October 2007 Vol. 25. No.

JobHealth Highlights Technical Information for Occupational Health and Safety Professionals

Respiratory Protection Basics for Welders

Introduction
Clifford Frey, CIH Increasing awareness about health hazards linked to welding has changed the
way welders work and the equipment they use to protect themselves. This article
Technical Service Specialist
is intended to help welders understand the importance of selecting the correct
3M Occupational Health and
respirator and using it properly.
Environmental Safety Division.
First time respirator users are often surprised to learn how many steps are
involved in the seemingly simple process of selecting and wearing a respirator.
But the detailed procedures required by the Occupational Safety and Health
Administration’s (OSHA) respiratory protection standard 29 CFR 1910.1341 are
there for a good reason: the consequences of selecting the wrong respirator for a job,
or using it incorrectly, can be fatal. If after reading this document, you are still in
doubt about the respiratory hazards you may be exposed to, or how to select and use
a respirator to protect yourself from those hazards, seek help from a qualified safety
professional before proceeding.

Airborne Hazards Common to Welding

Studies show that full-time welders are at increased risk of bronchitis, airway
irritation, lung function changes, pulmonary infections (pneumonia), and lung
Filtering facepiece respirator cancer. Recent studies suggest a possible link between welding fume and nerve
disorders.2 Respiratory hazards in welding can be divided into two main categories:

Welding Fume
The primary airborne contaminant found in arc welding is welding fume. Welding
fume is a complex mixture of very small particles of metal oxides. The specific
components depend on the composition of the welding electrode (stick, wire or filler
rod), base metal, surface coatings and the type of shielding gas or flux.

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 Gases and Vapors
When electrode coatings, fluxes, shielding gases and surface coatings are burned or
exposed to ultraviolet arc rays, they can generate potentially harmful gases such as
carbon monoxide, ozone, nitrogen oxides, gaseous fluoride and phosgene.

Special consideration must be given to welding in enclosed areas or confined spaces.

These locations may have poor ventilation, leading to very high exposure levels. In
severe cases, gases can build up to levels that cause loss of consciousness and death
in minutes. Even relatively benign shielding gases such as argon can accumulate
to levels where there is no longer enough oxygen to support life. None of the
respirators discussed here are suitable for use in such acutely toxic atmospheres. For
more details on respiratory health hazards associated with welding, see “Don’t Let
Powered Air Purifying Respirator (PAPR) with Your Health Go Up in Smoke” in the January 2006 issue of Job Health Highlights.
Loose-Fitting Headpiece

Determining Exposure Levels

The generation rate of welding fume and other contaminants increases as welding
amperage increases. In addition, fume generation is typically much higher for
flux-shielded processes such as SMAW (stick) and FCAW (flux core) than gas-
shielded processes such as GMAW (MIG) and GTAW (TIG). But the amount of
fume being generated is only one factor influencing the amount of contaminant a
welder might inhale. Other important factors include the position of the welder’s
face relative to the rising smoke plume and the effectiveness of ventilation systems.
Because of the many variables involved, it is difficult to estimate exposure levels
for welders. Therefore, exposure assessments typically involve the collection of air
samples by a qualified occupational health specialist, such as a Certified Industrial
Hygienist. Because each component of welding fume has unique toxic effects and
varying exposure limits, the exposure level of each component must be measured
independently. For example, exposure assessments for stainless steel welders usually
focus on chromium, nickel and iron. Several resources offering more information on
toxicity of welding fume and exposure assessment methods are listed at the end of
this document.

Exposure Limits
Occupational exposure limits are typically presented as a time-weighted average
concentration over a normal eight-hour workday (8-hour TWA). For more acutely
toxic substances, the exposure limit may be presented as a “ceiling limit”, which
should not be exceeded during any part of the work shift, or a short-term exposure
limit (STEL) which is a 15-minute time-weighted average. In the USA, OSHA’s
published Permissible Exposure Limits (PELs) are the legally enforceable standard.3
However, many choose to follow more current advisory standards such as Threshold
Limit Values (TLVs®) published by the American Conference of Governmental
Industrial Hygienists (ACGIH).4

 3M JobHealth Highlights Vol. 25 No. 6 October 2007

Selecting a Respirator
Whenever feasible, local and area ventilation systems should be used to remove
harmful fumes and gases. However, in many cases, engineering controls alone
cannot reduce exposure levels adequately. In such cases, it may be appropriate to use
respirators. For most welding applications, an array of respirator options exist that
offer specific benefits and limitations. A summary of the most common respirator
categories for welding is presented in Table 1.

