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1 VI . 3.1998 I: IZF'M NO.878 , P.3/6 Health Aspects of Welding By A. G- Craach, M.D.,T in collaboration v/ith B. L. Vosburgh, M,D.: HE purpose of this paper is to offer some practical lar changes including thyroid disease' and Hodgkin's Tjoints for the better protection of the health of disease, various skin diseases, neurological changes, welding operators. It is not intended as an sterility, and various other complaints, A careful 'exhaustive research document. The health hazardasnoaflysis of these reports generally shows little or no welding may be classed as "real and unreal." Tevhiedence of any connection with welding exposures. former should not be ignored, nor should the latter be pThe agents usually blamed for these various ailments allowed to cause undue alarm. The real hazards axe uwould ordinarily be present in entirely negligible con not mysterious; they should be easily understood by any centrations, if at all. reasonably well trained operator and means for protection .Such substances as silica, asbestos, manganese, are available and effective when used. chromium, nickel, cobalt, various other metals and even A welding operator is usually exposed to all the general iron have been given as "potential hazards" in welding accident hazards common to the industrial field in which fumes"} These have been charged with directly causing be is working. Structural iron workers, ship builders ill health or serving to activate other conditions such as and the like are exposed to increased accident hazards. pneumonia, tuberculosis, etc. With the exceptions As a large proportion of welding operations are in con shortly to be mentioned, there seem9 to be no evidence to nection with such work, this may be one reason for the indicate that they axe present in a form or an amount common assertion that welding is a dangerous and un which would constitute a health hazard. Some have healthy occupation.' stated that welding operators "are dying every day, and Another possible source for the charge that welding others suffering permanent health impairment as the is a health hazard is the circumstance that the formulas result of their work," and charge that no studies have of most rod coatings are "trade secrets" so that there is been made to identify or control the hazards. Anyone an opportunity to indulge in all sorts of speculation as to at all familiar with the research which has been done and the.danger to hcaith_from the "secret" ingredients in is still going on in this field will realize that such charges these "coatings. Actually very few coatings would ap must be due' to ignorance" or prejudice, The very pear to have introduced any important health hazards. thorough study conducted by Bntton and Walsh1 and As for the "mystery," most of these coatings have been the experimental' work and observations in this field patented. Not long ago the Bureau of Mines issued by many other investigators5'*., fail to show any excess an Information Circular1 giving much detailed in of ill health among welding operators, or any outstanding formation on the composition of welding rod coatings type of illness among them. and fluxes. This was based on patent information, purposes served by the various ingredients and analyses of many typical coatings. This and other reports re The Real Welding Hazards move the "mystery," A third and perhaps the most importvt reason for The real hazards peculiar to welding are essentially the assumption, that welding is a health hazard, are the from: (1) radiation and (2) air contamination by gases dramatic deaths which have been reported in a relatively and fumes. few instances following massive exposures to welding Radiation presents the hazard of intense light, glare fumes in strictly confined spaces without suitable pro and of ultra-violet exposures. Probably all workers tection for the operators. That such incidents do not even casually acquainted with welding operations are reflect a general hazard is well shown by the fact that familiar with the need for eye protection in this work. in the past three years the number of welding operators In the case of gas welding there is little, if any, ex has increased some 400% and in the past ten years con posure to ultra-violet rays, but only glare from too in sumption of welding rods has increased some 2800% tense light. The eyes must be protected by suitable with scarcely any increase in such fatalities. colored lenses. In electric arc welding there is not Until quite recently the health problems of welding only the glare but enough ultra-violet radiation to call have been "approached from a speculative rather than for a deeper shade of protective len9 for the eyes, and scientific viewpoint. Unfortunately in a number of also a face shield and protective clothing to cover all instances even medical men, apparently with little