Mistry

Pankaj J Kumar

CiteSeerX

17
International Journal of Advanced Research in 
Mechanical Engineering & Technology (IJARMET)Vol. 1, Issue 1  (Apr. - Jun. 2015) 
ISSN : 2454-4736 (Online)
ISSN : 2454-8723 (Print)
www.ijarmet.com © All Rights Reserved, IJARMET 2015
Impact of Welding Processes on Environment and Health 
Pankaj Kumar.J. Mistry
Dept. of Mechanical Engineering, Rungta Engineering College, Raipur, CG, India
I. Introduction 
Welding is a process of joining two metal parts together by 
applying intense heat between them, which causes the parts 
to intermix after melting. Welding processes are widely used 
for the manufacture of shipyards, civil engineering structures, 
mining industry transportation means, petrochemical industry, 
and metallurgy. The intense heat of the arc or flame vaporizes 
the base metal and/or electrode coating. This vaporized metal 
condenses into minute particles called fumes that can be inhaled 
[1]. All welding processes generate fumes, but most fumes are 
produced during electric arc welding. The thermal effects can 
cause agglomeration of the particles into particle chains and 
clusters that can be deposited in the human respiratory tract [2, 
3, 4]. Most of the fume particles are less than 1micron in diameter 
when produced, but they tend to grow in size with time due to 
agglomeration [5, 6].
Environment considerations tend to control, guide and develop 
engineering processes affecting both health and environment. In 
industrialized countries, around 2 % of the labor force works in 
the welding field. These workers are exposed to smoke and toxic 
gas emitted during the welding processes, which may endanger 
their health [7]. 
The vulnerability of welding depends on numerous factors: 1) 
type of welding process, 2) material being welded, 3) electrode 
material, 4) presence of coatings on the metal, 5) voltage and 
current used and 6) type of ventilation [8,9]. 
II. Environmental Hazards of Welding
Most of the small and medium enterprises (SMEs) have poor 
working conditions contributing to worker’s safety and health 
problem. Most welders who work in construction, factories, 
mining, manufacturing, metallurgy, railroad, petrochemical, 
ironworks, shipbuilding or steel industries, suffer from some kind 
of respiratory illness or pulmonary infection. Toxic gases like 
nitric oxide, carbon monoxide, ozone and nitrogen dioxide are 
produced from welding processes. These toxic gases can cause 
headache, pulmonary edema and drowsiness [8].  Phosphine and 
phosgene are the other gases which are a health hazard. Ozone, a 
colorless gas produced during welding, is a powerful irritant which 
attacks the cell membrane and the mucous membrane. Ordinarily 
safe gases become too concentrated if welders work in confined 
space, and cause edema, filling   lungs with water. 
Nitrous gases (nitrogen oxides) form when the nitrogen and oxygen 
in the air react with the hot arc and the hot base metal.  NO2 is 
present in workplaces where combustion processes or gas welding 
is in use [10]. The exposure limit for NO2 for an 8 hour work shift 
in most European countries is 2 parts per million, and the peak 
exposure limit for workplaces is 5 parts per million. Concentrations 
up to these levels occur and are sometimes exceeded [11]. These 
nitrous gases affect the lungs. 
Carbon monoxide forms during MAG welding as a result of 
the atomization of carbon dioxide in the shielding gas. Carbon 
monoxide affects the ability of the blood to absorb oxygen. 
Table-1 shows the type of gas, its source and its effect/symptoms 
on welders
Abstract
Environment considerations today tend to control, guide and develop engineering processes affecting both men and environment. 
The melting of filler metal, base metal and the coating on base metal during welding processes and subsequently the gases formed 
release minute, solid particles into the air creating a plume and is called welding fume. Compared to other industrial production 
processes, welding is fairly dangerous. Welding processes involve the potential hazards  for  inhalation  exposures  that  may  lead 
to  acute  or  chronic  respiratory  diseases. Risks include asphyxiation due to dangerous inhalants, damage to skin and eye due to 
