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Ted Mooney, P.E. RET
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for Metal Finishing 1989-2025
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Zinc or Galvanized Poisoning Symptoms (Metal Fume Fever)
Quickstart:
The high temperatures of welding vaporize galvanized/zinc coatings, producing clouds of zinc oxide. Zinc isn't a toxin (it's used in cold easing tablets), but inhaling of clouds of it constitutes a serious overdose, causing "zinc fume fever" -- usually one to three days of flu-like symptoms.
Whether repeated bouts of zinc fume fever can cause long term problems is debated, but work should never make people sick regardless, so prevention is needed.
Proper ventilation through fume extraction is the first line of defense; if that is not doable or insufficient, proper respirators, or welding helmets with fresh air supplies, should be worn.
Q. I would like to know the specific health hazards or what does it do specifically to the body, From welding galvanized pipe?
Rob Smith- Red Bluff, California
2002
Q. Does any body know the symptoms of inhaling fumes while welding galvanized steel? I was doing it about 3 days ago and I feel like I've got the flu, but I went to the doctor and he said it was just some anonymous virus. But now I'm starting to think it was b/c of the welding does anybody know?
Ian Davidson- Charlottesville, Virginia
A. It could be metal fume fever (see www.osha-slc.gov/doc/outreachtraining/htmlfiles/weldhlth.html ⇩). But I'm not medically trained and haven't even met you, so it would be silly to overrule the diagnosis of the doctor who examined you. Instead of trying to determine whether you had metal fume fever or a virus this time, I would suggest you stop welding galvanized material unless you have excellent ventilation.
You didn't mention whether this was at work, or you are a hobbyist, but something else to remember is that things that look like zinc galvanizing or plating may actually be cadmium, a cumulative poison like mercury and lead, in which case ventilation is not required merely for short term prevention of flu-like symptoms but because you can't afford to accumulate cadmium in your bloodstream.
If you're welding at work, proper fume extraction equipment should be employed, and a respirator or forced-air welding hemet worn.
Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
Ed. update: The above link is broken. Thankfully, the wonderful Internet Archive preserved a copy here 
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A. Metal fume fever typically starts having symptoms 4 hours after exposure, and is self limiting. It typically only lasts for 48 hours and is gone. Zinc is found in proteins in every cell in your body called "Zinc-finger proteins". So because it is normally found in your body, it is not toxic really and your body can just get rid of the excess by urinating it out. I think that if you got the symptoms 3 days after welding you are already past the time when you should be over the symptoms of metal fume fever.
Joe Atkin- Salt Lake City, UT, USA
November 18, 2008
Q. I have been doing Galvanized welding for about 7 years, I have a problem with coughing all the time. So I was told to drink a lot of milk so I do. But I have a question and I can't find the answer anywhere. People have told me that if you do a lot of galvanized welding you will start getting sores on your scalp leaving scars and that the sores or blisters will continue once it has started. If this is true please let me know.
Thanks..
- Jackson, Ohio
2002
Q. I am interested in any info on symptoms, treatment, and length of exposure for galvanized poisoning. I am in the Health and Safety Dept and have several questions posed to me lately and would like to be able to give up to the date responses to the welders.
Thanks,
- Denham Springs, Louisiana
2003
A. Hello all....
Although I've done my share of structural steel and aluminum welding, I recently became employed as a welder with a large firm that utilizes galvanized steel extensively. I was "warned" upfront (pre-hire) concerning the fumes, but was also assured that the effects are short-lived. However, after a few days of the fumes---with little effects noticed---I did some research of my own. The following link to a .pdf file should answer and allay any of your questions/fears. Hope you find it helpful. It not only made ME feel better, but it also helped my wife feel more comfortable about what I do for a living as well.
Keep the spatter down, Shubes
www.sperkoengineering.com/html/articles/WeldingGalvanized.pdf
- Monett, Missouri
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Concrete PoisoningQ. My husband has been in the construction business all his working life. He recently developed these sores on him that sorta blister up and then are VERY sore and actually ache. He then has to pull seedy looking stuff out of it. GROSS! Once he gets all the seedy things out of it, it goes away, only to reappear in another place. He has them on his forearms and on his face. But if he doesn't get the GROSS stuff out of it, it just gets worse. He's been to doctors and they have treated him for all kinds of stuff. He thought it was concrete poisoning, but doctors are unaware of this. Today he has developed the symptoms of galvanized poisoning again. Anyone else have anything like this? Crystal Boling- Geneva, Florida 2004 A. Let me preface by saying that we sometimes don't know whether some things that are deliberately ingested, and have been studied to death for decades already, are good or bad for us. Yesterday (3/18/04), Dr. Tim Johnson was on Good Morning America relating the results of yet another study on women drinking two alcoholic drinks per day, and how this one now shows a marked increase in breast cancer, but that most doctors feel this is still more than offset by a marked reduction in heart disease. How can we know so very little about something that has been studied so much and for so long, and which can be very carefully controlled and measured -- but expect to know in detail the effects of widely variable things like exposure to zinc fumes?
