Welders exposed to toxic substances at storage tank manufacturing company

Welding without proper safety precautions can expose workers
to hazardous chemicals and fumes. 

Workers welding stainless steel and other alloy steels containing chromium metal at a Wisconsin bulk storage tank manufacturer were exposed to hazardous levels of hexavalent chromium.

At high levels, hexavalent chromium can cause lung cancer and respiratory, eye and skin damage.

After a complaint, U.S. Department of Labor Occupational Safety and Health Administration inspectors visited Imperial Industries in Rothschild and identified two willful and 12 serious safety violations.

Proposed penalties total $161,100.

"Each year 50,000 workers die from exposures to hazardous substances like chromium during their careers. Failing to take steps to limit exposure to this dangerous substance is inexcusable," said Robert Bonack, area director of OSHA's Appleton office.

"Workers pay the price when companies don't follow standards to reduce injuries and illnesses. Imperial Industries needs to take immediate steps to comply with safety and health standards."

Inspectors determined employees were exposed to hexavalent chromium at levels exceeding permissible exposure limits while welding steels containing chromium metal. Chromium is added to harden alloy steel and help it resist corrosion.

Additionally, the company failed to implement engineering controls to reduce and monitor exposure levels among workers.

The November 2014 investigation also found workers endangered by amputation and struck-by hazards because machines lacked safety mechanisms. Numerous electrical safety hazards were also identified, and workers were found operating damaged powered industrial vehicles.

Imperial Industries manufactures heavy gauge metal industrial tanks that are typically mounted to commercial trucks.

Under the Occupational Safety and Health Act of 1970, employers are responsible for providing safe and healthful workplaces for their employees.

OSHA's role is to ensure these conditions for America's working men and women by setting and enforcing standards, and providing training, education and assistance.

Source: OSHA

Concerned about exposure to toxic chemicals and gases at your workplace? 

Electrocorp has designed a wide range of industrial and commercial indoor air cleaners with activated carbon and HEPA filters that remove dangerous chemicals, gases, fumes, odors and particles from the ambient air. Source capture units are also available. 

Check out Electrocorp's welding fume extractors or browse other industrial and commercial applications. Contact Electrocorp by calling 1-866-667-0297 or e-mailing sales@electrocorp.net.

Manufacturers ignore welders’ health: Experts

Welding is linked to various health risks.

A single welder produces 20 to 40 g of welding fumes per hour, which corresponds to about 35 to 70 kg per year.

Most welders understand the many health risks of working in the fabrication industry, which include electric shocks, fire, explosions and radiation exposure, but it appears that one of the biggest threats to a welder’s health - toxic welding fumes - is being ignored by many welders and their employers.

Research shows a lack of familiarity with the gases used or fumes produced during the welding processes can be a serious health risk. Workers can become ill if dangerous fumes are not removed from the workplace.

OHS groups say it is essential welders are familiar with the materials being used (such as gases, base metals, coatings and cleaners) and their possible health impact.

Research reveals fumes produced during welding processes can lead to workers experiencing eye, skin and respiratory system irritation, nausea, headaches and dizziness.

In some cases, the fumes can cause serious lung diseases and increase the risk of asthma and cancer and possibly lead to asphyxiation.

However, despite all these warnings, many manufacturers are unaware of the need for adequate fume extraction to create a safe working place.

An open roller door and a fan on the roof or in the wall may be able to affect the air changes per hour or minute, but welders are still exposed to the fumes. The area needs to be well ventilated to let toxic fumes and gases escape.

Central ventilation systems and even large extraction hoods over workbenches often fail to provide adequate protection, since the fumes still contaminate the general airflow.

Experts say that extraction-at-source is most effective – removing toxins as soon as the fumes are generated.

Fume extraction air cleaners are the most
effective when it comes to welding fumes.

Fumes from different welding methods

It has been shown that different welding methods give rise to different amounts of fumes containing different concentrations of hazardous substances.

Among the high-risk elements are hexavalent chromium Cr(VI), manganese, nickel and lead.

The particles at source are often extremely small; 0.01-0.1µm which means they are very easy to inhale deep into the lungs.

Furthermore, not only welders are at risk in unsafe environments. Production equipment, as well as end products, are negatively affected by the lack of adequate safety measures.

During welding, the intense heat of the electric arc vaporises a fraction of the metal in the electrode and weld pool.

