What health hazard is associated with welding galvanized steel, and what protective steps should be taken?

• A. Metal fume fever from zinc oxide fumes; use local exhaust ventilation, respirator if needed, remove galvanised coatings when possible, and avoid inhalation.
• B. Skin burns; wear sunscreen and gloves
• C. Hearing loss; wear ear protection
• D. None; galvanised welding has no special hazards

Answer: (A)

Welding galvanized steel introduces a specific inhalation hazard from the zinc coating. When the zinc is heated, it forms zinc oxide fumes that can be inhaled and trigger metal fume fever, a flu‑like illness with symptoms such as fever, chills, nausea, and fatigue that typically appear several hours after exposure and usually subside in a day or two.

Protective steps focus on keeping fumes out of the breathing zone and reducing the amount of zinc exposed to heat. Use local exhaust ventilation or close-fitting fume extraction to pull fumes away from the welder. If ventilation alone isn’t enough or exposure could exceed limits, wear a respirator approved for welding fumes. Whenever possible, remove the galvanizing coating from the weld area or weld in a way that minimizes zinc exposure to heat. Above all, avoid inhaling the fumes by staying upwind of the arc or using appropriate PPE and ventilation, and wash exposed skin after working.