at skin areas which might be exposed. At present no tempt to check exposures or weigh evidence available, attempt will be made to go into details as to this form have attributed au amazing variety of ills to welding of protection,, as these are easily available from a number exposures. These include digestive disorders and mal of sources, especially the American Standard Safety nutrition, liver diseases, respiratory affections even in Code for the Protection of Heads, Eyes, and Respiratory cluding cancer of the lung, circulatory, blood and glandu- Organs.7 * Hazards from radiation are not confined to the welding Pmc&tfld at the 31st National Ssfrty Cwgrem and Exposition, soealor. oa Cut sod Elactn. WeJdta;, October U8, 1942, nod rooriotcd from tht Slit Notional Selstr Coogrtsa Tras*actt6ai. 1* Toxicoltgy Sept., Union Carbide and. Cartcu Corp, Yorlc, N, Y. t ifedical Director. Garl JZlertric Co., Scbenectadr, N. Y, operator alone, but also involve his helpers and others working in the immediate neighborhood, usually con sidered to be within seventy-five to one hundred feet in the case, of arc welding. Any workman within this 343 13FM ,. , NO.07S P.4/6 _ 'area should' 6e protected either with, suitable goggles or atmospheric conditions would usually be unbears by the use of screens. If screens are used they should in a confined space before dangerous oxygen dej be so designed as to interfere as little as possible with occurred. "Oxygen deficiency," then can be put ft ventilation. Some types of operation can be done in the category of unreal hazard. ventilated booths, which may serve to reduce the One not infrequently sees references to the to" hazard to others. Not only must direct rays be kept effects of unbumed acetylene or the "impurities" prest, from the unprotected eye, but reflected rays mu3t be in acetylene gas. Acetylene is a simple asphyxiant g! considered. This invariably calls for the usi of dull not in itself a poison. It has had fairly wide use as 1 non-reflective paint on areas which may otherwise serve anesthetic. A hazard would exist only when the j as reflectors. _ _ is present in such concentration as to reduce the oxy^ Excessive exposure of the eye to ultra-violet radiation in the air breathed so that not enough remained proj damages chiefly the outer structures of the eye, setting erly to supply the body. As the lower explosive " up conjunctivitis of varying degree. The damage is of acetylene in air is about 2l/r-3% it is evident analogous to a blistering sun bum of the skin and if the in the presence of a flame an explosion would rei exposure is severe very painful reactions will occur, with long before the concentration would appreciably redui some temporary visual disturbances. Ultra-violet rays the available oxygen in the air. As for the alle; do not penetrate the lens or injure the deeper structures hazard from impurities--arsine, phosphine, hydrog of the eye. Experimental cataracts have been produced sulphide or ammonia--this purely theoretical hazs in rabbits by prolonged exposure to ultra-violet rays, but is based chiefly on early analyses of acetylene made froi in actual welding experience leas changes do not occur materials of foreign origin. No significant amounts and optic nerve injury is impossible from a physical present in acetylene produced today from raw mate standpoint. .. from North American sources. Recently tests we Before leaving the subject of radiation it should be made for arsine in dissolved acetylene from four cc mentioned that in welding there is no exposure to short merdal producers and not even a trace was detected] waves like the x-ray. This has been demonstrated The minute amounts of impurities sometimes found " repeatedly by having welding operators carry dental acetylene- are, of course, destroyed in the flame. T1 x-ray films in their pockets. No systemic effects have health hazards from acetylene and its "impurities" been demonstrated as due to the radiation in welding, belong in the "unreal" class. least of all sterility. This is mentioned because this Gases formed in the flame or arc axe the oxides oi charge has recently been revived in some quarters. It nitrogen, sometimes called "nitrous fumes." They was originally made during the last World War and not nitrous oxide, but are nitric oxide and other higher] several investigations proved it to be unfounded. There oxides of nitrogen. In the concentration present in is no valid evidence to support such a theory. connection with welding they are so diluted as to be;! colorless. Under other conditions of exposure these] Gas Hazards fumes may present other hazards but in welding the real' hazard is as a pulmonary irritant. Except in small rooms or in very confined spaces as in tanks, etc., no Among the much discussed hazards-of welding are**- dangerous concentration would be likely to occur. Just those due to gases. These gases may