Assigned Protection Factors

Assigned Protection Factor (APF) is the level of protection a class of respirator is
expected to provide when selected and used properly under real-world conditions.
APFs for each respirator class listed in the table on the next page. To determine the
maximum concentration of a substance in which a respirator can be used, multiply
its APF by the exposure limit of the substance.

For example, consider a disposable half facepiece respirator for a stainless steel
welder whose highest exposure is 25 micrograms per cubic meter (µg/m3) of
hexavalent chromium as an 8-hour average. This respirator class has an APF of 10,
and the PEL for hexavalent chromium is 5 micrograms per cubic meter (µg/m3). So
the maximum concentration of hexavalent chromium a welder could safely work
in with this respirator is 10 x 5 = 50 µg/m3. Since the actual exposure (25 µg/m3) is
less than the calculated maximum, this would be an appropriate respirator selection.
This calculation would then be repeated for each contaminant present.

Confined spaces
may have poor ventilation,
leading to very
high exposure levels
 3M JobHealth Highlights Vol. 25. No. 6 October 2007
 Table 1

Description APF Benefits Limitations

Disposable Half 10 No maintenance Not compatible
Facepiece with facial hair
Low unit cost
Increased heat
Fits under any retention and
welding helmet stuffiness
Light weight Fit-test required

Elastomeric 10 Replaceable filters Not compatible

Half Facepiece with facial hair
More filter options
May not fit all
More size options welding helmets
Moderate unit cost Increased heat
Light weight retention and
stuffiness
Fit-test required
Powered-Air, 25 Reduced stuffiness Increased weight
Loose-Fitting
Cooling effect Higher unit cost
No breathing Increased
resistance maintenance
No fit testing Increased user
training
Hard hat options
Need cartridges
Accommodates specific to
limited facial hair contaminants
Powered-Air, 1000* Same as Loose- Same as Loose-
Helmet (Hard Fitting plus: Fitting
Hat) Hard hat included
Higher protection
factor
Better neck
protection
Accommodates
facial hair including
some beards
Supplied-Air, 25 or 1000 Maximum Attachment to
(Loose-Fitting contaminant airline
or Helmet) versatility
Increased weight
Chilled or heated
air Higher unit cost
No breathing Requires
resistance compressor
No filters to change
No batteries to
charge
*Check respirator specifications - depending on manufacturer’s test results APF may be 1,000 or 25.

 3M JobHealth Highlights Vol. 25 No. 6 October 2007

Selecting a Filter
Particulate Filters
As mentioned above, welding fume consists of solid particles which can only be
captured with particulate filters. Table 2 lists particle filter classifications defined by
the National Institute for Occupational Safety and Health (NIOSH). Always look for
the NIOSH mark and classification code when selecting a particulate filter.

Table 2
Resistance to oil mist
Efficiency N-Series R-Series P-Series Welding Respirator Helmet
(not resistant) (medium resistance) (high resistance)
95% N95 R95 P95
99% N99 R99 P99
99.97% N100 R100 P100

The first letter refers to the filters resistance to liquid oil mist. The number that
follows refers to the filters efficiency in laboratory tests. N95 class filters are
recommended for most welding applications because welding fume is relatively
easy to filter and oil mist is seldom a factor. There is no harm in using a higher class
filter. When lead or cadmium exposures are involved, special regulations require the
use of 100 class filters. Particulate filters must be replaced when they become soiled,
damaged or difficult to breathe through.

Gas and Vapor Cartridges

Gases and vapors cannot be removed by particulate filters. They must be removed
by adsorption in a bed of activated carbon. Certain vapors require specially treated
carbon, so it is important to select a cartridge that is approved by NIOSH for the
specific vapors present. The approved contaminants will be listed on the label
on each cartridge. The most common cartridges used in welding applications
are organic vapor (black label), acid gas (white label) and organic vapor/acid gas
(yellow label). The service life of gas and vapor cartridges will vary depending on
the chemicals being removed and their concentration. Gas and vapor cartridges do
not clog like particle filters—they simply become saturated and allow contaminants
to flow through. In some cases, harmful levels can be exceeded without being
detected by the user. Therefore, it is critical that a service life estimate be calculated
for each application and a change schedule established as part of the maintenance
routine. Respirator manufacturers can help with this calculation.

