Safeguarding Welders from Invisible Hazards
Welding exposes workers to harmful fumes and gases linked to chronic respiratory illness and cancer. What are key steps to protect them?
- By David Kopf
- Jul 16, 2025
Welding is indispensable to many industries, but it exposes workers to a hidden danger: harmful fumes and gases that can compromise respiratory health. Proper respiratory protection for welders is critical not only for compliance with OSHA’s existing Respiratory Protection Standard (29 CFR 1910.134) but also for safeguarding long-term worker health. For EHS and safety managers, understanding the unique hazards of welding and implementing a comprehensive respiratory protection program is essential.
According to NIOSH, approximately 500,000 workers1 in the United States perform welding-related tasks, and studies have shown that welders have a 40 percent increased risk of lung cancer2 compared to non-welders, largely due to exposure to welding fumes. A 2020 study published in Occupational and Environmental Medicine also found that chronic exposure to welding fumes can result in significant declines in lung function,3 increasing the risk of chronic obstructive pulmonary disease (COPD) and other respiratory illnesses.
Why Welding Fumes Are Dangerous
Welding generates fumes composed of tiny metal particles and toxic gases. The exact composition depends on the materials being welded, filler metals, coatings, and the welding process itself. Common hazards include:
- Metal fumes. Iron oxide, manganese, aluminum, chromium (including carcinogenic hexavalent chromium), and nickel.
- Gases. Ozone, nitrogen oxides, and carbon monoxide.
- Additional risks. Welding on surfaces with residual paints or coatings can release lead, cadmium, or other toxic substances.
Long-term exposure to these hazards has been linked to serious health issues, including metal fume fever, occupational asthma, chronic bronchitis, neurological damage (particularly from manganese), and, per the CDC, increased risk of lung cancer.
Key Elements of a Respiratory Protection Program
A successful respiratory protection program for welders must address hazard identification, respirator selection, fit testing, training, maintenance, and program evaluation.
Hazard assessment. Conduct air monitoring or review historical exposure data to determine the specific fumes and gases present during welding tasks. Identify operations or materials that could create exposures exceeding OSHA’s permissible exposure limits (PELs).
Engineering controls first. Before relying on respirators, implement feasible engineering controls, such as local exhaust ventilation (LEV) systems to capture fumes at the source or general shop ventilation improvements. Effective ventilation can significantly reduce exposure.
Selecting the right respirator. When exposures exceed limits or engineering controls can’t sufficiently reduce hazards, provide appropriate respiratory protection. For most welding applications:
- Reusable half-mask or full-face respirators with P100 particulate filters are common for fume particulates.
- Powered Air-Purifying Respirators (PAPRs) with loose-fitting hoods offer protection and increased comfort, especially in hot environments.
- For stainless steel or high-chromium alloys, combination filters for particulates and specific gases may be necessary. Always choose NIOSH-approved respirators suitable for the specific contaminants identified in the hazard assessment.
Fit testing and seal integrity. Tight-fitting respirators must undergo annual fit testing. EHS managers should ensure welders are clean-shaven where the respirator seals against the face, as facial hair can compromise protection. Fit testing should mimic welding positions, such as working in confined spaces, to ensure a consistent seal during actual tasks.
Medical evaluations. OSHA requires medical evaluations before a worker uses a respirator. This ensures welders can safely wear respiratory protection, especially considering the physical demands of welding and underlying health conditions like asthma or cardiovascular issues.
Employee training. Workers must receive thorough training covering:
- The hazards of welding fumes.
- How to don, use, and remove respirators correctly.
- Maintenance, cleaning, and storage procedures.
- Recognizing signs of respirator failure or respiratory distress.
Maintenance and replacement. Set clear schedules for replacing filters or cartridges based on manufacturer guidance, exposure levels, or resistance felt during use. Clean and disinfect reusable respirators regularly, and inspect them for wear or damage.
Program evaluation and recordkeeping. Regularly review the effectiveness of your respiratory protection program by evaluating exposure monitoring results, observing work practices, and soliciting worker feedback. Maintain records of hazard assessments, fit tests, training, and medical evaluations.
Other factors that can impact welders’ respiratory health include:
- Confined spaces. Welding in confined or poorly ventilated areas increases the risk of dangerous fume concentrations. Use ventilation, air monitoring, and respiratory protection appropriate for confined space hazards.
- Hot work permits. When welding on tanks or structures that previously contained hazardous substances, evaluate potential exposures from residual contamination.
- Changing conditions. Monitor worksite changes, such as new materials or processes, which could introduce new respiratory hazards requiring respirator reassessment.
The Safety Manager’s Role
EHS and safety managers are critical in ensuring respiratory protection programs are more than a formality. By conducting thorough assessments, engaging welders in safety discussions, and fostering a culture of compliance, managers can protect workers from the long-term effects of welding fume exposure.
A proactive, well-managed respiratory protection program significantly reduces respiratory risks for welders. By combining effective engineering controls with appropriate respirators, rigorous training, and regular program evaluations, EHS managers can safeguard welders’ health and ensure compliance with OSHA requirements. The investment in respiratory protection pays off through reduced absenteeism, improved productivity, and the peace of mind that comes with knowing the team is protected from invisible, but very real, hazards.
REFERENCES:
- https://tinyurl.com/ym6sw9uy
- https://tinyurl.com/4jwa3nu4
- https://tinyurl.com/3ukyw9m6
This article originally appeared in the July/August 2025 issue of Occupational Health & Safety.