4/9/2019

77th Wisconsin Safety Council Annual Conference Wisconsin Dells, WI

Welding Fumes and Health: Tools for the Safety Professional

Safety Moment

“Giving the Nod” - some helmets can be up to two pounds. This motion has caused repetitive stress and strain injuries.

Agenda Agenda Section title one basic charts and 1.graphsLearning Objectives Section2. Basic title twoWelding bullet pointsFume andIH 3.imagesIntro to our weld shop Section title three Section4. Sampling title four and results Section5. What’s title five the deal? 6. Controls 7. How can you sell to management?

1 4/9/2019

Learning Objectives

• Understand the basic characteristics of fumes • Apply occupational exposure limits to welding fume data • Evaluate laboratory results from welding fume sampling • Describe factors impacting welding fume sampling results • Discuss the basic adverse health effects of welding fumes • Advocate for controls to minimize worker exposure

Welding Industrial Hygiene Basics

What are welding fumes? • Welding fumes are a complex mixture of metallic oxides, silicates and fluorides.

• Fumes are formed when a metal is heated above its boiling point and its vapors condense into very fine particles (solid particulates).

• Welding fumes generally contain particles from the electrode and the material being welded.

2 4/9/2019

Scoping for Exposure – What to Test?

Initial Questions

• What are you welding?

• What kind of welding (or cutting) are you using?

• What residuals or coatings might be on the metals you are welding or cutting?

• What are the characteristics of the work environment?

Basic Welding Types

• Shielded Metal Arc Welding (SMAW) – “Stick” • Fume: Parent metal, coatings, welding rod • Rod coating vaporized for shielding

• Flux Core Arc Welding (FCAW) • Fume: Parent metal, filler metal, flux, and flux decomposition • Welding with shielding gases with high argon concentration-generates UV light and potentially ozone and nitrogen dioxide • Review SDS for filler wired (pay attention to products of decomposition) • Fluorides may be a concern

3 4/9/2019

Basic Welding Types

• (GTAW, “HeliArc,” or TIG) • Fume: Parent metal and filler metal • Overexposure more common in confined spaced • Shielding gasses, asphyxiant in confined spaces • Phosgene, chlorine, and halogenated compounds (degreasers)

• Gas Metal Arc Welding (GMAW, MIG) • Fume: Parent metal and filler metal • Tubular wire may have element-specific fillers,

Other Dangers

• UV Radiation • Thermal Burns • Noise

• Compressed Gasses (Ar, He, CO2) • Electrocution • Cleaners and Degreasers • Particulates in Eyes • Confined Spaces

Variables - What can effect results? What should we look out for when monitoring?

4 4/9/2019

Occupational Exposure Limits PEL and TLV

• Both are workday concentrations (8-hour TWA values) • TLVs do not mean healthy/unhealthy, many not fully protective due to: • Age • Gender • Genetic factors • Lifestyle choices • Medications • Medical conditions • Sensitization • Work loads • Variations in temperature & humidity

Dantec Weld & Fab, Inc.

Dantec Weld & Fab

• Welding and Fabrication shop located in Menomonee Falls, WI

• Process Various Parts for Numerous Clients • Utilize variety of materials including carbon, stainless, and galvanized steels • Because different parts are made onsite, different welding methods must be utilized • Metal Inert Gas (MIG) and Tungsten Inert Gas (TIG) methods most common • Some torching, air arc gouging activities

• Building • Original construction in 1960s • Approximately 65,000 ft2 • Contains general dilution ventilation units on roof • Overhead bay doors on east, west, and north walls • Office area on south end of facility

5 4/9/2019

• Most continuous welding operations in partitioned cells.

• Equipped with local exhaust ventilation in some workstations

• Some employees complain about local exhaust hoods in cells

• Site requires all employees to wear a welding jacket, welding gloves, and a welding shield for PPE during welding operations

• Steel-toe boots with metatarsal guards, safety glasses, and hearing protection required at all times

• Use of half-mask respirators with P100 filters required in welding area

Dantec Weld & Fab

Personal Breathing Zone

• Radius within 10 inches of a worker’s nose and mouth

• Generally the area of contaminant where airborne concentration is equivalent of that inhaled by a worker (no respiratory protection)

MIG Welder – James

• Stick welds on carbon steel beams

• Beams not painted/coated

• Works in middle of two other welders • No local exhaust provided in this workstation

• Works in standing position primarily • Overhead doors in nearby area closed • Performed this work activity continuously during shift

6 4/9/2019

James Personal Monitoring Results

James Welding Results

• We can’t completely avoid bullet points • So if we must use them, this is the layout to use • Notice that there is no more than 5 bullet points on the slide.

• Exceeds respirable TLV • Key word is “respirable” • May want to perform another sample Potential • Sample we collected was for total determination Issue • How do we collect samples for respirable?

7 4/9/2019

James Respirable Manganese Retest

Manganese What’s the deal with Manganese?

