Both acute and chronic health risks for welders are directly linked to welding fume exposure. Occupational lung disease is the most common risk including lung cancer, but welding can also affect the eyes and skin. Additionally, welding in confined spaces poses a significant risk of asphyxiation. This article is a key resource not only for HSE inspectors but also for occupational physicians and Occupational Safety Specialists.
Main Health Risks for Welders
Acute Respiratory Health Effects
Acute effects appear immediately after exposure to welding fumes. HSE estimates that exposure to metal fumes at work sends 40–50 welders to the hospital every year.
Throat Irritation and Airway Inflammation
Gases and particulates in welding fumes can cause throat dryness, chest tightness, and coughing. These effects are usually short-lived. Ozone exposure, particularly during TIG welding of stainless steel and aluminum, is a major cause. High exposure to nitrous oxides (formed during most arc welding processes) can also irritate airways. Excessive ozone exposure may lead to fluid build-up in the lungs.
Acute Irritant-Induced Asthma
High-level exposure to irritants can trigger the development of asthma, though this is relatively uncommon. This condition was historically called Reactive Airways Dysfunction Syndrome (RADS).
Metal Fume Fever
Many welders experience flu-like symptoms after welding. Symptoms are often worse at the start of the workweek. Metal fume fever is usually associated with welding or hot work on galvanized metals but can also result from high exposure to mild steel fumes.
This condition generally has no lasting side effects and symptoms usually begin within hours of exposure and resolve after exposure ends.
Acute Pneumonia
Inhalation of welding fumes increases the risk of pneumococcal pneumonia. Welders are especially susceptible to severe and sometimes fatal lung infections.
Pneumonia claims the lives of at least two welders per year.
Vaccination can reduce the risk but does not replace good fume exposure control. Additional guidance on pneumococcal vaccination is available for workers exposed to welding fumes.
Chronic Respiratory Health Effects
Chronic effects develop gradually after prolonged exposure to welding fumes and can lead to severe illnesses.
Lung Cancer
Multiple studies report an increased risk of lung cancer in welders and workers exposed to welding fumes. The International Agency for Research on Cancer (IARC) has classified all welding fumes as Group 1 carcinogens, confirming they can cause lung and kidney cancer.
HSE has issued a Safety Bulletin highlighting the link between mild steel welding fume and cancer, requiring adequate control measures for all welding fume exposures.
Chronic Obstructive Pulmonary Disease (COPD)
Evidence suggests that welding fume exposure contributes to COPD, characterized by progressive breathlessness, wheezing, and fatigue. If advanced, COPD can lead to severe disability.
Welder’s Lung
Welder’s Lung describes the accumulation of metal particles in the lungs. It is usually a benign form of pneumoconiosis but may worsen COPD symptoms if present.
Occupational Asthma
Certain metals in welding fumes (e.g., hexavalent chromium, nickel, cobalt) can cause occupational asthma. Stainless steel welding fume is a common source. Symptoms include severe breathlessness, wheezing, cough, and chest tightness.
Confined Space Welding Hazards
Welding in confined spaces can cause death by poisoning or asphyxiation due to oxygen depletion. This may result from:
- Carbon monoxide exposure, reducing oxygen transport in the blood (symptoms include headache, dizziness, nausea).
- Accumulation of shielding gases (argon, helium, nitrogen, CO2) displacing oxygen in the workspace.
Use specially designed Confined Space Fume Extraction and Ventilation Systems to prevent toxic buildup and reduce suffocation risks.
Other Health Risks for Welders
Skin Effects
Nickel and chromium can trigger allergic contact dermatitis. Ultraviolet radiation from welding arcs can cause sunburn-like skin damage.
Neurological Effects
Manganese exposure from welding mild steel fumes has been linked to neurological symptoms similar to Parkinson’s disease, including speech and balance disorders.
Ocular Melanoma
A rare eye cancer associated with UV radiation exposure during welding, reinforcing the need for eye protection.
Arc Eye
Arc eye is an acute injury to the cornea caused by welding radiation, leading to painful redness and light sensitivity hours after exposure.
Noise and Vibration
Vibration
Welding and cutting typically produce low vibration risk, but associated tasks like grinding can introduce harmful vibration exposure.
Noise Levels
Except for TIG welding, most welding processes generate high noise levels. The table below shows typical noise levels by process:
| Process | Typical Noise Level |
|---|---|
| TIG | Up to 75 dB(A) |
| MMA | 85–95 dB(A) |
| MIG | 95–102 dB(A) |
| Plasma Cutting (Handheld up to 100A) | 98–105 dB(A) |
| Oxy-Fuel Gouging | 95 dB(A) |
| Oxy-Fuel Cutting | Up to 100 dB(A) |
| Air-Arc Gouging | 100–115 dB(A) |
| Chipping / Scaling | 105 dB(A) |
| Grinding | 95–105 dB(A) |
Noise Control Measures
Employers should eliminate noisy processes where possible (e.g., purchasing pre-cut material). Where welding and cutting are unavoidable, noise should be minimized by:
- Using low-noise equipment and techniques
- Providing hearing protection (earplugs, earmuffs) and training workers on proper use
Hearing Protection
Hearing protection should be selected based on:
- Noise attenuation level
- Compatibility with PPE (helmets, masks)
- Comfort and suitability for the work environment
Workers must consistently use hearing protection when exposed to high noise levels to prevent permanent hearing damage.
Our content emphasizing worker and environmental health is for informational purposes only and is based on research available at the time of publication. For any questions, concerns, diagnoses, or treatment needs related to your health, please consult a physician or a qualified healthcare provider.