Ensuring Safety in Metal Fabrication: Common Industrial Hygiene Testing Needs

By Liz Cox, MS, CSP, Sr. Supervisor –Environmental, Health & Safety, U.S. Compliance

Metal fabrication is a cornerstone of modern industry, playing a vital role in sectors ranging from automotive to construction. This process, which includes cutting, welding, brazing, and assembling metal, poses numerous health risks to workers due to hazardous substance exposure. Industrial hygiene testing is essential in identifying and mitigating these risks, ensuring a safe and compliant workplace. This blog post delves into the common industrial hygiene testing needs associated with metal fabrication, offering a detailed guide to fostering a healthy work environment.

Process to Determine Required Testing

Identifying the specific industrial hygiene testing needs for a facility that completes metal fabrication tasks begins with a thorough workplace assessment. This involves:

1. Facility Walkthrough & Hazard Identification: Evaluating the tasks performed and the materials used to identify potential hazards. Common hazards in metal fabrication include exposure to welding fumes, dust, noise, and chemicals.
2. Risk Assessment: Determining the level of risk associated with each identified hazard. This involves considering factors such as the frequency and duration of exposure, as well as the toxicity of the substances involved.
3. Exposure Assessment: There are two types of exposure: direct and process-generated. In metal fabrication, direct exposure is typically minimal, as metal in its raw state does not pose significant industrial hygiene concerns. However, when metal undergoes processing, the exposure concern arises from the substances generated or released during the fabrication process.

Common Exposure Monitoring

Various industrial hygiene tests are essential to address the specific hazards in metal fabrication. Some of the most common testing needs include:

1. Industrial Hygiene Testing:
   1. Particulate/Fume Matter: Metal fabrication processes like welding, cutting, and grinding release fine particulate matter into the air. Testing for particulates is crucial to determine employee exposure. Some examples of necessary particulate tests include the following:
      1. Total weld fume
      2. Specific metals
      3. Hexavalent chromium
2. Noise Level Testing: Metal fabrication processes often involve loud machinery, which can lead to hearing loss over time. Noise monitoring is essential to identify areas where hearing protection or noise control measures are needed.
3. Carbon Monoxide Testing: Though not specifically associated with metal fabrication, using a propane-powered forklift in a facility would warrant carbon monoxide exposure testing.

Monitoring Frequency

Determining the appropriate frequency for industrial hygiene testing is crucial for maintaining a safe work environment. Several factors influence how often testing should be conducted:

1. Baseline Testing: Initial testing is performed when a facility is first established or when a new process is introduced. This establishes a baseline for future comparisons and helps in identifying any immediate hazards. We recommend re-testing every 3-5 years if no changes occur.
2. Periodic Testing: Regular, scheduled testing is essential to monitor ongoing exposure levels. The frequency of periodic testing depends on the nature of the hazards and the results of baseline testing.
3. Facility Changes: Any significant changes to the facility, such as modifications to ventilation systems, the introduction of new equipment, or changes in production capacity, call for additional testing to ensure that new risks have not been introduced.
4. Process Changes: Alterations to fabrication processes, such as switching to different materials, implementing new techniques, or changing operating conditions, can affect exposure levels. Testing should be conducted whenever such changes occur to assess their impact on worker safety.
5. Contaminant-Specific Testing: Certain contaminants may require more frequent monitoring due to regulatory requirements. For example, if exposure to hexavalent chromium is at or above the OSHA Action Level, then testing would be required within six months.

Metal Safety Data Sheet (SDS) Review

A critical component of determining industrial hygiene testing requirements is the review of Safety Data Sheets (SDS). The documents provide detailed information on the hazards associated with each chemical used in the workplace. Key sections to review include:

• Section 3: Composition/Information on Ingredients: Lists the hazardous components and their concentrations.
• Section 8: Exposure Controls/Personal Protection: Provides information on occupational exposure limits and recommended personal protective equipment (PPE).

By reviewing the SDS, individuals can identify which chemicals require monitoring.

Post-Testing Follow-Up

After conducting industrial hygiene tests, it is essential to follow up with appropriate actions based on the results. The follow-up process includes:

1. Data Analysis: Interpreting the test results to determine if the levels of hazardous substances exceed occupational exposure limits. Some of these limits are:
   1. OSHA’s Permissible Exposure Limit (PEL)
   2. American Conference of Governmental Industrial Hygienists’ (ACGIH) Threshold Limit Value
   3. National Institute for Occupational Safety & Health’s (NIOSH) Recommended Exposure Level (REL)
2. Risk Communication: Informing workers and management about the findings and their implications for health and safety.
3. Control Measures: Implementing engineering controls, administrative controls, or PPE to reduce exposure to acceptable levels. This may involve improving ventilation, modifying work practices, or providing appropriate respiratory protection. Typically, a combination of controls will reduce the hazard exposure to employees. Follow this hazard control hierarchy:
   1. Elimination: Physically remove the hazard
   2. Substitution: Replace the hazard
   3. Engineering Controls: Isolate people from the hazard
   4. Administrative Control: Change the way people work
   5. PPE: Protect the worker with personal protective equipment (PPE). An example of PPE is Respiratory Protection.

Respiratory Protection

Respiratory protection may be offered to employees either voluntarily or as a requirement depending on the results of industrial hygiene monitoring.  When offering respiratory protection on a voluntary basis, it is critical to ensure the correct elements of a respiratory protection program are implemented based on the protection offered.

If a filtering face-piece style respirator is offered to employees voluntarily, the below elements must be in place:

1. Equipment must be NIOSH-approved.
2. Industrial hygiene monitoring has been conducted and the data reviewed to ensure no overexposure.
3. Employees must sign the 1910.134 Appendix D.

For voluntary respiratory protection beyond a filtering facepiece, the majority of elements from a full respiratory protection program must be implemented.

Conclusion

Ensuring the health and safety of workers in the metal fabrication industry requires a comprehensive approach to industrial hygiene testing. By identifying hazards, conducting thorough testing, reviewing Safety Data Sheets, and implementing effective control measures, employers can create a safer work environment. Continuous monitoring and the use of appropriate control measures further enhance worker safety. Through diligent application of these practices, the risks associated with metal fabrication can be effectively managed, safeguarding the well-being of all employees.

In summary, industrial hygiene testing is not just a regulatory requirement but a vital aspect of workplace safety. By proactively addressing the hazards associated with metal fabrication, businesses can protect their most valuable asset – their workforce. Reach out to your U.S. Compliance Representative for metal fabrication testing or other industrial hygiene services.