ultraviolet light, chemical or electrical fires, and long-term negative effects from fumes.
This article is adapted from recent print and online resources to provide an overview of welding fumes, health effects and the measures 
to protect welders from welding fumes. This review describes the information currently available on air pollutant effects in welders, 
as the result of experimental studies. Results from the analysis shows that most of the welders’ posses limited knowledge of welding 
fumes hazard. The aim of this review is to gather  the  potential  toxic  effects  of  welding  fumes  documented  by  individual  efforts 
and spread awareness about the environmental and health hazards of welding fumes. 
Key Words
Welding Processes, Environmental Hazards, Fumes and gases, Health effects, Ventilation.
Table 1:  Type of Gas, Source and its Effect/Symptoms on Welders 18]
Type of Gas Source Effects / Symptoms
Carbon 
Monoxide
Formed in welding arc. Readily absorbed in the bloodstream causing dizziness headache, or 
muscular weakness. Unconsciousness and death may result due to high 
concentrations.
Hydrogen 
Fluoride
Decomposition of electrode 
coatings.
Irritates the eyes and respiratory tract. Lung, kidney, bone and liver damage 
can be caused due to overexposure. Chronic exposure results in persistent 
irritation of the throat, nose and bronchi.
18
International Journal of Advanced Research in 
Mechanical Engineering & Technology (IJARMET) Vol. 1, Issue 1  (Apr. - Jun. 2015) 
ISSN : 2454-4736 (Online)
ISSN : 2454-8723 (Print)
www.ijarmet.com© 2015, IJARMET All Rights Reserved
III. Health Effects of Welding Fumes
The vaporized metal produced by the heat of the welding process 
oxidises to produce a fume containing particles of metal oxide 
such as aluminium, cadmium, chromium, and copper [12]. The 
health effects of welding fume can vary considerably as they are 
dependent on the exact composition of metals involved in the weld, 
composition of the electrode, fluxes and the cleaning agents used. 
Workers deal with great percentage of health injuries when they are 
exposed to the toxic gases and fumes [13]. The effects on health 
may be acute (occurred following short-term inhalation of various 
gas and smoke) or chronic (long-term effects).The toxic gases and 
fumes do not affect the workers health in short period of time but 
long exposure to the toxic gases and fumes tends to cause serious 
health damage. Each type of fumes and the toxic gases has its 
own concentration to affect the workers health and give different 
health effect. The major toxic gases associated with welding are 
classifies as primary pulmonary and non pulmonary [14]. 
Table 2 shows the threshold limit value (TLV) for selected metals. 
TLV is the recommended exposures level to substances in the 
industrial environment. Workers can tolerate exposure below the 
TLV day after day at 8 hours per day for a working life without 
adverse health effects. The TLVs for fumes and dusts are in mg 
per cubic meter [15]. 
Welding fume particles are comprised of a large proportion of 
nano-particles [16].In fact, most of fumes and gases are smaller 
than one micrometer. At this size, the particles penetrate deep into 
the respiratory tract (they can reach the narrowest branches of the 
respiratory organs). Fig.1 shows particle sizes for a number of 
familiar pollutants [15]. 
Table: 2 Threshold limit values (TLV) for selected metals [15].
Fig. 1 Particle sizes for different pollutants [15].
Fig. 2 shows the concentration of respirable particulates in breathing 
zone of welders and non welders. The average concentration of 
respirable particulates in the breathing zones of welders was four 
times as high as in the breathing zones of non-welders. Table 3 
shows the health effects of fumes and organic vapours produced 
during welding.
Nitrogen 
Oxide
Formed in the welding arc. Higher concentrations lead to abnormal fluid in the lung and other serious 
effects Low concentrations causes eye, nose and throat irritation. Chronic 
effects include lung problems like emphysema.
Oxygen 
Deficiency  
Welding in confined spaces, 
displacement of air by shielding 
gas.
Dizziness, mental perplexity, asphyxiation and death.
Ozone Formed in the welding arc, 
especially during Gas Metal, 