be essential to what is a dangerous concentration has been undergoing the type of welding as "the oxygen and acetylene in considerable discussion in the last two or three years. oxyacctylene welding or they may be produced through The classic figure of 89 p.p.m. by volume in air ad the reactions occurring in the welding process as oxides mittedly was based on wary limited observations but of nitrogen, ozone or in some cases of imperfect com has proved a fairly satisfactory working standard, Just bustion carbon monoxide. It is hardly necessary to as much more extensive experiments were beginning to state that oxj'gen as used in welding does not produce indicate that 70 p.p.m. or even up to 100 p.p.m. might a. health hazard. Misused, for instance, as a substitute be a safe limit for a day's work; others, on what basis is for compressed air in ventilating small spaces, it may not clear, are advocating a "safe concentration" of only increase the hazard from bums, as any material will 10 p.p.m. Certainly a study of available evidence burn more actively in the presence of an excess of oxygen. indicates that in welding operations concentrations of Ozone, a "peroxygea," may be formed in the welding 50 p.p.m. or less have not produced symptoms, and that arc and in concentrations of over 1 p.p.m. may act as a probably under many conditions this amount may be pulmonary irritant. On leaving the arc, ozone rapidly exceeded without harm. Protection will be discussed ceases to exist as such and many investigators have dem under fume protection. onstrated that even in confined spaces a dangerous concentration is not found in the air breathed by an operator. It is extremely doubtful that ozone is any Carbon Dioxide and Carbon Monoxide thing but a theoretical hazard in welding. While speaking of oxygen, mention may be made of Carbon dioxide is produced by the oxyacetylene the hazard said to be due to "oxygen deficiency" from flame and by the electric arc but never in concentrations welding. Thi3 could occur only in very confined spaces, of physiological importance. Carbon monoxide may as in tanks or some of the small compartments in ship's be produced through jmperfeet combustion as when holds, and the like. There may have been some acci starting welding or cutting of cold material or through dents due to oxygen deficiency in such locations but in the combustion of organic matter which may be present all probability investigation would show that this condi on the surface to be welded, or in the coatings of rods tion already was present in the area before welding opera used. There is considerable divergence of opinion, on tions were attempted. In the case of oxyacetylene the degree of hazard from carbon monoxide in welding. welding where a certain proportion of oxygen is drawn A careful comparison of the various reports seems to from the atmosphere the welding flame will usually indicate that the danger of a significant concentration is Ibecome entirely unsatisfactory for its purpose and the very slight under all ordinaty conditions of welding. deficiency recognized before the oxygen reaches a level If standards of ventilation indicated by other features of low enough to be dangerous to the operator. Also the the work are followed the hazard from carbon monox heat generated by the welding operation under normal ide should be non-existent. > THE WELDING (JOURNAL MAY IDEC. 3.1398 Z:15PM MO.078 P.5/6 IFrobably the most discussed health hazards of welding Prevention *, those due to fumes. These are chiefly metallic, from J material being -welded or used as a coating on that To sum up; The real hazards or welding are not jterial or in the welding rod or its coating, The many, are generally easily identified and protective omposition of welding fumes is so varied that this furjgbes a wonderful field for the discovery of hypothetical ad unreal hazards. These fumes also are the source of ne very real hazards. If proper precautions are taken avoid the real and recognizable hazards the same .ccautions should eliminate the theoretical hazards, /elding is now in such general use and the number of metals and their combinations involved is so great that Ithere are probably but few metals which may not be |iaadled by a welding operator. measures are available and effective whan used. These real hazards should not be minimized or passed by. Briefly they axe due to: ' ' 1 Radiant energy--ultra-violet and visible light. 2. Oxides of nitrogen. 3. Metal fumes--lead, cadmium and'zinc. 4. Fumes from organic residues or wastes. 