Any metal vapour that escapes the arc area condenses as it cools and oxidises into weld fume. The vapour that develops condenses as it cools and oxidises into weld fume containing a complex mixture of metal oxides.

Particulate fume is formed mainly by vaporisation of metal and flux. As it cools, the vapour condenses and reacts with the atmospheric oxygen to form fine particles.

The size of the particles (0.01 - 1µm) tends to influence the toxicity of the fumes, with smaller particles presenting a greater danger.

Additionally, many processes produce various gases (most commonly carbon dioxide and ozone, but others as well) that can prove dangerous if ventilation is inadequate.

About 90% of the fume originates from the consumable, while the base metal only contributes very little.

The fume contains all the elements present in the consumable, but often in very different proportions. Volatile components have a higher concentration in the fume than in the consumable and the opposite is true for components with a high melting point.

The amount of welding fume varies between different welding processes: Fumes from manual metal arc (MMA) welding and fluxcored arc welding (FCAW) contain a high proportion of components coming from the electrode coating or the flux core. Comparatively little comes from the filler metal.

It has also been shown that particles in welding fumes are small enough to be suspended in the air for a long time. They can be inhaled and penetrate into the innermost area of the lungs. Over time, the particles can even reach the bloodstream.

Editor's note: This article has been edited for length.

Source: Manufacturers' Monthly

Remove toxins at the source with fume extractors

Electrocorp's LD450
welding fume extractor

Welding is dangerous enough, but the risk of inhaling harmful particles and fumes can be minimized by using an industrial welding fume extraction air cleaner from Electrocorp.

The air cleaning systems feature 40+ pounds of activated carbon for the removal of chemicals and volatile compounds, HEPA and pre-filters to trap airborne particles, a direct intake hood on an articulating arm to capture toxins at the source and a spark arrestor for welding applications.

Custom carbon blends are available for targeted chemical control.

For more information, contact Electrocorp.

Update: Study on effects of welding fumes on women

Welding fumes can affect workers'
health and well-being.

An ongoing study focusing on female workers' exposure to welding fumes and metal dust in metalworking and electrical trades has published some preliminary findings.

The researchers report that the study is now recruiting women from all provinces and territories across Canada, who can complete the questionnaires either in French or English by telephone.

Originally, the study focused on female workers in the province of Alberta. Participants can also complete the questionnaires online.

Up until this point, 531 women have completed the baseline questionnaire and 415 women have completed the first of the questionnaire about exposures at work.

The earliest participants are now nearing their 30 month follow-up questionnaire online or by telephone, having been enrolled for over two years.

Preliminary results focus on metal levels

At the time of their first exposure questionnaire early participants were asked to send in a urine sample so that we could examine the relationship between work and the level of metals inside the body.

There were 107 women who were working in their trade and provided a urine sample at the time of their first exposure questionnaire. This group included 56 welders and 51 electricians. Each urine sample was analyzed for a series of metals possibly related to work in the trades.

The result suggested that welders had higher levels of metals than the electricians, but the differences were small in most cases.

The researchers next looked at whether the metal levels differed depending on the tasks that were carried out on the last day at work before giving the sample.

Among electricians there were no differences in the metal levels, regardless of the tasks on that day. However, among welders, there were differences: those who reported stick welding had higher metal levels than women who did not do stick welding.

In addition, welders who reported TIG welding had lower metal levels than those who did not do TIG welding. We are continuing to analyze these metal levels and will have more results to share in future updates.

For those interested in participating can join the WHAT-ME study at www.whatme.ualberta.ca or write to whatme@ualberta.ca or call 1-866-492-6093.

Source: University of Alberta

Blog posts of interest:

• Study probes effects on dust, welding fumes on women
• Welding hazards: Protect yourself from welding fumes and soldering fumes
• Healthy welders may be at increased risk of brain damage
• Compensation fund set up for workers affected by welding fumes

Concerned about welding fumes and chemical exposures? Electrocorp has designed a wide range of air cleaners for industrial and commercial use, including welding fume extraction and chemical control. Contact Electrocorp for more information.

Captain sues marine company for exposure to toxic fumes

Chemical exposure ruined health and future, seaman alleges

Health and safety lawsuits can be
expensive for employers.

Comal County resident Paul Whetstone seeks more than $1 million in damages from a marine company he claims exposed him to toxic chemicals.

He was ordered to repair his ship after the Ashton T ran aground on the Galveston north jetty in March 2012. Whetstone was first captain of the vessel.