 3M JobHealth Highlights Vol. 25. No. 6 October 2007

 Powered Air Purifying Respirators (PAPRs)
Powered respirators, or PAPRs, use a battery-powered blower to pull air through
filters and/or cartridges. The blower units are usually belt-mounted and push
filtered air through a breathing tube connected to the helmet. Because filtered air is
constantly flowing into the headpiece under pressure, leakage of contaminants into
the helmet is greatly reduced, increasing the level of protection for these respirators.
The movement of air over the face also helps keep the welder cool and comfortable.

Supplied Air Respirators

Some gases and vapors, such as argon or carbon monoxide, cannot be effectively
filtered. In these cases, a supplied-air respirator may be the only alternative.
Supplied-air respirators require a compressor, located in an uncontaminated area,
to pump clean air into the respirator headpiece through an airline. Air used for
breathing-air must meet the requirements specified in the OSHA Respiratory
Protection standard 29 CFR 1910.134(i). The main disadvantage of supplied-air
respirators is the limited mobility afforded by the airline. However, an important
advantage of supplied-air is the ability to cool the incoming air -- a popular feature
in hot welding environments.

Other Factors
• Individual preferences are important. An uncomfortable respirator will be
worn less consistently. Removal of the respirator, even for short periods of time,
dramatically reduces the protection afforded by the respirator.

• Welders with facial hair must shave or use certain powered or supplied air
respirators. Even one-day stubble can cause tight fitting respirators to leak
significantly.

• Not all respirators are flame and spark resistant. Welders should select a
respirator recommended for welding.

Respirator Program
Before respirators can be used in a workplace, a written Respiratory Protection
Program must be established covering the basic requirements outlined in the OSHA
standard. Key elements of the program include:

Some gases
Training
Training must include instruction on respirator use, maintenance,

and vapors cannot

cleaning and storage. Respirator users must be trained prior to
use and at least annually thereafter.

be effectively
filtered
 3M JobHealth Highlights Vol. 25 No. 6 October 2007
 Medical Evaluation
Certain lung or heart conditions can make respirator use dangerous. Medical
clearance must be obtained before using a respirator.

Fit Testing
The OSHA standard requires fit testing for all tight-fitting respirators. Whether
you select a maintenance-free or a reusable respirator, the wearer must obtain a
satisfactory fit. Fit tests must be repeated for each model of respirator used and
when any physical changes occur that could affect the fit of the respirator to the
face.

Respirator Selection
How respirators were selected for each task.

Program Evaluation
A process must be established for regularly evaluating the effectiveness of the
program.

References:
1. Occupational Safety & Health Admin (OSHA), 1910.134, Respiratory Protection
2. Health Effects of Welding, James M. Antonini, Critical Reviews in Toxicology, 33(1)
Subscribe (2003)
If you would like to be notified by 3. Occupational Safety & Health Admin (OSHA), 1910, Sub Part Z, Toxic and Hazardous
e-mail when each new issue of Substances Threshold Limit Values for Chemical Substances and Physical Agents,
ACGIH (published annually)
JHH becomes available, register at
4. Occupational Safety & Health Admin (OSHA), Technical Manual, Respiratory
www.3M.com/jhh
Protection
5. AWS F1.1, Method for Sampling Airborne Particles Generated by Welding and Allied
For more information, please contact Processes
Health and Safety Services
Technical Assistance: 1-800-243-4630 6. AWS F1.5M, Methods For Sampling And Analyzing Gases From Welding And Allied
Fax-on-Demand: 1-800-646-1655 Processes
Internet sites:
www.3M.com/OccSafety
www.respexam.com

Occupational Health and

Environmental Safety Division
3M Center, Building 235-2E-91
St. Paul, MN 55144-1000
U.S.A.
1-800-243-4630 Please recycle.
www.3M.com/OccSafety © 3M 2007. All rights reserved.