic oxides in a gaseous state. Fumes are formed when a metal is heated above its boiling point and vapours (fumes) are given of and contain ultra fine particles of metallic oxides and chemical gases. Welding fumes generally contain particles from the electrode and the material being welded.

Welding fumes contain compounds such as complex oxides of iron, manganese and silicon. If these chemicals are inhaled, workers experience temporary bouts of dizziness, nausea and fever. Long-term exposure to welding fumes, on the other hand, may lead to silicosis, bronchitis and even lung fibrosis.

Welding gases are gases used or produced during welding and cutting processes like shielding gases or gases produced by the decomposition of fluxes or from the interaction of ultraviolet light or high temperatures with gases or vapours in the air.

Particles constitute possibly the greatest health hazard. Particles in size range 1-7 μm. The particles constitute the greatest health hazard because of their ability to penetrate deep into the lungs and because they are not readily cleared by the cilia lining the respiratory tract. The particles that are visible in the fume plume are usually heavier and will generally fall onto adjacent surfaces. Particles in the welder's breathing zone are usually 2 μm or less. These lighter, smaller, particles may remain in the air for some hours if not removed by some form of extraction.

Welders need to be mindful when working with new or uncommon materials such as chromium, copper, manganese, nickel, silica and even stainless steel.

It is now a known and recognised fact that welding fumes are cacogenic. An effect from this may take many years from the initial event to a clinical diagnosis of cancer. And diagnosis of cancer may not be made until long after cessation of welding fume exposure. Therefore these substances must be controlled to the maximum possible advantage.

Most welding professionals know which personal protective equipment (PPE) to use, according to Sasanka Sinha of the Welding Technology Institute of Australia. However, it is the management’s responsibility to ensure safety in their workplace.

Establishing safe systems at work  

According to Safe Work Australia, managing risks with welding processes starts with identifying all potential hazards to workers. Site managers, supervisors and health and safety professionals must carefully assess the workplace and talk to worker’s to know how the work is carried out. 

Managers must inspect the equipment and materials used in the welding work, read and study product labels and manufacturer’s instruction manuals and review previous incident reports. While WHS Regulations do not require risk assessments for the welding industry, it is imperative for specific situations, such as working in a confined space.

Risks and hazards can be minimized in various ways. One way is by substituting a process or material with one that is less hazardous to workers, if practically possible, to reduce the risk of exposure to radiation and fumes. Engineering proper control measures, such as installing proper ventilation systems, all help lessen welding fumes.

Using the right equipment

As much as possible, working in an enclosed or confined space needs to be at a minimum. If this is not the case, indoor workplaces need adequate ventilation. The employer have a duty of care as far as reasonably practicable to provide a safe working environment in ensuring that workers are wearing personal protective gear & using extraction systems provided to minimize and remove the presence of welding fumes as much as possible in the work area. Opening windows and doors help in cross-ventilating the workshop.

Welders must be informed of the risks of welding and to be included in the decision-making process drawing on their knowledge to help select the most appropriate local control measures including any personal protective equipment. Welders also have a responsibility to take reasonable care for their own health and safety at all times.

Local extraction is the most effective method: The hazardous substances are captured right at the source before they reach the welders breathing zone. This can provide sufficient protection and also provide clean breathing air at workplaces.

Alternatively is to protect and isolate the person from these fumes by using effective respirator systems. Powered Air Purifying Respirator or PAPR can offer comfortable, mobile, integrated protection against multiple hazards helping to provide respiratory, head, face, eye and hearing protection if required. They provide a constant safe flow of air in the helmet which allows you to breathe more naturally. Certain models allow for facial hair as well. PAPR systems need regular filter changing and regular physical checks to ensure that they are providing the required protection at all times. 

Supplied air systems generally consist of a clean compressed air supply connected to either tight or loose fitting respirators. The air supply could be either a low pressure or high pressure source. A low pressure source would be an ambient pump (an air compressor designed specifically for respiratory protection applications) located in a clean environment. A high pressure supply source would be either a cylinder or the compressed air supply within a facility as long as it is filtered and monitored to ensure it meets relevant occupational health requirements for breathing air.

These systems are ideal for workstations were mobilty is not such an issue such as in workshops and production lines where long term use prevails. Also these systems have the ability to heat or cool the supplied air. A huge benefit in areas where high physical demands are required.

In the 2017 Occupational Cancer Risk Series on Welding, welders were advised to wear either air supplied or air purifying respiratory protection and use a full face welding helmet, with a UV filtered lens as well as suitable clothing, welding gloves and welding boots.²

Sourcing the best welding safety equipment is key to ensuring a safe and healthy workforce. Investing in the right safety gear also helps your business comply with industry regulations and limit workplace incidents.

Alphaweld can provide detailed information on PAPR & supplied air systems that will meet your requirements.

We specialise in welding equipment and pipe working tools

Alphaweld Supply Group is a leader in welding protection solutions for your business. We provide a range of welding apparel and fume extraction systems suited to your company’s requirements.

We look forward to hearing from you. Contact us on 08 9456 8000 for enquiries.

¹Ref: https://www.aiha.org/publications-and-resources/TheSynergist/Industry%20News/Pages/IARC-Welding-Fumes-UV-Radiation-from-Welding-Are-Carcinogenic.aspx

²Ref: https://www.cancer.org.au/preventing-cancer/workplace-cancer/welding.html