Welding and cutting galvanised steel generates zinc oxide fume that causes metal fume fever, a flu-like illness characterised by chills, fever, nausea, and muscle pain that typically resolves within 48 hours but can recur with each exposure. Older galvanised coatings may also contain lead, cadmium, or chromate primers that generate highly toxic fume requiring specific respiratory protection beyond standard welding RPE. The fume generation rate from galvanised steel welding is significantly higher than from uncoated steel, and standard workshop ventilation is often inadequate to control exposure. This template maps controls to the binding Welding Processes and Hazardous Chemicals Codes of Practice effective 1 July 2026 under Section 26A.
WHS Regulation 2025 Part 7.1 — Hazardous Chemicals
Hot work with toxic fume generation
Welding Processes, Managing Risks of Hazardous Chemicals (binding 1 July 2026 under Section 26A)
Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.
| Hazard | Consequence | Likelihood |
|---|---|---|
| Zinc oxide fume inhalation causing metal fume fever | Flu-like illness, recurrent episodes with repeated exposure | Almost Certain |
| Lead fume from older galvanised coatings containing lead | Lead poisoning, neurological damage, kidney damage | Possible |
| Cadmium fume from cadmium-plated or older galvanised components | Acute cadmium poisoning, lung damage, kidney failure, death | Unlikely |
| Manganese fume from the base steel and welding consumable | Manganism, neurological damage | Likely |
| Standard welding hazards amplified by dense fume production | Reduced visibility, increased fume inhalation | Likely |
| Chromate primer fume if galvanised surface has been painted | Chromium VI exposure, lung cancer | Possible |
Workers exposed to metal fume and hazardous substances without adequate ventilation or health monitoring.
2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]
Apprentice injured during welding operations with inadequate training, supervision, and safety controls.
2022 — SafeWork NSW v KML Auto Parts Pty Ltd [2022]
Our WHS consultants build coating-specific SWMS that address zinc oxide fume, lead testing, and health surveillance for your galvanised steel welding operations.
Contact Us