Potential Welding Hazards and Gas/Fume Hazard from Welding Work

This article discusses the potential hazards of welding work, including gases and fumes, and their routes of exposure. It also covers the health effects of exposure, monitoring and analyzing methods, and legislative codes and standards that must be followed to ensure worker safety.

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1. Potential Welding Hazards
Welding is a process of fitting two metals together through heating the metal surface to a
point of melting with an electric arc, blowpipe, or using other means and uniting them by heat,
pressure or both. There are different a number of different welding methods, that is, Arc Welding
Gas Metal Arc Welding, , Oxy-Acetylene Welding and Cutting, Tungsten Inert Gas (Budhathoki,
2014). Welding processes can be broken down into two categories, pressure welding, and fusion
welding. Welding involves activities such as brazing and soldering, cutting, grinding,
smoldering, shielding, thawing pipes, welding and work environments such as confined spaces,
dealing with combustible materials, flammable materials and hot works. This activity presents
serious hazards and risks to a welder if they are not controlled properly and a welder is exposed
to them (Glassford, 2018). The following are hazards present in welding work activity with their
route courses.
I. Gases and Fumes. This is generally welding smoke, that is a mixture of very fine
particles usually below 1-7 μm; from oxidation and sublimation of molten metal, e.g.
lead, selenium, chromium, cobalt, nickel, arsenic, asbestos, manganese, silica, nitrogen
oxides, fluorine compounds acrolein, cadmium, beryllium, iron, phosgene, carbon
monoxide, ozone, copper and zinc. This can cause metal fume fever, irritation of the eye,
nose, throat, lung diseases, cancer of the larynx. The route causes of these fumes and
gases are,
 Base material that is welded or filter material being used.
 Shielding gases supplied from cylinders.
 Consumables and process used.
 Paints and coatings on the metal welded, or the coatings covering the electrode.

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 Air contaminants such as vapors from degreasers and cleaners.
II. Heat. The intense heat of welding causes burns, eye injuries, heat stroke and heat stress.
The route cause of these hazards is when a welder is exposed to hot slag, sparks, metal
chips or hot electrodes of metals.
III. Ultraviolet (UV), Visible Light and Infrared Radiation. The intense light due to arc
welding causes damage to the retina of the eye, Ultraviolet light causes welder’s flash,
skin burns that generally come from arc. The route cause for these hazards is from arc
welding.
IV. Noise. Noise is unnecessary sound beyond required measurement that is 84dB. This can
cause a permanent hearing loss when exposed to loud noise, hypertension, tinnitus, sleep
disturbances, high-stress levels, increases blood pressure, which contributes to heart
diseases. The route causes for this hazard in welding are the process of welding and
activities undertaken such as soldering, cutting and grinding.
V. Musculoskeletal Injuries. This includes shoulder pains, back injuries, tendinitis, carpal
tunnel syndrome, knee joint disease, white finger and reduced muscle strength. The route
cause of these hazards is due to work postures such as,
 Working in one position for extended periods.
 Heavy lifting of equipment,
 Welding overhead
 Vibrations
VI. Electrical hazards. Even if welding uses low voltage, there is a risk of electric shock that
causes brain damage, burns, heart diseases and when exposed to significant shock (10000
mA) can lead to cardiac arrest and probably death. The route cause for this is due to

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environmental conditions of a welder such as cramped spaces, wet conditions or exposed
live wires.
VII. Fires and Explosions. Sparks and intense heat produced during welding may cause a fire
that can burn the welder or cause facility damages. The route cause for this hazard is
welding flame, extreme heat, and sparks produced by welding, a worker wearing clothing
covered in oil or grease.
VIII. Trips and falls. This can cause an injury to a welder such as breaking his arm or leg, or
falling object that night cut/injure a welder. The route cause for this is unclear areas of
equipment, cables, hoses, machines and a worker not using safety rails or lines.
2. Gas and Fume Hazard from Welding Work.
Gases and fumes are generally welding smoke that is assortment of very fine elements
usually below 1-7μm; from oxidation and sublimation of molten metal used in welding work
like, lead, cadmium, ozone, iron, nickel, beryllium, asbestos, carbon monoxide, silica,
copper, fluorine compounds acrolein, selenium, arsenic, cobalt, phosgene, manganese,
chromium, nitrogen oxides and zinc which are enormously dangerous to the health of a
worker (Alif et al., 2016, p.1). This hazard is classified under chemical hazard as it occurs in
the form a chemical in its state.
3. Routes of Exposure of Gases and Fumes
This hazard is present in welding practices for instance, Plasma Arc Welding (PAW), Air
Carbon Arc Processes (ACAP), Shielded Metal Arc Welding (SMAW), Air Carbon Arc
Cutting (ACAC), Gas Metal Arc Welding (GMAW), Submerged Arc Welding (SAW),
Oxyfuel Gas Welding (OGW), Gas Tungsten Arc Welding (GTAW) and Air Carbon Arc

