Welding is a process that permanently joins materials, usually metals, by heat. Welding fumes are a by-product of welding, produced when a metal is heated above its boiling point and its vapours condense into fine particles. This fact sheet is for anyone at-risk of welding fumes and aims to educate on the risks associated with welding fumes exposure; control measures that can help protect against exposure and current regulations in Australia.
What are welding fumes?
Welding fumes consist of very fine particles that remain airborne long after welding has stopped. Commonly welded materials include metals such as aluminium, chromium, copper, iron, lead, and manganese.
Other welding hazards
Welding also poses other health hazards, including:
• Radiation
• Heat/Fire
• Electricity
• Noise
Who is at risk?
Anyone near or involved in welding processes is at risk of exposure to welding fumes. Factors increasing exposure risk include the frequency of welding tasks, the type of materials and processes used, the location of welding, and the control measures in place.
Health risks of welding fumes
Welding fumes are classified as a Group One carcinogen, meaning they can cause cancer in humans, including lung cancer. Short-term respiratory effects include irritated throat and airways, metal fume fever, and pneumonia. Long-term effects include lung cancer, COPD, occupational asthma, and pneumoconiosis.
Managing exposure to welding fumes
Employers have a legal obligation to manage risks to workers’ health and safety. Control measures include:
- Elimination: Avoid welding activities.
- Substitution: Use safer welding techniques and materials.
- Isolation: Separate welding activities from other workers.
- Engineering Controls: Use ventilation systems and exhaust treatments.
- Administrative Controls: Implement training, policies, and regular maintenance.
- Personal Protective Equipment (PPE): Use air-supplied or air-purifying respiratory protection and full-face welding helmets.
For more information, visit the Lung Foundation Australia website.
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