Metal Fume Fever: Symptoms, Risks & Prevention for Welders

Metal Fume Fever: The Welding Flu You Didn’t Sign Up For

If you've ever spent a long day welding, grinding, or cutting galvanized metal and felt like you got hit by a truck the next morning, you may have experienced metal fume fever. This nasty but temporary condition is often compared to the flu, and while it won’t turn you into a superhero, it’s a reminder that metalworking comes with its own set of risks.

What Is Metal Fume Fever?

Metal fume fever is an illness caused by inhaling fine metal oxide particles, most commonly from zinc, copper, or magnesium. These toxic metal fumes are produced when metals are heated during welding, cutting, or brazing—especially galvanized steel. The symptoms mimic the flu, but instead of catching it from your sick coworker, you get it from your own work environment.

Symptoms of Metal Fume Fever

The symptoms usually kick in a few hours after exposure and can last anywhere from 12 to 48 hours. Here’s what to watch for:

1. Fever and chills
2. Fatigue and muscle aches
3. Headache
4. Nausea
5. Coughing and tightness in the chest
6. Metallic or sweet taste in the mouth (some say it tastes like you licked a battery—don't test this theory!)

Why Does It Happen?

When metal fumes enter your lungs, your immune system overreacts, thinking it’s under attack. The body floods itself with white blood cells and inflammatory responses, causing those flu-like symptoms. Prolonged exposure to welding fumes can also increase the risk of chronic respiratory issues.

How to Prevent Metal Fume Fever

Fortunately, metal fume fever is preventable. Here’s how to avoid it:

1. Use proper ventilation. Always work in a well-ventilated area or use fume extraction systems to keep the air clean.
2. Wear the right respirator. A simple dust mask won’t cut it—use an N95 or a welding respirator rated for metal fumes.
3. Avoid welding galvanized metal. If you must, remove the zinc coating by grinding or using an acid bath before welding.
4. Stay hydrated. Some welders swear by drinking milk to ‘coat the lungs,’ but science says hydration in general is key to helping your body flush out toxins.
5. Take breaks. Continuous exposure increases your risk, so step away from the fumes regularly.

Other Hidden Hazards in Metalworking

Beyond metal fume fever, there are other dangers in the shop that don’t get talked about enough:

1. Metal Dust Inhalation: Fine metal particles from grinding and sanding can accumulate in the lungs over time, potentially leading to occupational lung diseases like pneumoconiosis.
2. Hearing Damage: The constant noise from grinding, cutting, and hammering can contribute to long-term hearing loss. Proper ear protection is a must.
3. Skin Irritation & Burns: Certain metals, like aluminum, can cause dermatitis or chemical burns when exposed to sweat or moisture.
4. Eye Damage from UV & IR Exposure: Welding arcs produce intense ultraviolet and infrared radiation that can cause “welder’s flash” or even long-term vision damage.
5. Hand Injuries from Sharp Edges: Handling freshly cut metal without gloves can lead to serious cuts and lacerations.
6. Toxic Coatings & Paints: Burning or cutting through painted or coated metals can release dangerous chemicals like lead or cadmium into the air, increasing the risk of metal poisoning.
7. Heat Stress: Working in high temperatures while welding or fabricating metal can lead to dehydration, dizziness, and heat exhaustion if proper precautions aren’t taken.

What to Do If You Get Metal Fume Fever

If you suspect you have metal fume fever:

1. Get to fresh air immediately.
2. Drink plenty of fluids to help your body recover.
3. Rest—your immune system is doing overtime.
4. If symptoms worsen or persist beyond 48 hours, seek medical attention.

Final Thoughts

Metal fume fever is a common yet preventable hazard in welding and metalworking. If you take the right precautions, you can keep yourself from feeling like you wrestled a flu-ridden grizzly bear after a long day in the shop. Staying informed about welding safety, proper ventilation, and respiratory protection can help reduce the risk of exposure to hazardous metal fumes.

Have you ever experienced metal fume fever? What’s your go-to prevention tip? Drop a comment below!