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Gouging (ACAG), and Flux Cored Arc Welding (FCAW), (Bjerg 2015, p. 605). The route
causes of this hazard include;
 Base material that is welded or filter material being used in the welding process.
 Shielding gases supplied from cylinders.
 Consumables and process used.
 Paints and coatings on the metal welded, or the layers covering the electrode.
 Air contaminants such as vapors from degreasers and cleaners.
4. Health Effects of Gases and Fumes to Welders.
Worker’s health effects due to exposure to gases and fumes may vary since they comprise
numerous different elements that are dangerous. These substances can affect some part of the
body such as skin, heart, kidney, and central nervous system. Exposure to fumes and gases may
have acute (short-term) and chronic (long-term) effects to a worker, (Ziarati 2015, p. 116).
Acute (Short-Term) Health Effects of Fumes and Gases
When a worker is exposed to metallic fumes like copper, magnesium, zinc and copper oxide,
can lead to metal fever, which has signs of chills, chest soreness, thirst, wheezing, nausea,
fatigue, muscle ache, metallic taste in the mouth and fever, (Doney, 2017). A worker may suffer
from irritation of the eyes, chest, nose, respiratory tract and cause coughing, bronchitis,
pulmonary edema, pneumonia, wheezing and shortness of breath, (Schyllert et al., 2016, p. 665).
These fumes and gases also cause gastrointestinal effects like cramps, loss of appetite, nausea,
vomiting. Ozone generated in GMAW can cause nose and throat irritation and inflammation of
respiratory tract. Phosgene gas leads to chills, dizziness, and cough. Cadmium can be fatal in a
shorter time.

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Chronic (Long-Term) Health Effects of Fumes and Gases.
Studies of welders indicate that they have a higher risk of cancer of the larynx, lung cancer
and urinary tract due to carcinogenic fumes and gases from nickel, beryllium, cadmium, arsenic,
and chromium, (Dharmages et al., 2016). They may also suffer from asthma, bronchitis,
emphysema, silicosis, pneumonia, pneumoconiosis, siderosis and decreased lung capacity.
Welders are at risk of heart diseases, skin diseases, gastroduodenitis, chronic gastritis, ulcers and
kidney damage due to exposure to fumes and gases from chromium and nickel, (Cullina et al.,
2017, p. 450). Studies also show that welders exposed to fumes and gases such as nitrous gases
and ozone cause an increase in miscarriages or delayed conception.
5. Monitoring and Analyzing of Welding Hazards.
Monitoring is used in evaluating a hazard and assessing its risks to determine a valid control
measure. Monitoring gases and fumes can be periodic or continuous, which is the qualitative or
quantitative assessment of air contaminants. Sampling techniques like personal sampling, area
sampling, source sampling should be used to obtained samples. Sampling methodology such as
active, Real-time monitoring and biological sampling should be used in monitoring the gases and
fumes in a workplace depending on terms such as costs and practicability, (Popović 2014, pp.
509-516). Fumes and gases may be analyzed to get specific toxic constituents, e.g., chromium
(IV), manganese and nickel using standardized methods such as Analytical methodologies, that
is, chromatographic techniques, (gas-liquid chromatography, gas chromatography, ion
chromatography), (Tang 2015, p. 290).
In the case of heat hazards, qualitative heat measurements shall be used whereby the
locations comprises of both with and without heat exposure including indoor locations.

