Why welders are at risk

HSE states that all welding fume, including mild steel fume, can cause lung cancer, and expects employers to control it with engineering measures such as local exhaust ventilation, plus respiratory protective equipment where needed. OSHA's welding guidance lists fumes and gases, electrical shock, fire and explosions, burns and eye damage as key hazards. WHO notes that ultraviolet radiation damages skin and eyes, and welding arcs produce intense ultraviolet light.

01Welding fume and lung disease

Fume contains fine metal particles that reach deep into the lungs. Effects include metal fume fever, pneumonia, occupational asthma, and lung cancer with long-term exposure. Stainless steel and coated metals add extra hazards.

What helps

  • Use on-torch extraction or local exhaust ventilation positioned close to the arc.
  • Wear suitable respiratory protection (such as a powered air respirator) when extraction alone is not enough, and get face-fit tested for tight-fitting masks.
  • Keep your head out of the fume plume.
  • Take part in health surveillance and report breathing symptoms early.

02Arc eye and skin burns

Ultraviolet light from the arc can cause painful inflammation of the eye surface, often appearing hours after exposure, and burns on exposed skin. Bystanders are at risk too.

What helps

  • Use a helmet with the correct filter shade for the process and current.
  • Cover all skin with flame-resistant clothing, gloves and a neck cover.
  • Use screens to protect people nearby.
  • Wear safety glasses under the helmet for grinding and chipping.

03Burns, fire, noise and posture

Sparks and spatter cause burns and can start fires, especially near flammable materials. Grinding, gouging and air tools are noisy. Welding in confined or awkward positions strains the neck, shoulders and back.

What helps

  • Clear flammables from the area and keep an extinguisher nearby; follow hot-work permits.
  • Wear hearing protection for noisy processes.
  • Use positioners and supports to avoid long periods in awkward postures.
  • Never weld in a confined space without a safe system of work.

Weekly checklist for welders

  • Check extraction is working before striking an arc.
  • Inspect your helmet filter and respirator before each shift.
  • Cover all skin, including neck and wrists.
  • Wash hands and face before eating.
  • Stretch neck and shoulders at each break.
  • Note any cough, wheeze or eye irritation after work.

When to see a professional

  • Cough, wheeze, breathlessness or chest tightness, especially if better on days off.
  • Flu-like symptoms after welding (possible metal fume fever).
  • Eye pain, grittiness or light sensitivity that does not settle.
  • Ringing in the ears or difficulty hearing conversation.

Get urgent help for severe eye pain or vision changes, serious burns, or breathing difficulty after welding in a confined space.

Where ONU fits

ONU brings your sleep, activity and recovery trends together, so you can see how heavy work weeks affect your rest. ONU does not measure fume exposure or lung function and cannot detect lung disease; use workplace health surveillance and your doctor.

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Common questions

Does welding fume cause cancer?

Yes. Welding fume is classified as carcinogenic to humans, and HSE states that all welding fume, including mild steel, can cause lung cancer. Controlling exposure is essential.

What is arc eye?

Arc eye is painful inflammation of the cornea caused by ultraviolet light from welding. Symptoms usually start hours later, with pain, watering and a gritty feeling.

Is a welding helmet enough to protect my lungs?

A standard helmet protects eyes and face but not lungs. You need extraction and, where required, a respirator, such as a powered air helmet.

Sources and further reading

Educational information drawn from the public-health sources listed on this page. It is not a diagnosis, a treatment plan or a guarantee that you will avoid an illness or injury. ONU does not diagnose, treat or prevent disease. Speak to a qualified professional about anything that concerns you, and follow the rules of your employer, sport or local health service.