Safeguarding Against Metal Fume Fever in Welding Operations

Metal fume fever prevention starts with ending exposure to zinc in workshops and facilities where welding applications are present. Metal fume fever, or MFF, is an acute allergic condition experienced by many welders during their career lifetimes. The primary cause of metal fume fever is overexposure to zinc oxide fume (ZnO). A thin surface layer of zinc is featured on galvanized steel to provide corrosion resistance and vaporizes into zinc-oxide fumes during various welding processes.

The main source of exposure is breathing fumes that are produced from welding, cutting, or brazing on galvanized steel. During metalworking applications, machines generate high speeds which result in fumes, smoke, and other harmful airborne contaminants.

Because galvanized steel is becoming more common in the industry, welders are working with it more frequently. Copper and magnesium may cause similar effects. When overexposed to zinc oxide fumes, a welder will experience a flu-like illness —— metal fume fever. Symptoms of metal fume fever typically occur 3-10 hours after heavy exposure.

Metal fume fever is a temporary illness with symptoms ranging from headache and fatigue to chest soreness and gastrointestinal pain, and can even result in convulsions and hallucinations. It is contracted by inhaling zinc-oxide fumes, not by exposure to the mouth or skin — it happens quickly and at times without notice to the welder. Metal fume fever is most likely to occur at the beginning of the workweek and has been dubbed by some as monday morning fever.