Ted Mooney, P.E. Striving to live Aloha finishing.com - Pine Beach, New Jersey THIS MESSAGE IS FOR CRYSTAL FROM GENEVA,FL:THIS SOUNDS LIKE THE SAME THING YOUR HUSBAND HAS concrete - Winter Park, Florida 2005 ? Hi, Tracie. I very easily believe that your husband's sores may be related to concrete work. But two of your children getting such sores because their father works with concrete? That sounds like a reach. What does your doctor say about your theory? Ted Mooney, P.E. Striving to live Aloha finishing.com - Pine Beach, New Jersey ! My husband has been in the concrete business for 10 years, a few years ago he began developing huge sores on his knees (puss filled and very painful) after being admitted to the hospital we found it is a 'superbug'- MRSA - or staph infection that is very resistant to antibiotics... 2 years ago I developed the same symptoms. We are now colonized with this bug and there are other concrete workers in our area with the same problems... I definitely think the chemicals used in the concrete have a direct link to this. Staph is a natural bacteria on everyone's skin but when your immune system is weakened the staph can really take over, I believe something in the concrete can weaken your immune system so much it is allowing this to spread. look up MRSA or staph infections/concrete poisoning. Good luck all! Crystal Martinez- Derby, Kansas 2007 |
Q. I WELD GALVANIZED TO HOT ROLLED WITH A MINIMAL EXHAUST SYSTEM THAT COVERS HALF THE AREA. I WOULD LIKE TO KNOW SYMPTOMS THAT GALVANIZED POISONING WOULD CAUSE.
JOSEPH GEIGERWELDING - FT. LAUDERDALE, Florida
2007
A. To my knowledge and belief the symptoms are flu-like, Joseph, but unlike flu they last only a day or two. But you should not be inhaling weld smoke whether the metal is galvanized or not!
There should be excellent ventilation, probably fume extractors; and if something prevents them from being effective then you should be wearing either a proper respirator or a welding helmet with fresh air supply ⇨
Regards,
Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
Q. My name is Jason Nolfi and I have been a welder for 15+ years. I weld stainless, iron, aluminum and galvanized metals. Over the past 3-4 months I have experienced headaches, coughing and sore throats that are not associated with any cold or flu. I am aware of what is called "fume fever". Can you please let me know more about this and what risks there are from inhaling fumes from galvanized metals. I would like to try to prevent any possible medical problems now if it is not too late. I am only 38 years old, with two sons and want to be here and healthy for them.
Jason Nolfiwelder in sheet metal industry - Glassport, Pennsylvania
2007
A. Well, what you've seen on this page is a claim that it's not too late and will never be too late because there are no long-term effects. I don't know that that is the case, but the effect of zinc exposure has been pretty well studied, and cold prevention tablets are zinc.
By analogy, though, glass is probably the least toxic material in all of history, you can still get painful shards in your foot, and swallowing a mouthful of shards would probably be fatal. Likewise, inhaling fumes of anything is not good for you, and simply saying that zinc is not believed to be cumulatively toxic is not the same thing as saying inhaling welding fumes is okay -- it isn't! Proper respirator or air supply welding helmet! Good luck.
Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
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Welding Chromed SteelQ. I have been welding chromed steel, bike rims, car bumpers, other chromed steel into sculpture and furniture for about 5 yrs. I have a welding hood system hat removes most of the fume. I usually wear a N95 type, paper filter mask, NOT a respirator. I am wondering if there is any accumulative effect of the chrome fumes that I am exposed to. I have heard of the accumulative effects of welding Galvanized steel. Is there a similar hazard with welding chromed steel? Matt Cartwright- Portland, Oregon |
Q. My chest hurts and back also from welding galvanized steel/do I have the choice to refuse this part of my job since it is affecting my health. If anyone knows the answer would I still be able to keep my job just because of refusal of something that is affecting my health. Not so easy to just go out and find a new job, thanks for any input you have,John
John OverWelder - Wooster, Ohio
2007
A. Although you'd need to speak to a lawyer, laws attempt to create fairness. I'd expect that your employer would try to accommodate you, John, but it would depend on the reasonableness of your refusal. For example, if your job is to go to computer installations that require extensive prep work for your visit, and then you refuse to do the work 75 percent of the time, saying another employee will have to come back another time, any employer would find that an untenable situation :-)
There are other issues like whether you know that welding galvanized steel is causing these backaches or you are only guessing. I'd suggest a visit to the doctor first and then a lawyer if you are afraid it might cost your job. Good luck.
Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
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I was recently welding a couple of bits of galvo. The day went grand and though I had sufficient ventilation I felt later on that I was getting the shakes. This was followed by other recent illnesses reoccurring. Such as aneurysms, back pain, severe vomiting and sore feet and diarrhea. After a six pack of Dutch gold and small helping of cocaine I thought the symptoms would go away. They didn't. I awoke the next morning to even more vomiting, a headache, which could only be described of as if I had a hangover, and red eyes. It was the day after Halloween and I was late for work as a result. What should I do? Skips. Deco Kane- Vancouver, BC, Canada 2007
Ted Mooney, P.E. Striving to live Aloha finishing.com - Pine Beach, New Jersey Q. What are the effects of galvanized poisoning Lesley Cathcart- Haledon, New Jersey October 23, 2008 A. Hi, Lesley. Can you please phrase try to phrase your question in terms of what has already been said because starting over prevents moving forward 🙂 Ted Mooney, P.E. Striving to live Aloha finishing.com - Pine Beach, New Jersey |
What you should probably do is get an air-supply welding helmet (and keep your day job), Deco.
Beware for those of you who are experiencing metal fume shakes or galvanized poisoning. This is a very fast moving and highly unrecognized condition. If you are exposed to toxic levels and do not die as a result, the blood test for zinc poisoning must be taken within 24 hrs. After 24 hrs, your body will eliminate the excess zinc. Zinc poisoning has similar properties as arsenic poisoning because of its position in the periodic table.
There are only about 50 reported or recognized cases per year in the US, as such, most doctors have never seen this condition and don't know what it is. Symptoms include, severe vomiting, metallic taste in mouth, pulmonary edema and increased blood clotting. The pulmonary edema is likely caused by the embedding of highly ionic metal fragments into the lining of the lungs. The increased clotting factor is likely caused by the reduction of copper in the blood.
Treatment involves: fresh air, oxygen, IV's, anti-emetic drugs and close observation by medical personnel.
Once an individual has developed symptoms of heavy metal poisoning, their resistance to reoccurrence of the condition is greatly reduced. The only prevention is proper ventilation and a clean air supply.
- Soda Springs, Idaho
February 2, 2009
? Hi, Willis. Effective ventilation perhaps including air supply welding helmets should be used when welding zinc coated items (probably when welding anything). And people should never get sick from their jobs, so I certainly don't want to underplay metal fume fever ...
But can you cite any report or medical journal article that can give further info on what you are talking about? Your statement that "if you are exposed to toxic levels and do not die as a result" is alarmist and terribly frightening to welders and their spouses. Are there any records of people dying from welding zinc, since you are very clearly implying that they often do?
Regards,
Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
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Q. I am a fabricator's helper in a Steel shop. I would like to know if the particles from Grinding on Galvanized steel could Cause galvanized poisoning. How long after exposure will symptoms occur (from the fumes). I would also like to know the lighter symptoms. I am asking this question because I have been told it can KILL you, which to me isn't quite so settling. I have had stomach aches when working with galvanized material, but I am not sure if it was just being nervous or if it was from the fumes. I wear a 3M respirator, like a dust mask. Will that always help me/ prevent galv. poison. I am open to all answers, but need facts. Thanks to all who reply. JD Matheny- LaPlace, Louisiana April 8, 2009 A. The boiling point of zinc is 907 °C, 1664 °F, so I doubt that there are any substantial zinc fumes from grinding, JD. But people should wear a respirator when grinding or sanding anything, even wood or paint. Nothing but clean air and specialized medicines should ever be inhaled. Ted Mooney, P.E. Striving to live Aloha finishing.com - Pine Beach, New Jersey |
Q. I've read all the above posts. A few weeks ago I was welding some sculptures (I make robots from used car parts). I hit some galvanized pretty heavy, my exhaust fan is ALWAYS running when I work (in my cellar workshop). Ever since then, I have had a lot of phlegm in my lungs and I seem to be sweating profusely whenever the ambient temps go up or if I am under a bright light. None of my symptoms seem to be listed for MFF, but I don't know what else to say. My wife and family are concerned, they are also saying that I am being moody lately (I disagree).
I appreciate your help and this wonderful resource here.
- Phila. area, Pennsylvania
May 30, 2009
A. Hi, Sage. I understand that metal fume fever is typically a one or two day affair. So it doesn't sound like that's your problem. But this is just book knowledge. I think you should see a doctor.
