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Objectives Workplace measurements in the past have shown that the applicable occupational exposure limits (OELs) are regularly exceeded in practice when high-emission welding processes are applied. The InterWeld pilot study was planned as part of an intervention study to show under which conditions compliance with the OEL is achievable in gas metal arc welding (GMAW) with solid wire. The investigation focussed on local exhaust ventilation, i.e. captor hoods and welding torches with integrated fume extraction. Methods Forty tests with hand-guided GMAW were configured by experts with regard to all technical parameters and carried out by a professional welder. Effects of protective measures and process parameters on the exposure to respirable welding fumes and airborne manganese (Mn), chromium, nickel, and hexavalent chromium were investigated. Personal sampling was carried out in the welder’s breathing zone outside the face shield at high flow rates (10 l min−1) in order to achieve sufficient filter loading. Particle masses and welding fume concentrations were determined by weighing the sampling filters. Metal concentrations were analysed by inductive coupled plasma mass spectrometry. In order to evaluate the effects on exposure, the measurements were performed under similar conditions. The data were analysed descriptively and with mixed linear models. For measurements below the limit of detection, the exposure level was estimated using multiple imputation. Results Two to five times higher exposures to respirable welding fumes and airborne metals were observed during welding of 10 mm sheets than during welding of 2- or 3-mm sheets. Welding fume and Mn exposure were reduced by 70 and 90% when on-torch extraction or a captor hood was applied. Other airborne metals were reduced to a similar extent. Modifications on welding parameters led to a reduction of exposure against respirable particles by 51 up to 54%. Conclusions Although proper extraction at the point of origin and lower-emitting process variants ensure a drastic reduction in exposure, compliance with current OELs is not guaranteed. In order to ensure adequate health protection, especially at workplaces where thick sheets with long relative arc times are processed, there is a need for technical development.

Due to mounting evidence of neurotoxic effects of manganese (Mn) already at low concentrations, occupational exposure limits (OELs) have been adopted. We analyzed 5771 personal measurements of inhalable manganese (Mn) together with information on sampling conditions and job tasks from the German exposure database Messdaten zur Exposition gegenüber Gefahrstoffen am Arbeitsplatz (MEGA) to assess exposure levels in welders and other occupations between 1989 and 2015. Geometric means (GMs) of exposure to Mn were estimated for various occupational settings adjusted for 2-h sampling duration and analytical method, centered at 2009. Measurements below the limit of quantification (LOQ) were multiply imputed. The median concentration was 74 µg m-3 (inter-quartile range 14-260 µg m-3) in welders and 8 µg m-3 (inter-quartile rangeLOQ-31 µg m-3) in other occupations. Every third measurement was higher than 100 µg m-3, 20% exceeded 200 µg m-3, and 5% of welders inhaled concentrations ≥1000 µg m-3. GMs100 µg m-3 were observed in gas metal and flux-cored arc welders and in shielded metal arc welders using consumables of high Mn content (5%). Tungsten inert gas welding, laser welding and working in other occupations such as foundry worker, electroplater, or grinder were associated with GMs10 µg m-3. A shorter sampling duration was associated with higher Mn concentrations. High-emission welding techniques require protective measures to cope with adopted OELs. Results of this study are useful to assess cumulative Mn exposure in community-based studies on neurotoxic effects.

Hazardous substances in welding and allied processes are the inhalable/respirable substances generated, which are absorbed by the human body (Fig. 1.1). At a certain concentration, these substances may cause a risk to health.

To determine the health and safety program required to protect welder workers, an evaluation of workplace hazards which complies with national, regional or international health and safety regulations (e.g. labour protection law), shall be completed.

Any predominant hazardous substance is called a key component (for a specific combination of process and material). A main component of the welding fume is a component of occupational medical importance, the percentage of which in the welding fume is not predominant, i.e., this component is no key component of the welding fume. Main components shall not be equated with key components.

The effects can be considered on the basis of the structure of welding fumes (see also Sect. 2.2), as they are gaseous or in the form of particulate matters.

Welders have an increased susceptibility to airway infections with non-typeable Haemophilus influenzae (NTHi), which implicates immune defects and might promote pneumonia and chronic obstructive pulmonary disease (COPD). We hypothesized that welding-fume exposure suppresses Th1-lymphocyte activity. Non-effector CD4+ T-cells from blood of 45 welders (n = 23 gas metal arc welders, GMAW; n = 16 tungsten inert gas welders, TIG; n = 6 others) and 25 non-welders were ex vivo activated towards Th1 via polyclonal T-cell receptor stimulation and IL-12 (first activation step) and then stimulated with NTHi extract or lipopolysaccharide (LPS) (second activation step). IFNγ and IL-2 were measured by ELISA. In the first activation step, IFNγ was reduced in welders compared to non-welders and in the GMAW welders with higher concentrations of respirable particles compared to the lower exposed TIG welders. IFNγ was not influenced by tobacco smoking and correlated negatively with welding-fume exposure, respirable manganese, and iron. In the second activation step, NTHi and LPS induced additional IFNγ, which was reduced in current smokers compared to never smokers in welders as well as in non-welders. Analyzing both activation steps together, IFNγ production was lowest in smoking welders and highest in never smoking non-welders. IL-2 was not associated with any of these parameters. Welding-fume exposure might suppress Th1-based immune responses due to effects of particulate matter, which mainly consists of iron and manganese. For responses to NTHi this is strongest in smoking welders because welding fume suppresses T-cell activation towards Th1 and cigarette smoke suppresses the subsequent Th1-response to NTHi via LPS. Both effects are independent from IL-2-regulated T-cell proliferation. This might explain the increased susceptibility to infections and might promote COPD development.

