The total pollutants generated during the welding workflow consist of a mixture of vapors and gases, which also contains solid particles originating from the metal, insulating materials, and other substances (such as paint, degreasers, and various chemicals). Therefore, the smoke visible to the naked eye is a cluster of these solid airborne particles, which can be as small as a tenth of a micron.

If we do not protect our eyes properly during welding or do not wear appropriate protective clothing, we can immediately feel harmful effects such as burns or eye and skin irritation, whereas symptoms caused through our lungs may only manifest weeks, months, or even years later. We must be aware of these negative impacts, and the defense against the adverse effects of welding fumes must be taken seriously as early as the planning phase of the welding facility.

In the span of a single minute, we breathe in an average of 20 liters of air. If a welder  colleague works an eight-hour daily shift, they will breathe in approximately 2,300 m³ of air in a year. If the particulate matter content in their breathing zone is approximately 5 mg/m ³ (which is typically higher without proper ventilation and/or source extraction), then roughly 10 grams of hazardous particles will enter their lungs, from where they will never leave.

The health effects vary depending on the composition of the vapor, gas, and smoke, but welding fume extraction/ventilation is necessary for reasons beyond solid particles alone. Gases generated during arc welding also pose a hazard. Shielding gases (Ar, He, CO2 ) are non-toxic but can displace oxygen from the air, causing headaches, dizziness, loss of consciousness, and in extreme cases, death if the brain does not receive sufficient oxygen.

Zinc fumes, for instance, can cause metal fume fever, which exhibits symptoms similar to influenza. Prolonged exposure to fumes generated during welding can lead to iron deposition in the lungs (siderosis) and may impair lung function.

Toxic cadmium can be found in steel and silver. Cadmium fumes can cause death even with short exposure times, accompanied by symptoms similar to metal fume fever. However, the two phenomena must not be confused. In the presence of cadmium, welding for even half an hour can be fatal.

Under the influence of heat and UV radiation, certain compounds used during degreasing (e.g., trichloroethylene, perchloroethylene) decompose.

UV radiation generates ozone and nitrogen oxides in the air, which cause headaches, chest pain, and irritation of the eyes,
nose, and throat.

If dizziness or nausea occurs during work, it may be caused by excessive smoke and/or gas concentration, or oxygen deficiency. It is always critical to pay close attention to these symptoms. If you experience such symptoms, ventilate the area or activate your welding fume extraction system. If you do not have such capabilities, please feel free to contact our company with confidence.

Welding fumes are therefore no laughing matter and can cause severe health problems. It is no coincidence that an entire industry has emerged for the extraction and filtration of welding fumes, and numerous renowned manufacturers (e.g., KEMPER) focus almost exclusively on this specialized field. However, alongside the proper operation of individual equipment, a precise understanding of the application conditions and expected pollutants is essential. Simpler cases can be resolved with local source extraction, but when welding large metal structures in enclosed spaces, one must consider a complete, comprehensive system, including fresh air supply.

The KL-System team actively contributes to executing the above requirements in the most ideal manner possible.  Our expert staff, backed by extensive practical experience and references, is at your service!