Zinc !!

[roy_tate]

Every time I talk to someone new and welding comes up, I mention the danger of zinc or galvanized. If we would prepare (clean up) the surfaces before welding, we might spot this more often. Maybe hit the area with at least a wire brush until the bare metal is clearly visible?

Another way to approach this is to assume that ALL metal that you weld is poisonous, and do your very best to be upwind, well ventilated, etc. in addition to cleaning up and examining the surfaces to be welded.

[Nick]

This is probably my worst experiance with galvy. A few months ago I was taking the advanced raising/metals class at NMU. Another girl in the class was making a chair for one of the projects. The welding and forging areas are adjacent in the same open area, and I was using one of the forges, perhaps 30 feet from the welding deck.

The girl in question was torch cutting about a dozen curved pipes which were clearly galvanized. The only safety precuations she took were to put the vent hose over the cutting area, and put a hankercheif around her face. The vent was about as useful as the hankercheif, since it was over the cutting area, and white smoke was pouring out the other end of the pipes.

She was told by several people that what she was doing was a Bad Idea, but plowed on anyway. I left after a while because I didn't want to breath what she was spewing into the air.

She finished the chair, and no one got the galvy shakes, but I wasn't very pleased with what happened. If she wants to cut galvy pipe, that's her business, but when there's 10 other people in close proximity, that's just irresponsible.

[Alan DuBoff]

Ok, this might be a dumb question, but I hadn't known that zinc and other plated metals were so toxic. All the more reason to study smithin' under a real smith as I've been planning.

However, today when I was with my daughter over at the local high school pool, I noticed that the bleachers around the pool had railing that was welded, AFAICT, but it was galvanized.

This got me wondering, since the galvanizing process must plate the steel with a toxic coating, which I assume shouldn't be put into a forge or welded either.

First question, is all galvanized steel toxic? I read the link Glenn posted and they refer to galvanized.

Second question, if it is toxic, is this common for welding shops to weld steel together and then cover it with galvanizing? Or do they weld the galvanized with some special type of respiratory protection and/or ventilation (however that might be)?

[ThomasPowers]

Zinc metal is not that toxic to touch; however vapourized zinc is toxic to *breath*.

If you go over to anvilfire.com to the i-forge section you can read about the death of a smith due to breathing zinc fumes.

Many welders get the "zinc shakes" from welding on galvanized metal; the more so since it does build up in the body so that lower exposures sets it off later.

To weld it safely you need a fume extractor or do it outside witn a good breeze to carry the fumes away from you.

Thomas

[Glenn]

Since Jim Wilson's death, after being exposure to zinc fumes (specifically zinc oxide), this is yet another in depth search on the subject of fume fever (exposure to zinc oxide) I have included the URL's for your reference so you can read the whole article and evaluate the dangers for yourself.

It would seem that fume fever is not something I want to deal with again. My first exposure was the result of my lack of knowledge, and by overheating galvanized material. I discribed my flu like symptoms to Jim Wilson over the phone and he immediately said it as fume fever. In his next breath I got "the lecture" on safety and knowing the dangers of the materials I was dealing with as a blacksmith.

Jim Wilson, to the best of my knowledge, did not die due to breathing zinc fumes (zinc oxide). Jim had COPD* and I have seen first hand his impaired breathing. It is my non-medical opinion that the exposure to zinc fumes further weakened an already impaired resporatory system and pneumonia set in. From the zinc exposure to the time of death was about 2 weeks. Although, as best I can tell, zinc did not cause his death, the zinc fumes and COPD were, most likely, the primary contributing factors. Yes it is splitting hairs, but as best I can tell, zinc fumes (inhalation of zinc oxide) causing death is not correct. I can find no articles to support a build up of zinc in the body (heavy metal poisioning) from inhaliation of zinc fumes (zinc oxide). If you can provide me with a URL, please do, as I would be most interested.


An internet search for "fume fever" turned up the following information:

Anvilfire: Prior to this Paw-Paw had problems with emphysema and this is a factor in his case. However, metal fume fever can kill the young and healthy or leave lasting effects.

I am unable to confirm that "metal fume fever can kill the young and healthy". If you can locate an article that supports this, please let me know, as I am trying to educate myself on this matter.

Mills Welding & Specialty Gases, Inc. > Safety Tips > Welding Safety >Zinc Metal Fume Fever :

SUMMARY
Here are the main points when dealing with galvanized metal:

• Metal Fume Fever is the result of overexposure to zinc fumes from welding, cutting, or brazing on galvanized steel.
• Metal Fume Fever is a short-term illness with classic flu-like symptoms.
• The permissible exposure limit (PEL) according to OSHA is 5 milligrams of zinc oxide fumes per cubic meter of air – always monitor and measure your breathing air.
• To avoid the illness, keep your head out of the fumes and do not breathe the fumes. Use enough proper ventilation and/or exhaust. If
• uncertain about the ventilation, use an approved respirator.
• There are no known long-term effects of this disease.

It is these points that first got my attention:
• Metal Fume Fever is a short-term illness with classic flu-like symptoms.
• There are no known long-term effects of this disease.