To investigate the risk of lung cancer after exposure to welding fumes, hexavalent chromium (Cr(VI)), and nickel, we analyzed 3,418 lung cancer cases and 3,488 controls among men from 2 German case-control studies (1988–1996). We developed a welding-process exposure matrix from measurements of these agents, and this was linked with welding histories from a job-specific questionnaire to calculate cumulative exposure variables. Logistic regression models were fitted to estimate odds ratios with confidence intervals conditional on study, and they adjusted for age, smoking, and working in other at-risk occupations. Additionally, we mutually adjusted for the other exposure variables under study. Overall, 800 cases and 645 controls ever worked as regular or occasional welders. Odds ratios for lung cancer with high exposure were 1.55 (95% confidence interval (CI): 1.17, 2.05; median, 1.8 mg/m3 × years) for welding fumes, 1.85 (95% CI: 1.35, 2.54; median, 1.4 μg/m3 × years) for Cr(VI), and 1.60 (95% CI: 1.21, 2.12; median, 9 μg/m3 × years) for nickel. Risk estimates increased with increasing cumulative exposure to welding fumes and with increasing exposure duration for Cr(VI) and nickel. Our results showed that welding fumes, Cr(VI), and nickel might contribute independently to the excess lung cancer risk associated with welding. However, quantitative exposure assessment remains challenging.

The International Agency for Research on Cancer classified welding fumes as carcinogenic to humans, and occupational exposure limits should be established to protect welders. The aim of this study is to estimate exposure levels to inhalable and respirable welding fumes by welding process to use them for exposure assessment in epidemiological studies and to derive occupational exposure limits. In total, 15,473 mass concentrations of inhalable and 9,161 concentrations of respirable welding fumes could be analyzed along with welding-related and sampling information, which were compiled in the German database MEGA between 1983 and 2016. In both particle-size fractions, model-based geometric means of the concentrations were estimated by welding process and material for frequently used welding processes adjusted for sampling time and median-centered for calendar years. The inhalable concentrations were approximately twice the respirable concentrations, with medians of 3 mg/m3 (inter-quartile range: 1.2–7.0 mg/m3) and 1.5 mg/m3 (inter-quartile range: < limit of detection −3.8 mg/m3), respectively. The adjusted geometric means of flux-cored arc welding, metal inert and active gas welding, shielded metal arc welding and torch cutting ranged from 0.9 to 2.2 mg/m3 for respirable welding fumes and from 2.3 to 4.7 mg/m3 for inhalable fumes. In both particle-size fractions, geometric means were between 0.1 and 0.9 mg/m3 when performing tungsten inert gas, autogeneous, resistance, laser, and plasma welding or spraying. Results derived from this large dataset are useful for a quantitative exposure assessment to estimate health risks of welders.

Objectives Exposure to nickel (Ni) is widely distributed in the production and processing of steel or alloys. We compiled concentrations of inhalable Ni together with information about the duration of the measurement, analytical method, and workplace characteristics in the MEGA database. Methods This analysis was based on 8052 personal measurements of inhalable Ni collected between 1990 and 2009. Mixed-effects models were applied to the log-transformed Ni concentrations with imputed non-detects to assess the geometric means (GMs) of exposure to Ni in the various occupational settings adjusted by duration of sampling and calendar year. Results Most of measurements (38%) were collected in welders, which we further detailed by welding technique. Major predictor of the concentration was the technique and material in welding-related tasks. Highest exposure levels were estimated for welding materials of high Ni content with gas metal arc welding (48 μg/m 3 ; 95% CI 32–72 μg/m 3 ) and shielded metal arc welding (37 μg/m 3 ; 95% CI 24–57 μg/m 3 ). Furthermore, high GMs were estimated in metal sprayers (33 μg/m 3 ), in the manufacture of batteries (27 μg/m 3 ) and in forging-press operators (25 μg/m 3 ). We did not observe time trends of exposure to Ni in this period. Conclusion Ni concentrations varied considerably between occupations and were influenced by process and Ni content of consumables in welders. In order to assess exposure to Ni in community-based studies, supplemental information on job tasks, processes and materials is essential in addition to job titles.