Regards,
Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
Q. My name is Trysha. My fiancee has been an Ironworker for the past 11 years, he is generally a connector, but for the past several months he has been welding. Today he came home with a pretty bad case of galvanized poisoning. I was wondering if there is anything I can do for him. Are there any home remedies?
Trysha Bakerfiancee to an ironworker - Jerome, Idaho
June 8, 2009
A. Hi, Trysha. Some welders swear by milk, but by the time you see this he'll already be better. The thing to learn is to not allow himself to be exposed to zinc welding fumes! It's 2009 and I don't think people should be breathing welding fumes anymore. Best wishes.
Regards,
Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
My son never comes home sick from work. On the 21st of sept he had been at work about 4 hrs when he experienced severe headache vomiting extreme pain in eyes his blood pressure was up to 224 over 104; he was doing a job that he doesn't usually do. He was melting galvanized pipe. We ended up in ER with concerns for blood pressure being uppermost at this point. We did mention the fact that he had been working with galvanized melting; they took a lot of blood but am not sure if they checked for poisoning. we do have follow up with cardio spec . Thank you for your web site or I wouldn't have known about the chance of poisoning.
sincerely
a concerned mother - Katy, Texas
September 24, 2009
Q. I've been heating up galvanized pipes for a new job to about 600 °F and breathing that in. Someone told me this might not be good? I'm not welding just heating it up to about 600 °F. but there is no ventilation in the shop. Is this going to effect me over time?
timothy Kaeseshop employee - Santa Cruz
September 6, 2010
A. Hi, Timothy.
As mentioned before, I've read that zinc fumes have no long term effects, but don't know for sure. 600 °F should not be a high enough temperature for significant vaporization. Most flue pipes for water heaters, furnaces, etc, are galvanized.
But everything is relative and I'm not getting a good enough picture of what you are involved with when you say you are "heating up galvanized pipes" to have much to say about your exposure situation. You should probably be wearing some sort of respirator/dust mask and there probably should be some ventilation for whatever it is that you are doing. Do you smell or see any kind of fumes or emission?
Regards,
Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
I have been working with zinc products for the last 17 years. I first started in the foundry, where we would use the zinc to let us know how hot the brass was before we pour it into a mold, zinc turn to an ash like substance at around 1800 degrees. After each pour everything I ate or drink would taste really sweet, if I had a cigarette it tasted like I was smoking sugar. After two years of this I learned I was suffering from zinc poisoning, I never took it serious, because talking with the welders they always told me about zinc poisoning causing vomiting, never had that. I did develop gerds disease and acid reflux during this time. I no longer work in the foundry but now work as a welder. I'm just curious how much zinc the actual welding rod contains, one thing zinc does well is help make the molten metal more fluid.
With that little bit of history, I now suffer from the shakes and headaches all the time. The shakes I say are from low blood sugar, but the doctors don't think so, they also think the headaches are just from stress. But looking at all the symptoms, and zinc being in a lot of foods, and some claim zinc is similar to arsenic poisoning. Once you have the damage from the overdose will the internal damage be ongoing, and will it possibly get worse?
Any information will be greatly appreciated.
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- gulfport, Mississippi, us
January 4, 2011
A. A very valid point which I don't see demonstrated enough is the use of appropriate masks.
Even if there isn't the option of using a clean air feed, a silicon half face P3 mask is not an expensive item, and would stop the vast majority of fumes. Paper disposable types are no good; may as well wear them as a hat for all the good they'll do on fumes.
I use a Sundstrom silicon when I don't have the option to hood up, and find it to be very effective.
Don't expect a mask to be the first line of defense however, the mask is the backup. While it's not possible to always work in well ventilated areas, a portable extractor doesn't take long to set up.
A quick note to the concrete enquirers: symptom of the puffy sacs with nodules in them sound like there could be some necrosis of epidermic layer skin from prolonged exposure to lime.
Stay safe people.
- Sydney, Australia
January 4, 2012
Q. I was cutting galvanized steel the other day and a piece flew in my eye. What are the effects if I don't go to the doctor?
Jay whitt- hillsboro, ohio, america
October 14, 2012
A. Hi Jay. Although glass is non-toxic, a chip in your eye could blind you, or at least scratch your cornea or cause an infection. It's not a matter of zinc toxicity, it's a matter of physical damage. You should go to the eye doctor.
Regards,
Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
Q. Yeah I've been welding in mostly confined spaces for over 40 years 12-hour shifts. These years have been spent working on the largest mining equipment doing repairs. Fume masks during my time where non-existent! Over the last 4 years symptoms ranging from tremors, shakes, memory loss, speech problems, vision problems. All the toxic carcinogens and heavy metals might be a factor in my symptoms?
Dano Archer- Cal Alberta, Canada
November 21, 2014
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