5. Fumes from fluoride-containing fluxes and rod coatings. The most common complaint due to fume exposure is Protection from radiant energy has already been out jjjetal fume fever. This, often called "zinc chills," lined. Protection from the rest is almost wholly a ques `.'brass founder's ague" and the like, is really a non tion of ventilation. Various means of approach have specific reaction which might come from any of a number been tried to establish standards for ventilation. Stand 'of metal fumes. The most common source is zinc fume, ards in terms of concentration of contaminant expressed from welding on galvanized material, or brass, or from in ports per million by volume for the gases or milligrams Tiring rods with a high zinc content. Zinc should not per cubic meter for metallic and other fumes have been be considered "highly toxic," however, as this condition suggested, as have standards expressed in number of 'is au acute, self-limiting reaction of short duration and air changes per time unit. Both methods have value without known after-effects or complications. In a and studies made along these lines have done much to large number of those affected a considerable degree of solve some of the difficult points in ventilation re immunity is established so that subsequent attacks are quirements. Unfortunately, it is very difficult to obtain very mild or lacking altogether. The permissible limit quickly and easily a determination of fume concentration for zinc fume in the air has been suggested as 15 milli on a given operation. Local conditions may also change grams of zinc per cubic meter of air. If this concentra- the efficiency of measures based on rate of air change. " tion is not exceeded it is unlikely that any cases of metal Notwithstanding some of the practical difficulties in fume fever will occur.5 applying such standards in specific cases, several general . The most serious condition likely to result from metal fume exposure is probably lead poisoning. This is not a hazard common to all welding operations, but only in tire relatively few cases where welding or cutting is done on material previously covered with lead paint, coated with metallic lead, or where lead has been intro duced as an alloy as in certain steels. In such cases very definite protective measures will be required. Next to lead ranks cadmium as a potential hazard. Lately cadmium has come into more general use as a rust-proof coating for steel in place of zinc. It enters into some alloys. The fume may produce a pulmonary irritation and edema resembling in many ways the effects from inhaling oxides of nitrogen. _ A wide variety of other metals have been mentioned as injurious: manganese, chromium,. cobalt, copper, tin, antimony, magnesium, aluminum, tellurium, vanadium, titanium, and many others. As encountered in welding fumes the amounts are usually definitely less than those known to have toxic effects, and it is doubtful if any reports alleging injury from these metals in welding can be substantiated. Manganese has been most frequently suspected, but a study of the reports of alleged effects fail to show any conclusive evidence and the amounts in volved are below those known to have produced effects. The _ charge that even small amounts of manganese predispose to pneumonia is not borne out by the known experience of welding operators. rules on ventilation have been evolved which have proved to be of considerable help. _ Various studies of present-day practice have been ' made which indicate that welding out of doors or in large shops seldom results in any serious air contamina tion except in the case of lead. In- spaces of less than 1000 cu. ft. and especially inside tanks, ship holds, etc., special ventilation is necessary. Usually the exhaust of contaminated air is much more effective than an at tempt to force fresh air into the space. In stationary locations this can generally be done with properly located exhaust fans or by the use of hoods and ducts to withdraw fumes as near as possible to their source. Portable exhaust systems have been designed which are adapted to field needs. In the case of gases such a3 oxides of nitrogen, or the rare instances of carbon monoxide, if sufficient ventila tion is maintained from the beginning of the operation and sufficient to insure good visibility and to insure a comfortable temperature there should be no gas hazard even in confined spaces. If lead or cadmium fumes are present the only com plete protection is by the use oi air supplied masks. These are of three types--air supplied by special blower, air supplied from compressed air system and masks with larger hose without use of forced air supply. If com pressed air is used from a general supply, special filters and pressure regulators are required. In the last-named type with no forced air supply the length of hose can Other materials than gases or metals may create seldom be over 50 ft. In confined spaces one. of the fume hazards through air contamination. These may above devices should be used. Out of doors or in large be encountered especially in repair work on various tanks, well-ventilated shops and for moderately short ex vats, etc. Their presence calls for special ventilation. posures, one of the'filter type respirators approved by There is one other source of real hazard which may be the Bureau of Mines for lead fumes may be satisfactory. present in many operations involving aluminum or some In any confined space at least local exhaust ventilation of the "stainless" steels and alloy metals, This is from is required when there is exposure to zinc.or fluoride the presence of fluorides in many of the fluxes or rod fumes, or to fumes from heavy deposits of organic wastes coatings used for this work. Hydrofluoric add may be and sludge. Air supplied respirators offer, of course, formed and the fume if inhaled in appredable concen the most positive protection. .. . 