Whetstone claims that he had to work “in a closed environment with little or no ventilation and ingested fumes and vapors from paint, polyurethane, welding gasses and other toxic and harmful substances in the air.”

Whetstone filed a Jones Act lawsuit against T&T Offshore Inc. and T&T Marine Inc. in Galveston County District Court.

In his suit, Whetstone claims he now wears a pacemaker following the incident last year in which “his heart and entire central nervous system shut down and he died.” Whetstone was revived and stabilized shortly afterwards, but rendered unable to work again, the suit says.

Seaman now requires pacemaker because of ship’s toxic fumes, court papers say

He also claims that he was made to eat and sleep “in this environment” and not allowed to leave the Ashton T.

Whetstone claims he requested adequate protection from “such harmful and deadly fumes, vapors and metals in the air” to no avail.

He was released from duty on April 28, 2012, and Whetstone states he was taken to San Antonio’s Baptist Hospital where surgeons installed the pacemaker.

According to the suit, the pacemaker “has permanently prevented the plaintiff from performing any form of work activity in the maritime and aviation fields because he is no longer qualified to maintain his ship captain and aviation license(s).”

A jury trial is requested.

Source: Southeast Texas Record

Combat chemical fumes with carbon air cleaners

Working with hazardous materials in closed environments or indoor spaces requires adequate health and safety measures.

Electrocorp air cleaners for chemicals and
particles work in enclosed spaces.
Shown: Welding fume extraction

Aside from personal protective equipment and improved ventilation, the right type of air cleaner can also significantly improve the air quality in these spaces.

Electrocorp offers a wide range of air purifiers for the workplace, which can remove airborne chemicals, vapors, fumes and odors, as well as particles and biological contaminants.

The air cleaners can tackle welding fumes, paint vapors, gasoline fumes and other airborne chemicals with a superior activated carbon filter featuring many pounds of carbon.

Contact Electrocorp for more information and ask about specialized carbon blends as well as other options.

Compensation fund set up for workers affected by welding fumes

Plaintiffs in welding fume litigation cases
may be able to benefit from a resolution fund.

Exposure to welding fumes is a high-risk occupational hazard and often the subject of legal pursuits.

Now a US District Judge has set up a fund for a $21.5 million settlement in a multidistrict litigation over the hazardous effects of welding fumes.

The Welding Fume Resolution Fund created by Judge Kathleen M. O’Malley is overseen by a fund administrator, who can determine how the money is dispersed, in accordance with Law360.

The multidistrict litigation involved almost 100 lawsuits, and another 700 or more were pending in other state or federal courts.

The plaintiffs in these lawsuits sought compensation for allegedly developing brain damage after exposure to dangerous welding fumes containing manganese from welding rods.

What are the effects of manganese?

Manganese poisoning (also known as manganism or “welders’ disease”) is caused by excessive exposure to the chemical element manganese (Mn), which is an essential component in iron and steel production.

The disease is sometimes mistaken for Parkinson’s disease, Lou Gehrig’s disease, or multiple sclerosis.

Manganese poisoning has been the subject of a number of product liability suits brought by welders who claim that manufacturers failed to warn that their products could cause welding fumes to contain dangerously high manganese concentrations.

The MDL agreement was reached earlier this year and affects many of these plaintiffs trying to get some justice in court.

Source: Sokolove Law

Welding fume extractors can remove dangerous chemicals, gases

One of Electrocorp's
welding fume extractors
with source capture.

Welding is an important part of many business processes, but keeping workers’ health and safety in mind has to be of utmost importance.

Electrocorp has developed industrial strength air cleaners for welding fume extraction that can handle the different chemicals, gases and toxins present in welding fumes.

The welding fume extractors contain a deep-bed activated carbon filter for gaseous pollutants, a source capture attachment for protection right where it’s needed and other filters for maximum overall dependability.

Contact Electrocorp for more information and options.

Related posts:  

• Sick welder sues welding rod manufacturer
• Study probes effect of dust, welding fumes on women
• Occupational risk: Former welders are often clumsier
• Metal fume fever a persisting problem, toxicologists say

  

Welding hazards: The effects of manganese on the brain

Welders can be exposed to toxic fumes -
but manganese can affect the public as well.

In a new study, Penn State College of Medicine researchers try to understand the effects of metal manganese on brain functions.

