Welding Fume Monitoring & Exposure

Monitoring your workers’ exposure to welding fume will help you to ensure that their health is not at risk. It also helps to ensure that company owners stay on the right side of the COSHH Regulations.

01782 614236

[email protected]

Introduction

Welding is an indispensable process in numerous industries across the United Kingdom, vital for constructing structures and various products. However, it carries inherent risks, with one of the primary concerns being exposure to welding fumes. In detail, these fumes consist of a complex mixture of metallic oxides, particulate matter, and gaseous compounds. These pose significant health hazards to workers. In this page, we will explore welding fume exposure, its health implications, and the undoubtedly crucial role of monitoring within the context of UK legislation.

Composition of Welding Fumes

Welding fumes comprise several elements, each with potential health risks, in line with UK regulatory guidelines:

Metallic Particles:During welding, the process of melting and fusing metal generates small, respirable particles of various metals, including iron, manganese, chromium, and nickel. These particles can range in size from nanometers to micrometers and can therefore penetrate deep into the respiratory system.

Metal Oxides: The vaporization of metal during welding reacts with oxygen in the air to produce metal oxides. Some of these oxides are highly toxic, such as hexavalent chromium, which is known to cause lung cancer.
Gaseous Compounds: Welding also releases gases like ozone, nitrogen oxides, and carbon monoxide, which can irritate the respiratory system. This too leads to coughing, wheezing, and shortness of breath.
Flux and Coating Materials: Some welding processes involve the use of flux or coatings to protect the molten metal from atmospheric contamination. These materials can emit additional hazardous compounds when heated, further contributing to the complexity of welding fumes.

Health Effects of Welding Fume Exposure

Exposure to welding fumes can result in various health consequences. The severity of which depends on factors like the type of welding, duration of exposure, and the effectiveness of control measures. Some common health effects include:

Respiratory Issues: Short-term exposure to welding fumes can cause symptoms like coughing, wheezing, and chest tightness. Prolonged exposure may lead to chronic bronchitis or exacerbate pre-existing respiratory conditions like asthma.
Metal Fume Fever: Zinc oxide fumes trigger this acute condition. Symptoms include fever, chills, muscle aches, and coughing. It typically resolves within 24 to 48 hours but can be quite uncomfortable.
Pneumonia and Lung Infections: Inhaling certain metal fumes, such as those containing nickel and chromium, can increase the risk of lung infections, including pneumonia.
Lung Cancer: Welders exposed to carcinogenic agents like hexavalent chromium and nickel compounds are at an increased risk of developing lung cancer.
Neurological Effects: Chronic exposure to manganese in welding fumes cause neurological disorders resembling Parkinson’s disease.
Eye and Skin Irritation: Fumes and UV radiation generated during welding can cause eye irritation and skin burns. Adequate personal protective equipment (PPE) is crucial to prevent these effects.

UK Regulations and Guidelines

In the United Kingdom, a comprehensive framework of regulations and guidelines , govern the protection of workers from the harmful effects of welding fume. These standards set exposure limits for specific substances within welding fumes. Key regulatory bodies and guidelines include:

Health and Safety Executive (HSE): The HSE in the UK enforces health and safety legislation, including regulations related to welding fume exposure. The Control of Substances Hazardous to Health (COSHH) Regulations provides detailed guidance on controlling exposure to hazardous substances, including welding fumes.
British Occupational Hygiene Society (BOHS): BOHS provides occupational hygiene professionals with valuable resources and guidelines for monitoring and controlling welding fume exposure.
UK Threshold Limit Values (TLVs): Occupational Hygiene professionals use these values as reference points to assess and control exposure to hazardous substances, including those found in welding fumes.

These regulations and guidelines are pivotal for safeguarding the well-being of workers, and adherence to them is essential. However, effective monitoring is a critical component of ensuring compliance.

Monitoring and control of welding fumes

Monitoring Welding Fumes

Measuring welding fume exposure is integral to upholding the safety and health of workers in the United Kingdom. This practice involves the measurement of airborne contaminant concentrations in the workplace to evaluate compliance with exposure limits and to pinpoint areas necessitating control measures. Here are the key elements of monitoring welding fume exposure within the context of UK legislation:

Exposure Assessment: The initial step in monitoring is conducting an exposure assessment. This involves identifying the welding processes in use, the materials involved, and the potential health risks. It also encompasses measuring welding fume concentrations in the air over specific periods.
Exposure Limits: The Occupational Hygienist compares the monitoring results against established exposure limits, such as those outlined in the HSE document EH40. If the monitoring reveals exposure levels that exceed these limits, corrective actions are essential.
Personal and Area Sampling: Only personal sampling can assess welding fume exposure. Personal sampling entails attaching sampling equipment to a worker’s clothing or equipment to measure their specific exposure. Area sampling measures fume concentrations in a specific work area.
Real-time Monitoring: Technological advancements have facilitated real-time monitoring of welding fume exposure. These systems provide instantaneous feedback and can trigger alarms when exposure levels become hazardous.
Periodic Monitoring: Regular monitoring is vital because exposure levels can fluctuate over time due to changes in welding processes, materials, or work conditions. Occupational Hygienists should conduct monitoring at regular intervals or whenever significant workplace alterations occur.
Data Analysis: The Occupational Hygienist meticulously analyses the collected data to discern trends and patterns in exposure. This analysis can aid in the development of more effective control measures.

Control Measures

Companies can implement several control measures to mitigate welding fume exposure.

Effective Ventilation: Firstly, adequate local exhaust ventilation (LEV) systems can capture welding fumes at the source. These systems require appropriate design, maintenance, and utilization.
Isolation Measures: Enclosing welding areas or employing screens to separate workstations from non-welders can prevent fume dispersion.
Respiratory Protection: When engineering controls prove inadequate, workers should employ suitable respiratory protective equipment, such as respirators.
Substitution: When possible, consider using welding processes that produce fewer fumes or alternative materials with lower health risks.
Training and Education: Workers should also receive education and train in safe work practices regarding the risks of welding fume exposure.

Welding fumes can cause cancer and also some of the metals are sensitizers. For this reason, employers should keep up a program of monitoring and keep exposure as low as reasonably practicable. In fact, because there is no safe level, HSE document WL3 states how much control is needed for good practice. In summary, the HSE expects sites to stop exposure to fumes in most cases using LEV systems. When it is not possible to use an LEV outside, it is sometimes acceptable to use RPE on its own. But, more often than not, for high-intensity welding (more than 1 hr per shift), it is better to use RPE along with LEVs.

Employers have a legal duty to test and maintain systems following HSE guidance HSG258 ‘Controlling airborne contaminants at work’. Synergy’s occupational hygiene consultants also offer this testing service. We recommend combining monitoring welding fume in the workplace air with LEV testing if at all possible. Give us a call today about our monitoring services to see how we can help you to reduce exposure to fume.

Summary of Welding Fume Exposure and Monitoring

Welding is a cornerstone of various industries in the United Kingdom, but it carries inherent risks, particularly associated with welding fume exposure. In summary, protecting the health and safety of workers is of paramount importance. By adhering to regulations, implementing effective monitoring practices, and robust control measures, the welding industry can minimize the adverse consequences of welding fumes and ensure a secure working environment for all. Monitoring is not merely a legal requirement but a vital tool in safeguarding those who dedicate their skills to welding from the concealed hazards of fume exposure.