Based on several studies, the Scientific Committee on Occupational Exposure Limit Values (SCOEL), under the EU Commission, recommended a significant reduction in the occupational exposure levels for oxides of nitrogen. This best practice document aims to describe the situation regarding the generation of oxides of nitrogen during different welding and cutting procedures and also outlines the potential health hazards that might arise as a result of exposure. Finally, protective measures for welding and cutting in workshop and on site are reported.

The aim of this study was to estimate average occupational exposure to inhalable nickel (Ni) using the German exposure database MEGA. This database contains 8052 personal measurements of Ni collected between 1990 and 2009 in adjunct with information on the measurement and workplace conditions. The median of all Ni concentrations was 9 μg/m3 and the 95th percentile was 460 μg/m3. We predicted geometric means (GMs) for welders and other occupations centered to 1999. Exposure to Ni in welders is strongly influenced by the welding process applied and the Ni content of the used welding materials. Welding with consumable electrodes of high Ni content (>30%) was associated with 10-fold higher concentrations compared with those with a low content (

To evaluate an adequate strategy for biological monitoring of aluminium (Al), a group of 62 Al welders (age in 1999: 23-51 years, median 35 years) was surveyed annually from 1999 to 2003 by determination of pre- and post-shift Al in urine and plasma. Biomonitoring was supplemented by personal air measurements of the total dust concentration. The welders' internal exposure was compared to the exposure of 60 non-exposed assembly workers (age in 1999: 21-51 years, median: 36 years) who were surveyed in 1999, 2001 and 2003. Having a nearly constant dust exposure, median concentrations of Al in urine (Al in plasma) of the welders decreased from 40.1 microg/g to 19.8 microg/g creatinine (8.7 to 4.6 microg/l). For the control group the median levels of Al in urine (plasma) ranged from 4.8 microg/g to 5.2 microg/g creatinine (2.4-4.3 microg/l) indicating a higher sensitivity for the marker Al in urine. No systematic differences have been found between pre- and post-shift internal exposure. This might be caused by the slow elimination kinetics and low systemic bioavailability of Al. A correlation analysis did not yield close relationships between dust exposure, Al in plasma and Al in urine underlining the importance of biomonitoring for assessment of Al exposure.

This study aimed to estimate occupational exposure to inhalable hexavalent chromium (Cr(VI)) using the exposure database MEGA. The database has been compiling Cr(VI) concentrations and ancillary data about measurements at German workplaces. We analysed 3659 personal measurements of inhalable Cr(VI) collected between 1994 and 2009. Cr(VI) was determined spectrophotometrically at 540 nm after reaction with diphenylcarbazide. We assigned the measurements to pre-defined at-risk occupations using the information provided about the workplaces. Two-thirds of the measurements were below the limit of quantification (LOQ) and multiply imputed according to the distribution above LOQ. The 75th percentile value was 5.2 μg/m(3) and the 95th percentile was 57.2 μg/m(3). We predicted the geometric mean for 2h sampling in the year 2000, and the time trend of Cr(VI) exposure in these settings with and without adjustment for the duration of measurements. The largest dataset was available for welding (N = 1898), which could be further detailed according to technique. The geometric means were above 5 μg/m(3) in the following situations: spray painting, shielded metal arc welding, and flux-cored arc welding if applied to stainless steel. The geometric means were between 1 μg/m(3) and 5 μg/m(3) for gas metal arc welding of stainless steel, cutting, hard-chromium plating, metal spraying and in the chemical chromium industry. The exposure profiles described here are useful for epidemiologic and industrial health purposes. Exposure to Cr(VI) varies not only between occupations, but also within occupations as shown for welders. In epidemiologic studies, it would be desirable to collect exposure-specific information in addition to the job title.

Objectives To assess level and trend of exposure to hexavalent chromium (Cr(VI)) in chromium-exposed occupations for the estimation of lung cancer risks in community-based studies. Method This analysis was based on 3666 personal measurements and auxiliary data compiled in the German MEGA database from 1988–2009. Cr(VI) was determined spectrophotometrically at 540 nm after reaction with diphenylcarbazide. We assigned jobs tasks with known Cr(VI) exposure using coded and textual information about the workplaces. Measurements below the limit of quantification (LOQ) were multiply imputed according to their distribution above LOQ. Statistical modelling was performed to the log-transformed Cr(VI) concentrations to adjust for duration and reason of sampling. Results Cr(VI) exposure could be assessed for eight out of 30 jobs tasks with known Cr(VI) exposure. The majority of measurements (53%) were collected in welders (N = 1930), which we further detailed by welding technique. Spray painting and the welding of stainless steel with shielded metal welding were associated with adjusted geometric means above 5 µg/m 3 , the permissible exposure level of the U.S. Occupational Safety and Health Administration. We could not detect an overall time trend in the Cr(VI) concentrations. Conclusions Exposure to Cr(VI) varied by occupation and job task, particularly between welding techniques, but less across calendar time. Supplemental occupational questionnaires should be administered in community-based studies when estimating the lung cancer risk of Cr(VI).