MSDA zinc oxide


Centers for Disease Control and Prevention, CDC Toxicologic Review of Selected Chemicals - 229

The most prevalent toxic effect of zinc oxide fume is a condition known as "metal fume fever," whose symptoms include chills, fever, muscular pain, nausea, and vomiting (Turner and Thompson 1926/Ex. 1-1124). Studies in the workplace have shown that welders exposed to zinc oxide fume at concentrations of 320 to 580 mg/m3 reported nausea, with the development of chills, shortness of breath, and severe chest pains 2 to 12 hours later. Most workers took approximately 4 days to recover, and some eventually developed pneumonia

OSHA

Inhalation of zinc oxide fume can result in metal fume fever. This in a self limiting condition characterized by flu-like symptoms which resolve within 24 to 48 hours [ACGIH 1991, p. 1755]. Repeated exposures to zinc oxide by skin contact have resulted in papular-pustular skin eruptions in the axilla, inner thigh, inner arm, scrotum and pubic areas

Wikipedia

Prognosis: The symptoms of metal fume fever are usually self-limiting, and dissipate rapidly upon removal from the source of metal fumes. Depending on the metals involved, repeated exposure can lead to longer term illnesses such as bronchitis, pneumonia, pulmonary edema, nasal cancer and even bone damage.

Zinc Compounds by Edouard Bastarche

Exposure to freshly generated zinc oxide fumes, usually from welding on galvanized iron/steel, leads to metal fume feverbeginning 4 to 12 hours after exposure. Symptoms may last from 1-3 to 24-48 hours.No long-term sequelae have been observed.

Agency for Toxic Substances and Disease Registry (ATSDR)

Metal fume fever is characterized by chest pain, cough, dyspnea, reduced lung volumes, nausea, chills, malaise, and leukocytosis. Symptoms generally appear a few hours after exposure, and are reversible 1–4 days following cessation of exposure.

American Welding Society Safety and Health Fact Sheet No. 25

EFFECTS OF OVEREXPOSURE Zinc oxide fumes cause a flu–like illness called Metal Fume Fever. Symptoms of Metal Fume Fever include headache, fever, chills, muscle aches, thirst, nausea, vomiting, chest soreness, fatigue, gastrointestinal pain, weakness, and tiredness. The symptoms usually start several hours after exposure; the attack may last 6 to 24 hours. Complete recovery generally occurs without intervention within 24 to 48 hours.

*COPD (Chronic Obstructive Pulmonary Disease) is a term referring to two lung diseases, chronic bronchitis and emphysema, that are characterized by obstruction to airflow that interferes with normal breathing.

[Glenn]

eMedicine Specialties > Emergency Medicine > Toxicology June 28, 2006

The classic acute occupational heavy metal toxicity is metal fume fever (MFF), a self-limiting inhalation syndrome seen in workers exposed to metal oxide fumes. MFF, or “brass founders ague,” “zinc shakes,” “Monday morning fever” as it is variously known, is characterized by fever, headache, fatigue, dyspnea, cough, and a metallic taste occurring within 3-10 hours after exposure. The usual culprit is zinc oxide, but MFF may occur with magnesium, cobalt, and copper oxide fumes as well. A neutrophil alveolitis ensues, with hypoxia, reduced vital capacity, and diffuse bilateral infiltrates seen on radiographs.

The pathophysiology of MFF appears to be a direct toxic irritation. Treatment is supportive and effects generally resolve within 24 hours. The diagnosis of MFF is based on a history of exposure

International Programme on Chemical Safety (IPCS) and the Canadian Centre for Occupational Health and Safety (CCOHS)

Inhalation is associated with zinc fume fever. 06-29-06
Within 4 to 12 hours after exposure to freshly formed fumes, the first sign is an unusual metallic taste, or some alteration of familiar tastes such as tobacco smoke. This is accompanied by dryness and irritation of the throat, with coughing and dyspnoea, feelings of weakness and fatigue, pains in the muscles and joints,and general malaise, similar to the prodromal syndrome of influenza. Fever then drops, associated with alternating chills. Body temperature is usually around 102 F, but may reach 104 F, with febrile shivering or rigors, accounting for the trade terms of "brass founders ague," "brass chills," spelter shakes," and "zinc chills". The subject sweats profusely while the body temperature begins to fall, occasionally associated with convulsions. Severe pain in the chest, aggravated by difficult breathing, has been described. Clinical and symptomatic recovery is usually complete in 24 to 48 hours. Rapid development of tolerance is another characteristic feature of Zinc Fume Fever, but it is lost equally quickly.

People work with galvanized material on a daily basis, but they use the proper precautions. If you want to work with galvanized (zinc coated) materials you need to know the results of your actions before you start, and then know how to do the work safely.

The bottom line is we MUST educate ourselves to the hazards of the materials we choose to work with.

[Ten Hammers]

Glenn, thanks. Education is the key. You can't make a lot of folks care but thanks for posting the information. The hazards of this trade ( welding/smithing) are numerous and your disclamer should be read by everyone. I miss Jim Wilson. He was a sharp fella but like many of us, careless.

