Inhaling fumes from heated or welded galvanized metal can cause a temporary illness known as “galvanized poisoning,” medically termed Metal Fume Fever. This acute, flu-like syndrome results from breathing in fine, airborne particles of zinc oxide, a byproduct created when the zinc coating on galvanized steel is heated to high temperatures. While the condition is typically short-lived and resolves without lasting harm, it is a serious physical reaction. If you or someone else is experiencing symptoms, seek urgent medical attention immediately, as this information is not a substitute for professional medical advice.
Recognizing Symptoms and Immediate First Aid
Symptoms of Metal Fume Fever often feel like a sudden, severe case of the flu, but they are delayed, typically appearing four to twelve hours after the exposure has ended. Common signs include a high temperature, shaking chills, and profuse sweating. These are often accompanied by muscle aches, joint pain, and fatigue.
A distinctive symptom is a metallic or sweet taste in the mouth, sometimes paired with a dry or irritated throat. Nausea, headache, and a general feeling of malaise are also reported. The first immediate self-care step is to move away from the source of the fumes and get into fresh air.
Once removed from the exposure, the individual should rest and focus on staying well-hydrated. Increasing fluid intake helps the body manage the systemic inflammatory response. Over-the-counter medications like acetaminophen or ibuprofen can manage the fever and muscle aches. Monitor symptoms closely and seek professional medical help immediately if severe symptoms, such as difficulty breathing or chest pain, develop.
Clinical Treatment and Recovery Process
Seeking medical attention allows for an accurate diagnosis, based on the patient’s history of recent exposure to heated metals and characteristic flu-like symptoms. Since there is no specific antidote, clinical treatment is supportive, aimed at managing symptoms until the body clears the inhaled metal oxides. Medical professionals monitor vital signs, including temperature, heart rate, and oxygen saturation, to rule out serious respiratory issues like chemical pneumonitis.
For patients who are significantly unwell, supportive care may involve administering intravenous (IV) fluids to correct dehydration caused by fever and sweating. If a patient experiences shortness of breath or reduced oxygen levels, supplemental oxygen therapy may be provided. The inflammatory response in the lungs is caused by the release of pro-inflammatory cytokines triggered by the zinc oxide particles.
In most cases, the condition is self-limiting and resolves fully within 24 to 48 hours after the exposure stops. Hospitalization is unnecessary unless complications arise or symptoms are severe. Long-term health effects are rare, but individuals with pre-existing lung conditions, such as asthma, may require follow-up to ensure their respiratory function returns to baseline.
Preventing Metal Fume Exposure
Preventing Metal Fume Fever requires implementing safety protocols, especially for individuals who regularly work with galvanized metals, such as welders or fabricators. The most effective control involves engineering solutions, specifically ensuring adequate local exhaust ventilation (LEV) is in place. LEV systems should capture the fumes directly at the source, preventing zinc oxide particles from entering the breathing zone.
When sufficient ventilation cannot be guaranteed, workers must use appropriate Personal Protective Equipment (PPE). This includes wearing a NIOSH-approved respirator, such as an N95 filter or higher, to filter out metal oxide fumes. It is also recommended to remove the galvanized zinc coating from the metal surface before any high-heat processes like welding or cutting, whenever possible. This proactive step significantly reduces the amount of zinc oxide fumes generated.