Metal Fume Fever: Complete Guide & Prevention Tips

Safety is paramount in welding, yet one common occupational hazard is metal fume fever. This condition, widely recognized among welders, emerges as an immediate health concern, affecting many welders worldwide.

Our article aims to shed light on this often-overlooked aspect of welding safety. By understanding what metal fume fever is, its symptoms, causes, and most importantly, how to prevent it, welders can safeguard their health and ensure a safer working environment.

This guide will navigate the myths, like the famous milk misconception, and offer practical, effective strategies to protect against this occupational ailment. As we delve into the intricacies of metal fume fever, we aim to empower welders with knowledge and tools to minimize risks and promote a safety culture in the welding industry.

What is Metal Fume Fever?

Definition and Other Names

Metal fume fever, a condition well-known among professional welders, is an acute illness resembling the flu. The first documented case of metal fume fever dates back to 1831. It arises primarily from inhaling fumes generated during welding processes, particularly when welding materials like galvanized steel (zinc oxide).

This illness is not just a concern in professional circles; it’s a widespread issue, with hundreds of documented cases each year in the USA alone. Besides “metal fume fever,” it’s often referred to as “Monday morning fever,” “Monday fever” (hinting at its common occurrence after weekends or breaks from welding.), “zinc shakes,” or “welder’s cough.”

Causes

The primary culprit behind metal fume fever is the inhalation of various metallic oxides. Welding galvanized steel, for instance, releases zinc oxide fumes, a significant trigger for the condition. However, it’s not just zinc that’s to blame.

Various other metal fumes, including copper, magnesium, chromium, aluminum, cadmium, iron oxide, manganese, nickel, selenium, silver, tin, titanium, and beryllium, can cause the illness. The diversity of these metals underlines the widespread risk associated with different welding activities.

Metal fume fever is one of the obvious signs of inadequate fume extraction in your workshop.

Symptoms and Diagnosis

Metal fume fever typically manifests with symptoms resembling those of the flu. Affected individuals may experience chills, fever, nausea, and body aches. These symptoms generally arise four to ten hours after exposure, making it a condition that often goes unnoticed during welding.

The condition is predominantly seen in adults (99% of cases) and is more common in men (96%). It makes sense since it is an occupational disease, and men still mostly do welding.

While metal fume fever is primarily diagnosed based on these symptoms and a history of recent welding activity, its nonspecific nature can sometimes make diagnosis challenging. The condition is usually self-limiting, with symptoms resolving spontaneously within 12 to 48 hours after cessation of exposure, without long-term sequelae, as reported by sources like PubMed.

However, its occurrence indicates that fume exposure levels are excessively high and need immediate attention.

It is recommended to wait until the symptoms of this occupational disease are gone before welding again, which shows the importance of solving this issue to avoid workers missing workdays.

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The Misconception About Milk

A surprisingly prevalent myth in the welding industry is the belief that drinking milk can prevent the harmful effects of welding fumes, particularly in warding off metal fume fever. This old wives’ tale posits that milk, with its calcium content, can bind with and help eliminate heavy metals from the body. However, this belief, despite its popularity, lacks scientific backing.

The origin of this myth remains unclear, but its persistence in the welding community is a cause for concern. Relying on milk as a protective measure against inhaling toxic fumes can lead to a dangerous false sense of security. Such misconceptions may divert attention from essential safety practices, like effective fume extraction.

Preventing Metal Fume Fever

Preventing metal fume fever involves understanding the risks, adopting safer working practices, and using appropriate protective equipment. Here are some key strategies.

This is a summary of the strategy. You will find a more detailed version in our dedicated article. You can also use the links in some sections for more specific information.

Minimize Welding When Possible

Consider alternative materials joining methods, such as bolts, fasteners, or robotic welding. Reducing the amount of manual welding decreases the exposure to harmful fumes.

Isolate welding activities from other work areas. Utilize a specific building or location exclusively for welding, or at the very least, employ welding screens to contain fumes.

Selection of Processes and Materials

Opt for welding processes known to produce fewer fumes. Additionally, adjusting power settings can help reduce fume generation.

Use materials that generate less toxic fumes, which includes removing coatings such as paint before welding and avoiding materials containing carcinogenic or highly toxic substances (such as the ones discussed earlier).

Interesting article: Effective Strategies to Minimize Welding Fumes

Effective Fume Extraction

Implement fume extractors specifically designed to remove harmful fumes from the welding environment. We generally recommend fume extraction MIG guns for MIG and Fluxed-Cored welding and Arms for other processes.

Interesting article: Welding Fume Extractor Guide

Personal Positioning and Ventilation

Educate welders on how to position themselves to avoid inhaling fumes. For instance, they should avoid placing their head between the weld pool and the fume extractor. Using the wind to help disperse fumes can be effective when working outdoors.

Maintain a well-ventilated workspace (minimum four air changes per hour, ideally more). Proper ventilation is crucial in diluting and removing airborne contaminants.

Use of Personal Protective Equipment (PPE)

When the above measures are insufficient to reduce exposure to safe levels, personal protective equipment such as masks and respirators becomes necessary. These must be individually fitted to provide the best protection.

In general, these measures will help prevent metal fume fever and other welding occupational diseases and meet welding fume regulations and exposure limits in the US and Canada.

Conclusion

Metal fume fever, a preventable occupational hazard in welding, underscores the importance of understanding and mitigating the risks associated with welding fumes. By debunking myths, educating about symptoms, and implementing effective safety measures, we can significantly reduce the incidence of this condition.

Remember, the key to preventing metal fume fever lies not in folklore but in scientifically proven methods like proper ventilation and safe work practices. As we prioritize the health and safety of welders, we foster a safer, more informed welding community.

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