• Manganism (chronic • TLV established as exposure) – Effects similar to respirable since Parkinson’s, but different manganese absorbed in fine, gas-exchanging • Neurological issues regions of the lungs • Sleepiness • Welding (hot-work) • Leg weakness generates particles mostly • Spastic gait less than 4 microns • Psychiatric • Inhalable TLV applies to • Increase in rates processes where particles • Reproductive issues anticipated to be > 4 microns

Exposure to Manganese

• Oral ingestion is well-regulated by the body • Gastrointestinal track and liver, about 3-5% Mn absorption

• Inhalation: Mn directly to the bloodstream to brain, by passing liver

8 4/9/2019

Exposure to Manganese

• Mn crosses the blood brain barrier

Health Effects – Dose Dependent

• Mild to unnoticeable effects • Forgetfulness, anxiety or insomnia • Mood disturbances • Hand-eye coordination • Coordination and balance • Olfaction (smell) • Visual reaction time decreased • Hand steadiness • Neurological damage • Clinical manganism

Current Research • 2015: Baker, et al. MRI scans of brain revealed pre-clinical brain changes in asymptomatic welding trainees

• 2016: Racette, et al. Exposure to Mn-containing welding fume may cause a dose-dependent progression of Parkinsonism, especially upper limb bradykinesia, limb rigidity, and impairment of speech and facial expression

• 2018: Park, et al. Small particles and aggregates of fumes appear to have a higher potency. Over 5 years, exposures of approximately 10 µg/m3 for Mn fume, resulted in an excess prevalence of symptoms. 25 µg/m3 for larger particle sizes

9 4/9/2019

TIG Welder – Erica

• Performs on stainless steel piping

• Worked alone near corner of facility

• No local exhaust provided in this workstation

• Overhead door at nearby north wall open

• Performed this work activity intermittently during shift

• Generally in crouched position to side of weld operation

Erica Personal Monitoring Results

Erica Welding Results

• We can’t completely avoid bullet points • So if we must use them, this is the layout to use • Notice that there is no more

How does this result look?

10 4/9/2019

MIG Welder – Ross

• Performs on stainless steel plates

• Worked near center of facility

• Did not use local exhaust provided in this workstation

• Performed this work activity regularly during shift

• Generally in standing position

Ross Personal Monitoring Results

Ross Welding Results

• We can’t completely avoid bullet points • So if we must use them, this is the layout to use

How does this result look?

11 4/9/2019

Hexavalent Why such different results?

Erica Ross • TIG Welding • MIG Welding • Performed intermittently • Performed • Worked in crouched position frequently/continuously to side of welding operation • Worked in standing position • She stated she does this over weld operation intentionally to avoid fume • Did not utilize exhaust • Overhead door open nearby ventilation • Worked in more secluded • He stated it’s difficult to location position, “it’s a pain”

What’s the deal with Hexavalent

Hexavalent Chromium Chromium?

• Confirmed human carcinogen • TLV and PEL established • Nasal irritation to minimize potential for: • Rhinitis • Respiratory tract irritation • Perforation of septum • Dermatitis • Irritant and allergic contact • Cancer dermatitis • Kidney damage through • Has expanded OSHA absorption through damaged skin standard 1910.1026 • Skin ulcers • Specific requirements based on monitoring results • Action Level 2.5 µg/m³

MIG Welder – Tom

• Performs on aluminum flooring materials • Works in department with several other welders • Adjustable local exhaust provided and used in this workstation • Hood did not appear to draw fume during work observations • Overhead doors nearby to east open • Performed this work activity continuously during shift

12 4/9/2019

Tom Personal Monitoring Welding Results

Tom Welding Results

• We can’t completely avoid bullet points • So if we must use them, this is the layout to use

How do these results look?

What’s the deal with Aluminum? Aluminum

• Not a confirmed human • TLV established: carcinogen • Effects shown at 1.6 mg/m³ for 40 years can show neurological effects • Neurological Effects • Cognitive function • Concentration difficulty • Production of ozone • during aluminum MIG • Emotional lability welding • Reaction of ultraviolet radiation and oxygen in air

13 4/9/2019

Ozone

MIG Welder – Sean

• Performs on galvanized steel plates

• Works in middle of two other welders

• Local exhaust provided in this workstation

• Positions local exhaust above head

• Overhead doors in nearby area closed

• Performed this work activity continuously during shift

• Works in standing/leaning body position

Sean Personal Monitoring Results

14 4/9/2019

Sean Welding Results

• We can’t completely avoid bullet points • So if we must use them, this is the layout to use

What’s the deal with Oxide?

