The Dangers of Carbon Monoxide in the Welding Industry

Understanding Welding Safety Requirements

Safety concerns with welding are typically taught in most industries for them to comply with regional regulations and laws. However, for the average hobbyist or independent worker, it is up to them to learn the ins and outs of safety as it relates to welding. Unfortunately, that means a lot of people out there are regularly using welding equipment without the adequate PPE and safety equipment required. Not only are PPE like respirators, face shields, eye protection, gloves, clothing, hard-tipped boots, etc., required in the workplace for welding, but proper ventilation requirements are crucial to the health and safety of welders.

The process of welding creates fumes that contain multiple byproducts and aerosolized particles of the welding materials being used. Some types of welding can produce far more toxic byproducts than others. When it comes specifically to carbon monoxide (CO), oxy-acetylene cutting/welding creates the most CO by a landslide over other types. With oxy-acetylene welding, CO can be produced at a rate of roughly 100,000 µg/minute. If we assume a room of 20ft x 20ft x 10ft, like a standard 2-car garage, this rate translates to a 35 PPM CO concentration in the room in just under 1 hour with no ventilation. Proper ventilation brings this number down significantly. OSHA recommends a ventilation rate of 2,000 CFM for this type of welding, or a local exhaust near the welding point of at least 100-150 CFM. Without adequate ventilation, the levels of CO can reach deadly levels near 400 PPM in just under 11 hours.

The above scenario becomes dramatically more dangerous if a carburizing (reducing) flame is added to the mix. This addition brings the time to 35 PPM to just 15-20 minutes, and the time to 400 PPM to just 2.5-3.5 hours. It cannot be stressed enough how crucial adequate ventilation is for this scenario.

Unless a person is wearing a supplied air respirator, a standard respirator meant for particulates and fumes CAN NOT scrub CO from the air. CO is a very small, non-polar, and chemically inert molecule which cannot be captured by particulate, OV/AG, or hybrid cartridges on respirators. Many people commonly misunderstand this, and as a result, can end up in a CO poisoning scenario while thinking that they are protected.

Welding Fumes Are Only Part of the Problem

It should come as no surprise that many places where welding takes place do not meet adequate ventilation standards. Since often welding takes place in-situ, welders find themselves on various job sites, homes, confined spaces, and other areas where a controlled ventilation system designed for that space may not be available. This is where portable ventilation solutions, meant to be placed close to the welding point, should be used. I say should be used here, because often the inevitable truth is that they are not. Regardless of the ventilation in an area, care should always be taken to ensure that welders are not being exposed to carbon monoxide. As I have written before in many other industry publications, even low-level CO exposure becomes a significant health risk when it is repeated time and time again over months and years. People may think they just get headaches or nausea more often than others for whatever reason, when the actual reason is low-level CO exposure over time. Cognitive abilities become impaired, with people experiencing memory loss, brain fog, fatigue, and other serious neurological disorders. CO cannot be detected by humans. It is colorless, odorless, and robs the body of the ability to absorb oxygen in the blood cells and tissues, effectively suffocating a person as more is absorbed. While it does so, it causes the onset of headaches, nausea, fatigue, and impairs a person’s ability to think and reason properly, making the situation even worse.

The Critical Role of Personal CO Monitoring

The problems stated above are entirely preventable with proper training and equipment. Something as simple as a portable CO monitor can provide crucial, life-saving information if CO exposure becomes an issue. Our portable monitors are pre-programmed to trigger a low alarm at 35 PPM to make users immediately aware of the presence of low-level CO. The Pro series boasts the ability to allow users to set custom alarm points, as well as a time-weighted average (TWA) alarm that can warn users of dangerous exposure levels averaged over an 8-hour shift. When it comes to something that can save your life and prevent something catastrophic by providing crucial information at the right time, a CO monitor is something that should not be overlooked.

Stay safe and know your environment!