They aim to expand on the insights of a previous, smaller scale study, which looked at welders specifically, since they are often exposed to manganese in the welding fumes.

But the general population should also be aware of manganese and its effects, the researchers say, since we may all be exposed to the toxin through gasoline additives and the burning of fossil fuels.

According to research, very low concentrations of manganese are essential for life, but high levels of exposure quickly become toxic for humans.

In the previous study on welders, the researchers found a link between exposures to manganese-containing welding fumes and decreased motor performance.

Technical advances make it easier for the researchers to study the effects of manganese exposure in the brain, so they are hoping to see how manganese affects the general population.

The study has received funding from the National Institute of Environmental Sciences.

Source: Gettysburg Times

Reduce exposure to welding fumes and other occupational hazards

Electrocorp fume extractor
(other models available)

Welders have to make sure they don’t breathe in too many welding fumes, which have been shown to be toxic.

Along with the usual precautionary measures (including good ventilation and personal protective equipment), Electrocorp’s industrial-strength welding fume extractors can help reduce exposures.

The welding fume extractors feature the most effective activated carbon blends for the removal of toxic chemicals, gases and fumes, the deepest carbon beds for more efficient adsorption and easy-to-use source capture attachments for more accurate toxin removal.

Electrocorp also features other air cleaners for a wide range of commercial and industrial applications, which contain activated carbon and HEPA air filters.

Contact Electrocorp for more information.
 
Related posts:

• Occupational risk: Former welders are often clumsier
• Metal fume fever a persisting problem, toxicologists say
• Study probes effect of dust, welding fumes on women
• Welders at increased risk of early brain damage
• Sick welder sues welding rod manufacturer

  

Occupational risk: Former welders are often clumsier

Welding can expose workers to toxic fumes and particulate.

A new study shows that former welders who were exposed to manganese from welding fumes have a risk of developing increased clumsiness.

The effects last long after the exposure has stopped, according to the study of former shipyard workers in Gothenburg, Sweden.

Previous research has linked exposure to manganese and welding fumes to effects on the central nervous system, but this study focused on the long-term effects on fine motor skills.

The welders in the study underwent several tests that measured their manual dexterity and motor speed, eye-hand coordination, tremor and balance. The results were compared to the results of other shipyard workers that did not do any welding.

Those participants that had a higher total manganese exposure showed a poorer performance, the study authors say, giving reason to believe there is a lasting effect of manganese exposure.

What is manganese?

Manganese is a naturally occurring metal in the environment and human bodies, where it aids in the turnover of carbohydrates and fats.

Workers who are exposed to high concentrations of manganese over a considerable time can develop a condition called manganism, a disease with symptoms similar to Parkinson disease.

Experts say that many welders may be regularly exposed to high-risk levels of manganese that exceed official exposure limits.

Source: Health Canal

Source capture air cleaners for welding applications

One of Electrocorp's fume extractor air cleaners.

Electrocorp fume extractors offer a high-draw solution to welding smoke and fumes.

The portable fume extractors feature at-the-source protection for removing airborne chemicals, vapors, fumes and smoke directly from the workstation.

 The air cleaners feature 2" HEPA fume filters that capture airborne smoke particles and a 40 lb. deep-bed activated carbon filter for chemicals, gases and smoke odor.

 The fume extractors are ideal for MIG, TIG, arc and robotic welding.

Contact Electrocorp for more information.
 

Ventilation problems shut down new welding lab

Gases and fumes released in
the welding process are dangerous.

The students enrolled in the welding program at Washington's Columbia Basin College learned a tough lesson this week about the importance of proper ventilation and adequate protection against welding fumes.

Their lab was shut down after several students were affected by welding fumes that were not vented properly.

After working in the lab, several students reported

• A metallic taste in the mouth
• Visible fumes that lingered
• Sore throat
• Other symptoms and complaints

Welding can produce noxious fumes from the metal, the coatings, residues and solvents, many of which have been linked to short-term and long-term health effects.

The university is installing new metal hoods to improve ventilation.

Source: NBC News 

Portable welding fume extractors can help protect welders

Electrocorp has designed a customizable line of welding fume extraction air cleaners with a spark arrestor, flexible arm and source capture attachment that can remove chemicals, fumes, gases, odors and particles.

The activated carbon and HEPA filtration system combines the most efficient filter media for enhanced protection against harmful fumes.

Contact Electrocorp and ask about our different models and customizable options.