[ThomasPowers]

"and some eventually developed pneumonia" So MFF doesn't kill but it can lead to pneumonia which does kill. Having once missed an entire month of work due to pnemonia one *summer* I will try to err on the side of caution. (sort of like jumping off the top of a building---the jump doesn't kill you it's the sudden stop at the end...)

Shall we now address the effects of cadmium which is sometimes confused with galvanization on metal scrap and also what Be does to people who accidently use it in bronze/brass scrap? (Be scares me; I purged my brass scrap of anything that *might* contain Be when I read up on it!)

Thomas

[Glenn]

Thomas, let me respectfully rephrase your example. Jim and others jump out of airplanes all the time. With the proper training, most people can do it safely, and live. An unfortunate few get killed by the sudden stop when things go wrong, or safety is lax.

I tried to limit my search to only zinc so the results would be specific to the problem. There are many more blacksmithing hazards, Heavy Metal Posioning being a nasty one. Like jumping out of an airplane, people work with heavy metals on a daily basis, but take the proper safety precautions to avoid that sudden stop.

The following is the extended excerp from one of the references. Please read the entire article by clicking on the link.

eMedicine Specialties > Emergency Medicine > Toxicology June 28, 2006

The classic acute occupational heavy metal toxicity is metal fume fever (MFF), a self-limiting inhalation syndrome seen in workers exposed to metal oxide fumes. MFF, or “brass founders ague,” “zinc shakes,” “Monday morning fever” as it is variously known, is characterized by fever, headache, fatigue, dyspnea, cough, and a metallic taste occurring within 3-10 hours after exposure. The usual culprit is zinc oxide, but MFF may occur with magnesium, cobalt, and copper oxide fumes as well. A neutrophil alveolitis ensues, with hypoxia, reduced vital capacity, and diffuse bilateral infiltrates seen on radiographs.

The pathophysiology of MFF appears to be a direct toxic irritation. Treatment is supportive and effects generally resolve within 24 hours. The diagnosis of MFF is based on a history of exposure and must be clearly differentiated from the true chemical pneumonitis that occurs after exposure to metal fumes from cadmium, manganese, mercury, and nickel. These exposures are clinically indistinguishable from MFF in the early stages but tend to progress to ARDS and cause significantly more morbidity and mortality.

Toxic effects from chronic exposure to heavy metals are far more common than acute poisonings. Chronic exposure may lead to a variety of conditions depending on the route of exposure and the metabolism and storage of the specific element in question. For example, chronic exposure to cobalt dust has been associated with the development of pulmonary fibrosis that can lead to cor pulmonale. This hard metal pneumoconiosis has been described for other metal dusts. Chronic inhalation of high levels of cadmium also causes both fibrotic and emphysematous lung damage, but it also has major effects in bone and kidney. Itai-itai (ouch-ouch) disease—a syndrome of chronic renal failure and osteoporosis described in the Fuchu area of Japan—is often attributed to high levels of naturally occurring cadmium in the soil coupled with increased industrial exposures around World War II.

Exposure to copper can lead to its accumulation in liver, brain, kidney, and cornea, leading to the classic impairment and stigmata of Wilson diseaseand Indian childhood cirrhosis. Many of the heavy metals have been implicated as carcinogens in the setting of chronic exposure.

The most common species implicated in acute and/or chronic heavy metal toxicity are lead, arsenic, and mercury. Overall, lead is the most significant toxin of the heavy metals. Industrial decisions, such as the addition of lead to paints, dyes, and gasoline, have created an epidemic of lead poisonings. Lead is a naturally occurring substance and can be found in organic and inorganic forms. Inorganic forms of lead typically affect the CNS, peripheral nervous system (PNS), hematopoietic, renal, GI, cardiovascular, and reproductive systems. Organic lead toxicities tend to predominately affect the CNS.

The inorganic forms of lead are absorbed through ingestion or inhalation, whereas organic lead salts are absorbed through the skin. Only about 10% of an ingested dose is absorbed in adults, but the absorbed percentage may be much greater in children. Lead absorption is enhanced by deficiencies of iron, calcium, and zinc.

Under typical conditions, lead is absorbed and stored in several body compartments. Five to ten percent is found in the blood, most of which is located in erythrocytes; 80-90% is taken up in the bone and stored with the hydroxyapatite crystals, where it easily exchanges with the blood. Some authorities list the half-life of lead in the bone as long as 30 years, while others estimate the lead half-life in bone to be 105 days. Generally, excretion of lead is slow, with an estimated biologic half-life in soft tissues of 24-40 days. The remainder of the stored lead is found in soft tissue, notably the kidney and brain. The primary route of excretion is through feces (80-90%). To a lesser extent, lead is excreted in urine (10%). Lead passes the placental barrier and is found in breast milk. A correlation exists between lead toxicity and fetal wastage, premature rupture of membranes, and sterility.

[Dan OHare]

Thanks for the heads up on the zinc- nasty stuff indeed. I used to weld full time and all of the hazards are the main reason I refuse to make my living that way anymore. Even with respirators and ventilation systems it's just not worth it when I can make just as much money doing something else, ANYTHING else. Once I quit welding (mostly galvanized) I felt much better right away. I won't go back to it full time. Period. Dan