# WHAT ARE WELDING FUMES AND HOW DO THEY AFFECT YOU?

All welding processes present risk factors; depending on the process, some factors are more significant than others. We will specifically analyze the fumes, vapors, and gases that develop during welding processes, which are characterized by being small particles of toxic metals.

Gases and fumes are a varied mixture of airborne gases and fine particles; their composition depends on the welding method and the materials being welded. These affect workers more than other hazards, which is why it is essential that welding operators are aware of these risk factors and use protective equipment to mitigate the various illnesses that can be generated.

Types of welding gases and vapors.

The gases generated during welding include: carbon monoxide, hydrogen fluoride, nitrogen oxides, ozone, and others. Continuous inhalation of these gases causes irritation to the eyes and respiratory tract; high concentrations can cause damage to the lungs and heart.

Vapors are metals in a gaseous state; the most common are: aluminum, beryllium, cadmium oxides, iron and zinc, chromium, copper, molybdenum, nickel, vanadium, lead, and manganese. These welding fumes contain contaminants that can damage the respiratory tract, lungs, and nervous system, and may even cause cancer — the damage can be very severe. In many cases, symptoms may take months or even years to manifest.

How welding gases affect health:

The health problems associated with inhaling these vapors and gases include diseases that cause damage to the respiratory tract and mucous membranes, as well as ear disorders, gastritis, stomach ulcers, kidney and liver damage, and heart disease. Depending on the level of exposure and the type of metal involved, blood poisoning can also occur.

How to protect yourself from welding gases.

To protect yourself adequately, the source generating the gases or fumes must be analyzed. In the case of welding, any paint residue and coatings must be removed from the area to be welded on materials contaminated with paint and oils. In addition, the most appropriate welding process should be selected to minimize contamination.

The most advisable measures are to use fume extraction hoods or systems, adopt a position that prevents the natural rise of generated gases and vapors, ensure proper ventilation, and when necessary, monitor air quality. Self-contained breathing apparatus should be used in areas where ventilation is impossible, especially when performing welding work in confined spaces. Keep in mind that in such applications, the electric arc will consume the oxygen in the area, making the use of a self-contained breathing system mandatory to prevent the welder from running out of breathable air. The appropriate regulations for each situation must be followed. Remember — this is a matter of your health.

In metal welding processes.

There are different welding processes depending on how energy is applied to join metals; each type of welding has its own specific characteristics and risks. The most common health hazards are burns, eye injuries, pulmonary disorders (asthma, chronic bronchitis, “welder’s lung”), gastritis and digestive ulcers, musculoskeletal injuries, and “metal fume fever” or “welder’s fever.”

Below is a list of practical recommendations for people exposed to this type of work:

• Always be fully informed about the specific risk factors of the welding method or process being used (arc welding, gas welding, etc.), as well as the characteristics of the base material and its surface condition.
• Perform tasks in well-ventilated areas and ensure air circulation to prevent welding fumes and gaseous impurities from affecting the respiratory tract. When working in an enclosed space, use air extraction systems capable of drawing in and exhausting the fumes produced to the outside. If adequate ventilation is not available, appropriate respiratory protection equipment must be used. Avoid performing this work in environments exposed to elevated temperatures.
• Clean workpieces before welding to remove oils, solvents, paint, and residues that could cause intoxication or a serious accident.
• Do not perform welding work while wearing contact lenses, as they can adhere to the cornea.
• Avoid awkward postures and prolonged physical exertion.

How to protect yourself during welding work.

Personal protective equipment and appropriate clothing must be used to cover the various parts of the body exposed to ultraviolet radiation, gases, chemical splatter, or molten metal spatter.

The most important elements from an occupational safety and health standpoint in welding are:

• Welding shield.
• Welding helmets and eye protection. Must have a certified filter and comply with ANSI Z87.1 requirements.
• Leather gloves.
• Leather apron.
• Leather spats with quick-release opening (worn over pants).
• Insulating foot protection.
• Hard hat with protective face shield.
• Hearing protectors.
• Heat-insulating clothing.
• Long-sleeve jacket.

Assistants who do not directly perform these activities must also wear personal protective equipment.

The risk of electric shock is high; therefore, you must:

• Check that terminals and plugs are in good condition and are not exposed.
• Verify that the welding equipment frames are properly grounded.
• Inspect the cable connections to the equipment, including the earth ground cable, the work lead to the workpiece, and the power supply cable to the switch terminals.
• Position the welding machine as close as possible to the power outlet.
• The use of electrode holders and work clamps is mandatory.
• Work on insulated flooring whenever possible.
• Wear rubber-soled footwear.
• Use dry gloves when handling equipment.
• Avoid leaving cables on hot objects, surfaces with sharp edges, or any other element that could damage them.
• Prevent welding spatter from falling on cables.
• Disconnect welding machines when work is stopped.
• Always avoid welding in areas where flammable gases or liquids are present.
• If using electrodes that generate fumes, ventilate the work area and/or use respiratory protective equipment.