Tungsten Inert and Plasma-Arc, 
Welding processes.
Very low concentration (1ppm) causes dryness of the eyes and headaches. 
Acute effects include fluid in the lungs and hemorrhaging. Chronic effects 
include significant changes in lung function.
19
International Journal of Advanced Research in 
Mechanical Engineering & Technology (IJARMET)Vol. 1, Issue 1  (Apr. - Jun. 2015) 
ISSN : 2454-4736 (Online)
ISSN : 2454-8723 (Print)
www.ijarmet.com © All Rights Reserved, IJARMET 2015
Fig. 2: Concentration of respirable particulates in breathing zone of welders and non welders [17].
Table: 3 Health Effects of Fumes and Organic Vapours Produced During Welding [18].
Fume Type Source Effects and Symptoms
Aluminum Aluminum constituent of some alloys, e.g., 
copper, brass, inconel, steel, magnesium, 
zinc, and filler materials.
Respiratory irritant.
Beryllium Hardening agent found in magnesium, 
copper, aluminum alloys and electrical 
contacts.
“Metal Fume Fever.” A carcinogen. Other chronic effects 
include damage to the respiratory tract.
Cadmium 
Oxides
Stainless steel containing cadmium or 
plated materials, zinc alloy.
Irritation of respiratory system, chest pain and breathing 
difficulty ,sore and dry throat,.chronic effects include kidney 
damage and emphysema. Suspected carcinogen.
Chromium Welding rods, most stainless-steel and high 
alloy materials. Also used as plating mate-
rial.
Increased risk of lung cancer. Some individuals may develop 
skin irritation. Some forms are 
carcinogens (hexavalent chromium).
Copper Alloys like monel, bronze, brass. Also 
some welding rods.
Acute effects include irritation of the eyes, nose and throat, 
nausea and “Metal Fume Fever.”
Fluorides Common electrode coating and flux mate-
rial for both low and high alloy steels.
Acute effect is irritation of the eyes, nose and throat. Long-
term exposures may result in bone and joint problems. 
Chronic effects  excess fluid in the lungs.
Iron Oxide Major contaminant in all iron / steel weld-
ing processes.
Siderosis – a benign form of lung disease caused by particles 
deposited in the lungs. Acute symptoms include irritation of 
the nose and lungs. 
Lead Solder, brass and bronze alloys, primer/ 
coating on steels.
Affects nervous system, digestive system, kidneys, and men-
tal capacity. Can cause lead poisoning.
Manganese Most welding processes, especially high-
tensile steels.
“Metal Fume Fever.” Chronic effects may affect central 
nervous system.
Molybdenum Iron, steel alloys, stainless steel, nickel 
alloys.
Eye, nose and throat irritation, shortness of breath.
Nickel Stainless steel, Inconel, Monel, Hastelloy 
and other high-alloy materials, welding 
rods and plated steel.
Acute effect is irritation of the eyes, nose and throat. In-
creased cancer risk has been noted in occupations other than 
welding. Also associated with dermatitis and lung problems.
Vanadium Some steel alloys, iron, stainless steel, 
nickel alloys.
Acute effect is irritation of the eyes, skin and respiratory 
tract. Chronic effects include bronchitis, retinitis, fluid in the 
lungs and pneumonia.
Zinc Oxides Galvanized and painted metal. “Metal Fume Fever.”
Organic Va-
pours Type
Source Effects and Symptoms
20
International Journal of Advanced Research in 
Mechanical Engineering & Technology (IJARMET) Vol. 1, Issue 1  (Apr. - Jun. 2015) 
ISSN : 2454-4736 (Online)
ISSN : 2454-8723 (Print)
www.ijarmet.com© 2015, IJARMET All Rights Reserved
IV. Measures to Protect Welders From Welding Fumes
During indoor welding, proper ventilation systems like roof vents, 
hoods and high-speed exhaust fans and intake are incorporated 
into work areas. Modern welding guns can also help to extract 
fumes from the air. In large work areas, the use of downdraft 
worktables is recommended so that the fumes are directed down 
and away from the welder’s breathing space. Ceilings more than 
16 feet high and routine air monitoring to determine any changes 
in exposure levels helps to reduce welding fumes and gases in 
work areas..For outdoor welding operations, welders must avoid 
standing directly in or near the fume plume and to work upwind 
to reduce their exposure. Fans may also be used to blow fumes 
away from welders. Respirators and training must be provided to 
welders for their well being.
