Flux-Cored Arc Welding Safety

Flux-cored arc welding (FCAW) uses a continuous tubular wire filled with flux, with or without shielding gas.
FCAW produces higher levels of fume than solid wire MIG welding due to the flux core burning.
The process is commonly used on structural steelwork, pipelines, and heavy fabrication on UK sites.
Welding fume from FCAW is classified as a carcinogen by the HSE — no exposure is considered safe.
Self-shielded FCAW produces more fume and spatter than gas-shielded variants.
UV radiation from the FCAW arc is intense and causes arc eye and skin burns to unprotected workers.
The wire feed system creates entanglement risks if loose clothing or gloves contact the feed rollers.
COSHH 2002 requires local exhaust ventilation at source for all indoor FCAW operations.
Slag from flux-cored welds must be chipped off — hot slag and fragments cause eye and skin burns.
Spatter from FCAW travels further than from other processes and ignites combustible materials easily.

Cancer risk	FCAW fume is carcinogenic — LEV at source is mandatory for all indoor operations.
High fume output	Flux-cored wire produces significantly more fume than solid MIG wire.
Spatter hazard	Hot spatter travels far, causing burns and igniting materials at a distance.
UV exposure	The intense arc causes rapid eye damage and skin burns to unscreened workers nearby.

Do

Don't

Use local exhaust ventilation at source for all indoor FCAW operations.
Wear RPE with minimum APF of 20 as additional protection even with LEV.
Select the correct shade filter in your welding helmet for the FCAW process.
Screen the welding area to protect nearby workers from UV and spatter.
Clear combustible materials from the spatter zone — at least 10 metres.
Chip slag wearing full face protection — hot fragments cause eye injuries.
Keep loose clothing, gloves, and rags away from the wire feed mechanism.
Use gas-shielded FCAW in preference to self-shielded to reduce fume generation.
Attend health surveillance including lung function testing as scheduled.
Have a fire extinguisher within reach when welding near any combustible material.

DON'T weld indoors with FCAW without local exhaust ventilation at source.
DON'T allow unscreened bystanders within line of sight of the welding arc.
DON'T chip hot slag without full face protection — fragments cause eye burns.
DON'T wear loose clothing or gloves near the wire feed mechanism.
DON'T ignore flu-like symptoms after welding — metal fume fever needs medical review.
DON'T leave spatter to ignite combustible materials — clear the area first.
DON'T use self-shielded FCAW indoors where gas-shielded is practical.
DON'T weld without a hot works permit where required by site rules.
DON'T refuse health surveillance — it detects lung damage before symptoms appear.
DON'T store gas cylinders inside the welding enclosure during operations.

See also: Welding Fume Extraction and LEV | Welding Safety Awareness

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