Welding operations carry the risk of injury, primarily through thermal contact and intense ultraviolet (UV) radiation exposure. Thermal burns occur instantly upon contact with hot metal, slag, or molten spatter, causing direct damage to the skin tissue. Arc flash, also known as “welder’s flash” or “arc eye,” results from the exposure of unprotected skin and eyes to the powerful UV light emitted by the welding arc. Both types of injury require immediate action to minimize damage, promote healing, and prevent lasting complications. Understanding the difference between these injuries and the severity of the damage is the necessary first step toward correct treatment.
Recognizing Burn Severity and Type
Welding injuries are generally categorized into two distinct types: thermal burns and arc flash injuries, which affect the body in different ways. Thermal burns are localized injuries caused by heat transfer, leading to damage depth classified into degrees. A first-degree burn is superficial, affecting only the outermost layer of skin, the epidermis, and typically presents as redness, mild swelling, and pain, much like a mild sunburn.
Second-degree burns damage both the epidermis and the layer beneath it, the dermis, resulting in bright red, swollen skin with the formation of painful blisters. These blisters indicate partial-thickness damage to the skin layers. Third-degree burns are full-thickness injuries that destroy all layers of the skin, and sometimes underlying tissue, often appearing dry and leathery with a color that may be white, brown, or charred.
Arc flash injuries are caused by intense UV radiation exposure that acts as a severe sunburn on the skin and eyes (photokeratitis). Skin exposed to the arc may become red and painful hours later. Eye symptoms, such as the sensation of grit or foreign bodies, often have a delayed onset, peaking six to twelve hours after exposure. Identifying the type and depth of the burn is paramount, as first aid procedures for thermal injuries differ significantly from those for arc flash exposure.
Immediate Care for Minor Thermal Burns
For minor thermal injuries, such as first-degree or small second-degree burns, immediate action focuses on stopping the burning process and cooling the tissue. First, swiftly and gently remove any restrictive items, like rings, watches, or clothing, from the affected area before swelling begins. Cooling the burn is achieved by holding the injured area under cool, clean running water for a minimum of ten to twenty minutes.
Cooling the burn helps reduce pain, limit swelling, and prevent heat from damaging deeper tissue. Cold or ice water must be avoided, however, as it can cause further damage. After cooling, gently cleanse the wound with mild soap and water to remove debris. Once clean, apply a thin layer of over-the-counter antibiotic ointment or aloe vera, followed by covering the burn with a sterile, non-adhesive dressing.
The dressing should be wrapped loosely to avoid pressure and protect the area from friction and infection. If blisters are present, they should not be intentionally broken. The fluid-filled sac provides a sterile environment that promotes healing and reduces the risk of infection. These steps are only appropriate for localized thermal injuries that are small and superficial.
Managing Arc Flash Injuries
Managing arc flash injuries requires a dual approach, addressing both the skin and the eyes, as both are vulnerable to the intense UV radiation. For skin that has been exposed, the treatment resembles that of a severe sunburn, focusing on cooling and moisturizing the area. Cool compresses can be applied to the affected skin to alleviate the immediate burning sensation and reduce inflammation.
Once the initial heat has dissipated, topical moisturizers containing aloe vera or cocoa butter can be applied to soothe the skin and prevent excessive dryness. Over-the-counter non-steroidal anti-inflammatory drugs (NSAIDs) can be taken to manage pain and reduce the widespread skin inflammation characteristic of this type of radiation burn.
Eye injuries (photokeratitis) require immediate attention; the individual must refrain from rubbing the eyes, which can worsen corneal damage. Applying cool compresses to the eyelids provides relief from the gritty, painful sensation. Using over-the-counter artificial tears or lubricating eye drops frequently helps to moisten the eye surface and ease discomfort. If symptoms persist, or if there is any noticeable vision change, professional medical evaluation is necessary.
When Emergency Medical Care is Necessary
Certain burn characteristics necessitate immediate professional medical attention. Any thermal burn suspected to be a third-degree injury, identifiable by dry, leathery, or charred skin, requires emergency care regardless of its size. Second-degree burns larger than the size of the injured person’s palm should also be treated as a medical emergency due to the significant risk of fluid loss and infection.
Burns that affect sensitive areas, including the face, hands, feet, major joints, or the genital area, are considered major injuries and need professional assessment. Signs of shock, such as pale, clammy skin or faintness, must prompt an immediate call for emergency services. Even if a burn initially appears minor, signs of subsequent infection—including increasing redness, swelling, fever, or pus—require prompt medical follow-up.