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Measurements shall be made during the hottest part of the day, (10:00 AM – 14:30 PM) and for
the sake of heat stress, wet bulb globe temperature shall be used, (Ellingsen et al., 2017, p. 104).
Lascar data logger shall be used for continuous heat monitoring. The done analysis shall be done
through Microsoft Excel 2016 and R-statistical software. Ultraviolet, visible light and infrared
radiations shall be monitored using wavelength manometers. Employees exposed to this hazard
shall also undergo medical surveillance, and the data shall be analyzed in laboratories, while the
measurements taken from the manometer shall be compared against the standardized values.
Noise hazards shall be monitored using an 8-hour work shift weighted against 85dB. Noise
dosimeters shall be used in calculating the time-weighted average. The analysis of the data
obtained through TWA criteria whereby 85dB is the recommended exposure of an employee per
8-hour tests, (Bjerg et al., 2015, p. 606). Musculoskeletal Injuries shall be monitored through
self-reports, observational methods, and direct measurements. Data obtained shall be analyzed
through electronic goniometry, body posture scanning systems, force measurements and cyber
glove.
Electrical hazard monitoring and analyzed using HAZOP based plan safety model and the
results shall be taken to safety engineering lab to determine the electric hazard trend (Van et al.,
2015, pp. 635-639). Fire hazards and explosions, the fire parameters such as flashpoints vapor
pressure and calorific value should be observed through a risk assessment, then analyzing the
risk factors taking account of existing precautions. Lastly, for fall hazards, monitoring can be
achieved by use of risk management program and analysis of any risk factor that contributes to
trips and falls hazards.

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6. Legislative, Codes and Standards Applicable to Gas and Fume Hazards.
The legal requirement to control the exposure of workers to dangerous substances such as
fumes and gases is contained in Work Health and Safety Act 2011 in various sections (WorkSafe
Queensland, 2018). WHS Act Section 17 provides for managing risks where a duty is obligated
to a person to guarantee health and safety. WHS Act Section 18 provides for reasonable practices
to ensure health and safety. WHS Regulation Section 32-38 provides for duties of a duty holder
to manage risks in the workplace. Section 46 of WHS Act provides for a person undertaking
business must consult, cooperate and coordinate activities with other duty holders. WHS Act
Section 47-48 provides for consultation of workers in decision making on health and safety.
WHS Act Section 19 and WHS Regulation 39 indicates that a person undertaking a business
must guarantee to provide information, instruction, supervision, and training that is suitable and
adequate to protect employees. WHS Act section 351 indicates that a person undertaking
business should manage risks allied with using, handling and storing harmful chemicals (air
contaminants). WHS Regulation Section 49 provides for exposure standards for airborne
contaminants. WHS Regulation Section 50 provides for monitoring airborne contaminants levels
by a person conducting a business. WHS Regulation Section 395 indicates that a person
undertaking business must provide information about lead processes to workers. WHS
Regulation Section 44 provides for personal protective equipment in minimizing risk to health
and safety. WHS Regulation Section 368 provides for health and monitoring of a worker
supplied by a person undertaking business. WHS Regulation Section 38 and 352 provides for a
person conducting business to review control measures. Failure to comply with these rules and
regulations, division 5 of the WHS Act 2011 provides for offenses and penalties.

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Apart from Work Health and Safety Act 2011, there are also codes of practice that help in the
management of this hazard, (WorkSafe Queensland, 2018). Welding processes code of practice
2013 that provides guidelines in welding work processes, How to manage work health and safety
risk code of practice 2011 that provides instructions in the management of workplace hazards,
managing risks of hazardous chemicals in the workplace code of practice 2013 that gives
directions in control of hazards related to chemicals.
Control Measures for Gas and Fumes Hazards.
To efficiently control hazards, one should consider the hierarchy of controls, (Albuquerque 2015,
p. 298).
MOST APPROPRIATE Elimination
Substitution
Isolation
Engineering Controls
Administrative Controls
LEAST APPROPRIATE Persona Protective Equipment
Substitution- substitute organic binder or lithium silicate with sodium or potassium
silicates to reduce chromium (VI) content of fumes. Use of a mixture of argon and carbon
dioxide instead of carbon dioxide alone thus decreasing fume formation by 20 percent. Add
nitric acid to shielding gas to minimize ozone when welding aluminum in GMAW.
Engineering Controls- Use of local exhaust ventilation and two novel methods to reduce
ozone. General ventilation systems to control minor emissions of low toxicity. Dilution
ventilation to dilute the concentration of with an adequate capacity of clean air to decrease the
level of impurity.

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Administrative controls- Provision of education and training to employees. Carrying out
health surveillance to assess the health status of work. Provision of first aid boxes in the
workplaces. Providing exposure standards for welding fumes and gases. Ensuring safe work
practices such as not welding on painted or coated parts, removal of rusts and paints on metals,
segregation of degreasing metals, positioning a welder far from the source of fumes and
promotion of no smoking policy.
Personal protective equipment- Respirators must be specific to a hazard, fitted, cleaned,
stored and maintained accordingly. Consider the composition of fumes and gases when selecting
respirators. Workers must be trained on how to use the respirators.

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