In this research paper, 15 welders with about 1-20 years working experience in a welding firm, and who had also been diagnosed with fume related illnesses, were investigated. The fumes generated from E6010 electrodes using the shielded metal arc welding (SMAW) process, were collected and analyzed. A fume formation rate of 0.195 g/min was obtained under normal operating conditions and the average size of the agglomerated particles was found to be 2.14 μm. Such fine particles would easily settle within the welders' lungs; and the minute morphology of these fume particles, makes them deleterious to health. It was discovered that the critical time frame of 8.1-13.3 years, was the expected time range within which the welders were likely to begin to have symptoms. Crucially, it was determined that hazard rate is proportional to the expected time within which a welder actually becomes ill. Hence it is recommended that the evolution of toxic gases should be controlled at source. This study has comprehensively considered the hazard profile of welding fumes and gases which have evolved during the SMAW process.
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