10X- trations or for long periods may cause considerable irrita Briefly, a minimum standard of ventilation is one that tion to the nose and throat or even pulmonary edema. will be sufficient to insure good visibility at the point of IAV 1943 HEALTH ASPECTS OP WELDING 345 DEC. 19= operation, and insure a temperature wiihia a reasonably comfortable limit. 'In confined spaces this would call for exhaust ventilation. In case of lead or cadmium exposures air-supplied masks are required. No serious hazard is apt to be present except in confined spaces or when lead is involved. Special standards for ventilation in welding of leaded steel have been given by Halley,3 General requirements for ventilation are given in more detail in the reports of Tebbens and Drinker,9 in Special Bulletin No. 5 of the U. S. Department of Labor, "Control of Welding Hazards in Defense Industries8 and by Hemeon.u Summary and Conclusions 1. Health hazards in welding may be divided into "real" and "unreal." , 2. Real hazards should not be.ignored or minimized, They are usually easy to recognize and effective pre ventive measures are available: 3. Unreal and hypothetical hazards are often alleged. If indicated precautions are taken to guard against the real hazards, the unreal will disappear entirely. 4. Hazards from radiation in welding are limited to eyes and skin. No systemic effects have been demon strated. Means of prevention are well known and available. 5. Hazards from air contamination can usually be controlled by ventilation and in some instances, by respiratory protective equipment. Hazard from gas is essentially limited to oxides of nitrogen. Ozone and carbon monoxide hazards are of minor importance. Oxygen deficiency, if present, is usually not due to the NO.078 P.6/6 welding operation but to other causes. Fume baz for practical purposes are limited to fumes from cadmium, zinc or fluorine, and rarely from or5 wastes or sludges. Fumes from other materials, wh present, are usually in non-toxic ambunts, or would removed by protective measures indicated for well-recognized hazards just mentioned. 6. No reliable evidence has been presented to sho that welding operators have any poorer health ah accident records than other tradesmen working in same environment, or that they show any characteristi type of illness which could be associated with their wor 7. That the health hazards due to welding exposure are not great and can be well controlled is evident fro the enormous increase in welding and its application without a corresponding increase in illness. Bibliography 1. V. S. Burtu of Mums, "Motarialfl Ussd. in Welding," RnUtoa os4 too Borncviac. IotannAtion Circular 7121Jime 1940. 2. Brittms and Walsh, "Health Hazards of Elfitt/Jt and Gm Welding." /. Ini. Byg. indTox.,22, 4 (April 1040). . 3. Voa Haam usd Gfoofl, "Ttia Potholoey of Shielded Are Welding,"' Ibid., U, 2 (Pah. 1941). 4. Harrold. Gordon C, "Weldm^.Puaas teoai Are Welding," Tus Wcto- rwo Touhnal. 21 (6), 347-370 (1045). . 5. Gardner end MeCwm, "Effect nf Pail/ Exposure* tn Are Welding Fumca and Gases upon Normal and Tuberculous Animals," J tnd. Bye- and Tax., Vol.*24; 173-142 (Sept. 1043). ^ 0. Tcbbes* od Drinker, "VentUatlon In Are Welding with Coated Steetredci." ibid., 23 7 (oept. 1941). 7. "Aawricau Standard Safety Code for the Prcrtaction of Hands, Syct and Respiratory Orjanj," Noil. Bureau of Standards. Handbook H 34. U, S. Department of Coomvce, 1093. ^ 3- Halley, "Atsoipberic Concentration of Lead Puma Associated with FoTRiac, Welding, end Owgro Cutting of Lead* Beering Stool/1 J. Ini. By?. aniTol.. 90. 3 Oder. 1040. 0. "Control of Weidin? Hosord* in Deienae Industries/' Special Bull. 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Jefferson. Welding Eng ., vol. 28, no, 3 (Mar. 1943), pp. 3S--52. _ Welding Rods, Coatings. Extruding Coatings on Welding Electrodes, H. Chase. Iron Age. vol. 151. no. 0 (Feb. 11,1943), pp. 67-69. ' Welds, Design. Can Weld Metal Be Conserved and Better Welds Made by Using Root Openings? S. I. Rosenthal. Steel, vol. 112. no. 9 (Mar. 1. 1943), pp. 92-98 and 133-135. X-Ray Analysis. Radiography- as an Inspection Tool. Metal Progress, vol. 43, so.. 2 (Feb. 1943), pp. 220-234. THE WEDDING JOURNAL MAY