• Metal Fume • TLV established to reduce • Cough incidence of metal fume • fever • Fever • Studies have found • incidence can occur at 2.5 • Chest pain mg/m³ for 2-hour • Joint pain exposure • Fatigue • Respirable TLV • Muscle aches established because high • Recovery with 24 - 48 hours temp operation produces fine and ultrafine particles

MIG Welder and Repair – Rob

• Performs on various carbon steel assemblies for repair purposes • Worked near west side of facility • Local exhaust not provided in this workstation • Performs cutting/torching regularly to disassemble for repair • Also air arc gouges occasionally • Performed this work activity regularly during shift • Works in various body positions depending on activity needed

15 4/9/2019

Rob Personal Monitoring Results

Rob Welding Results

• We can’t completely avoid bullet points • So if we must use them, this is the layout to use

How Did This Happen?

16 4/9/2019

Cadmium Exposure

• Discovered from torch-cutting of coated bolts

• Previously unknown potential exposure at site

• Result well over PEL

What’s the deal with Cadmium? Cadmium

• Confirmed animal carcinogen • Total TLV established to • Has expanded OSHA minimize potential for standard 1910.1027 development of preclinical • Specific requirements based on kidney disfunction monitoring results • Respirable TLV • Action Level 0.0025 mg/m³ established to minimize for accumulation in lower respiratory tract • Both reduce potential for metal fume fever

What’s the deal with Cadmium? Cadmium

• Acute Symptoms • Chronic Symptoms • Severe tracheobronchitis • Gastrointestinal issues • Pulmonary edema • Anemia • Pneumonitis • Pulmonary emphysema • Pulmonary irritation delayed for • Microfractures several hours • Teeth discoloration • Rhinitis • Kidney disease

17 4/9/2019

Maintenance Staff – Jason

• President of Dantec Weld & Fab wanted new stairwell placed in Facility • To save costs, he had Maintenance staff cut down old stairs and cut up to sell as scrap • Cut using mostly torches • Stairwell contained original paint

Jason Personal Monitoring Results

Jason Welding Results

• We can’t completely avoid bullet points • So if we must use them, this is the layout to use

18 4/9/2019

What’s the deal with ? Lead

• Confirmed animal carcinogen • TLV intended to minimize • Has expanded OSHA potential for adverse standard 1910.1025 health effects including: • Specific requirements based on • Blood dyscrasias monitoring results • Reduced nerve condition • Action Level of 0.03 mg/m³ velocities • Peripheral neuropathies • Blood lead levels may be • Kidney dysfunction better indicator of exposure, but standard requires air monitoring and then blood draws based off results.

Sample Exceedances Controls

• Ventilation, ventilation, • Training on how to use ventilation! ventilation • Proper usage, train to use it, • Work practices and importance of use • Trust but verify!

• PPE • Materials used • PAPR, ½ APR, N-95 • Substitution? • HAZCOM Training • Review health effects • Review results

How to advocate to management

• Risk of cancer • Likelihood of exceeding • Reproductive effects PEL during OSHA visit • Chronic health effects • Citations (willful, repeat) • What would your mom, • Criminal? grandmother, or dad • Public image think? • Customer/client rapport • Would you let your child • Employee productivity work here? • Decrease PPE expense • What would Homer do? • Decrease welder turnover

19 4/9/2019

Sample Exceedances Advocate with Data! 1. Use statistical analysis tools for analyzing your data. Show them why you expect you’ll exceed the PEL!

2. Document key rationale for exposure judgements. Accuracy is improved when people are forced to document the reasons!

3. Incorporate a feedback loop into the process that requires comparison of data over time.

Think about data, rather than OELs?

OEL approach Data-driven approach • “We’re lower than OSHA • “The exposure PEL, our people are o.k.” assessments and • “We’re not getting fined by statistics demonstrate OSHA, we’re less than that…” OEL.” • “Based on our results we • “Our hex crome IH sample conclude that a high proportion of our welders was less than the limit, will be exposed to lead they’re safe.” above the OEL.” • “Worst-case sampling • “Investment in ventilation showed us we were under for this process will likely the PEL, we’re fine.” decrease both airborne • “We’ve got PPE, we’re fine.” hex chrome and decrease PPE spend.”

Section Title Key Take-Aways

• True/False: What comes out of an Aqua Net hair spray is fume?

• True/False: Flux Core welding generates the least amount of fumes?

• True/False: Some metal elements found in welding fumes are also found in the human body?

• True/False: The size of welding fume particulates may impact their health effects on the body?

20 4/9/2019

Section Title Key Take-Aways • Which of the following are confirmed human carcinogens? a) Hexavalent chromium b) Aluminum c) Iron oxide d) Manganese

• Which of the following can be found in welding fumes and gases? a) Nitrogen dioxide b) Metal oxides c) Phosgene d) Ozone e) All of the above

Section Title Key Take-Aways

• True/False: The use of any local exhaust ventilation for welding is better than no use of ventilation?

• True/False: The TLV and PEL are delineators between safe and unsafe exposures to welding fume?

• Which of the following should be considered when evaluating for welding fumes exposure: a) Environment, welding type, base metal, filler metal, coatings b) Location of the welding shop c) Wisconsin based sport-team stickers on welding helmet

Safety brings first aid to the uninjured.

F.S. Hughes

Working safely may get old, but so do those who practice it.

Unknown

21