Metal Fume Fever Prevention in Welding Facilities
Summary
Metal fume fever (MFF) is a temporary, flu-like illness caused by inhaling zinc oxide fumes, most often released when welding, cutting, or brazing galvanized steel. Symptoms appear 3–10 hours after heavy exposure and typically resolve within 1–2 days. The most effective prevention is fume extraction at the source, combined with proper PPE and worker training, to keep zinc oxide fume levels below OSHA and NIOSH exposure limits.
Table of Contents
What Is Metal Fume Fever?
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
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
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.
Symptoms
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.
Risk Factors and When It Occurs
The amount of zinc-oxide fumes that welders are exposed to varies and is most common in facilities and workshops without proper ventilation and/ or fume extraction in place.
Because of the symptoms, metal fume fever can be difficult to diagnose and is often suggested by welders who understand that it is a potential risk.
When metal fume fever is acute, emergency medical assistance may not be required because most symptoms go away within 1-2 days, with the exception of welders with pre-existing heart and lung ailments. Long-term exposure to zinc-oxide fumes can result in more severe health effects.
The amount of zinc-oxide fumes that welders are exposed to varies and is most common in facilities and workshops without proper ventilation and/ or fume extraction in place.
Because of the symptoms, metal fume fever can be difficult to diagnose and is often suggested by welders who understand that it is a potential risk.
When metal fume fever is acute, emergency medical assistance may not be required because most symptoms go away within 1-2 days, with the exception of welders with pre-existing heart and lung ailments.
Long-term exposure to zinc-oxide fumes can result in more severe health effects.
Prevent Metal Fume Fever with Fume Xtractors!
Employers are responsible for providing guidelines, manuals, and training to ensure that employees are aware of metal fume fever and how to prevent it.
The most effective way to prevent overexposure to zinc is with welding fume extraction systems - including source capture and local exhaust ventilation. By extracting metal fume at the source, the surrounding air is kept clean and safely breathable and ventilation helps remove fumes from the airstream. Other ways to help prevent metal fume fever include PPE to protect respiratory zones and continued training with knowledge of welding fumes, and present chemicals.
Exposure Limits
The current OSHA standard for zinc oxide fume is 5 milligrams of zinc oxide fume per cubic meter of air (mg/m3) averaged over an eight–hour work shift. NIOSH recommends that the permissible exposure limit be changed to 5 mg/m3 averaged over a work shift of up to 10 hours per day, 40 hours per week, with a Short–Term Exposure Limit (STEL) of 10 mg/m3 averaged over a 15–minute period.
Fume Xtractors was developed to combat the health hazards that industrial machine operators are faced with on a daily basis. Our welding fume removal solutions range from fume extraction arms to welding booths, depending on the demands of your application.
Fume Xtractors welding fume extractors provide an easily adjustable and convenient way to remove harmful contaminants before they reach the breathing zone of machine operators. Our team works directly with engineers, distributors, and general contractors to provide turn-key prices and customized fume extraction systems to fit their application demands. To learn more about metal fume fever, or to get started on your free quote, get in touch with our specialists.
FAQs: Metal Fume Fever
What causes metal fume fever?
Metal fume fever is caused by overexposure to zinc oxide fume, released when welding, cutting, or brazing galvanized steel. The zinc coating on galvanized steel vaporizes during these processes, and inhaling the resulting fume triggers the illness.
How long does it take for metal fume fever symptoms to appear?
Symptoms typically appear 3–10 hours after heavy exposure to zinc oxide fume.
How long does metal fume fever last?
In most acute cases, symptoms resolve within 1–2 days without requiring emergency medical care, except for welders with pre-existing heart or lung conditions.
Why is metal fume fever sometimes called "Monday morning fever"?
Metal fume fever is most commonly reported at the start of the workweek among welders who regularly work with galvanized steel, leading to the nickname "Monday morning fever."
What is the OSHA exposure limit for zinc oxide fume?
OSHA's standard is 5 mg/m³ of zinc oxide fume averaged over an 8-hour work shift. NIOSH recommends the same 5 mg/m³ limit averaged over shifts up to 10 hours, with a Short-Term Exposure Limit of 10 mg/m³ over 15 minutes.
How can facilities prevent metal fume fever?
The most effective prevention is fume extraction at the source combined with local exhaust ventilation, along with respiratory PPE and ongoing worker training on the fumes and chemicals present in galvanized, copper, or magnesium welding applications.
You may also like:
• Why Is Welding Fume Removal Important?
• Welding Safety in Schools & Education
• 5 Things to Know About Fume Extraction Arms