V. Conclusions 
Analyzing the obtained data, the following general conclusions 
can be drawn: 
1. Ventilation, respiration and exhaust systems greatly decrease 
the health hazards.
2. Standing directly in or near the fume plume should be 
avoided.
3. Respirators and training must be provided to welders for 
their well being.
4. Welders should be provided with personal protective 
equipment .
5. Reduce exposure to fumes and gases by adopting stringent 
controls for safe work practices and work –rest schedules. 
References
 Azian Hariri, Preliminary Measurement of Welding Fumes in [1].
Automotive Plants, International Journal of Environmental 
Science and Development, Vol. 3, No. 2, April 2012, pp 
146-151
 H. S. Ashby, Welding Fumes in the Workplace: Preventing [2].
Potential Health Problems Through Proactive Controls, 
Professional Safety, pp. 55-60, Apr 2002.
 S. R. Fiore, Reducing Exposure toHexavalent Chromium [3].
in Welding Fumes, Welding Journal, August 2006 pp. 38-
43,. 
 E. Ravert, Controlling Chromium Fumes, Welding Journal, [4].
November 2006
 Mansouri et al, Gravimetric and analytical evaluation of [5].
welding fume in an automobile part manufacturing factory. 
J. Res. Health Sci., 8, 2008, pp 1-8. 
 Isaxon et al., Characteristics of welding fume aerosol [6].
investigated in three Swedish workshops, Journal of 
Physics: Conference Series, 151(1), 012059. http://dx.doi.
org/10.1088/1742-6596/151/1/012059), 2009.
 Gheorghe.A, Research on environmental pollution when [7].
using shielded metal arc welding (SMAW), U.P.B. Sci. Bull., 
Series D, Vol. 72, Iss. 3, 2010, ISSN 1454-2358, pp 73-
88.
 Blunt and Balchin, Health and safety in welding and allied [8].
processes, Cambridge: Woodhead Publishing Limited., 
2000.
 Hewitt, P. J., Strategies for risk assesment and control in [9].
welding: challenges for developing countries, Ann. occup. 
Hyg., 45(4), 2001, pp 295-298.
 World Health Organization. Oxides of nitrogen, [10].
Environmental Health Criteria 4. WHO, Geneva, 1977.
 T. Sandström, Respiratory effects of air pollutants: [11].
experimental studies in humans, Eur Respir J, 8, 1995, 
976–995.
 Antonini J.M, Health effects of welding. Crit Rev Toxicol [12].
2003, 33:61-103
 American Welding Society: Fumes and gases, Safety and [13].
Health Fact Sheet no 1.2005 Miami. FL
 A.M Leman, Monitoring of welding work environment in [14].
small and medium industries (SMIs) , IJRRAS 5 (1) , October 
2010, pp 18-26 
 http://www.nortonsandblasting.com/weldhealth2.pdf[15].
 McNeilly J.D et al , Soluble transition metals cause the [16].
pro-inflammatory effects of welding fumes in vitro, Toxicol 
Appl Pharmacol, 2004, 196:95-107.
 A. Nastiti et al , Determination of Informal Sector as Urban [17].
Pollution Source : Fume Characterization of  Small-scale 
Manual Metal Arc Welding using Factor Analysis in Bandung 
City, Atom Indonesia Vol. 38 No. 1 (2012) 35 – 42
 [18]. http://humanservices.alberta.ca/documents/WHS-PUB_
ch032.pdf
Author’s Profile
Dr. Pankajkumar holds Master 
of Engineering (Mechanical from 
Government Engineering College, 
Aurangabad and  Ph.D., Mechanical 
Engineering from IIT, Delhi.He has more 
than 25 years of Experience and at present 
working as Principal of REC, Raipur. 
Aldehydes 
(such as 
formaldehyde)
Metal coating with binders and pigments. 
Degreasing solvents.
Irritant to eyes and respiratory tract.
Diisocyanates Metal with polyurethane paint. Nose, eye and throat irritation. High possibility of sensitiza-
tion, producing asthmatic or other allergic symptoms, even at 
very low exposures.
Phosgene Metal with residual degreasing solvents. 
(Phosgene is formed by reaction of the 
solvent and welding radiation.)
Severe irritant to nose, eyes and respiratory system. Symp-
toms may be delayed.
Phosphine Metal coated with rust inhibitors. 
(Phosphine is formed by reaction of the 
rust inhibitor with welding radiation.)
Irritant to eyes and respiratory system, can damage kidneys , 
other organs.


Impact of Welding Processes on Environment and Health

http://citeseerx.ist.psu.edu/viewdoc/download;jsessionid=7F6525FD380037295B699BC40BDDD914?doi=10.1.1.1040.9023&rep=rep1&type=pdf

Impact of Welding Processes on Environment and Health

Abstract

Similar works

Full text

Available Versions

CiteSeerX