You’re suffering from arc eye, but what should you do?

By Staff Report March 7, 2025 7:12 pm IST

It’s just another typical day in the workshop: sparks are flying, metal is glowing, and the arc’s burning brightly. Suddenly, you feel a brief stabbing pain in the eyes and stumble backwards. All it took was a few seconds of carelessness, and your eyes were exposed to the dazzling plasma’s extreme intensity. What happened?

An intense arc is generated during gas-shielded arc welding, establishing an electrical voltage between the electrode and the workpiece. If the voltage is high enough, the shielding gas of the welding torch is ionised to form an electrically conductive plasma. This plasma permits the flow of an electric current, which produces the arc. The radiation released is extremely energetic and can cause painful damage to unprotected eyes. The medical term for this unpleasant phenomenon is keratoconjunctivitis photoelectrica, known to us in the trade as ‘arc eye’.  It is an acute inflammation of the cornea and conjunctiva caused by intense UV radiation.

What makes an arc?

The ionised plasma contains free-moving negatively charged electrons, positively charged ions, and photons—light particles that release a broad spectrum of visible light, ultraviolet (UV) and infrared (IR) radiation. It also contains non-ionised neutral gas atoms and metal vapor, the latter containing vaporised particles from the electrode and the workpiece. The arc column reaches temperatures between 3,700 and 15,700 degrees Celsius (4,000 to 16,000 Kelvin).

Light types and risk

The arc emits various types of radiation, each of which poses risks to the health of welders.

1. Visible light can cause dazzling, impairing the visibility of the welder and creating hazardous working conditions.
2. Infrared (IR) radiation can penetrate deep into tissue and cause thermal damage. It is often perceived as heat and may result in burns if exposed to it for a long time.
3. Ultraviolet (UV) radiation is particularly hazardous for the eyes and skin. It can damage the cornea and conjunctiva of the eyes, resulting in the aforementioned keratoconjunctivitis photoelectrica (arc eye). It can also cause burns on the skin and, in the long term, skin cancer.

How to respond to arc eye injuries

Franz Bichler, welding trainer at Fronius International, commented, “Back in the day, I always used to get arc eye. Whenever I was close to somebody in welding, I often underestimated the reflection of arcs off nearby walls.

Many welders rinse their eyes in a sterile saline solution and then apply cloths soaked in cold milk.  However, we know that self-help procedures are counterproductive, as they increase the risk of inflammation. This occurs because the arc eye causes small scars that can easily become inflamed.

“I recommend consulting a doctor immediately, as one cannot take risks with arc eye. I know welders who can hardly see a thing during TIG welding because they have not used adequate protection for years and have not sought medical advice,” adds Bichler. Bichler.

Eye injury statistics

According to the German Society of Ophthalmology (DOG), there are around 300,000 eye injuries in Germany every year, 5% of which have serious consequences. These include permanent visual impairment, chronic pain, and, in extreme cases, even blindness.

Eye injuries caused by welding work are also a serious problem in Austria. According to AUVA, the national health insurance body for occupational accidents and illnesses in Austria, there were 129,866 workplace accidents in 2023, a significant proportion of which involved eye injuries. AUVA has pointed out that adopting suitable protective measures could have prevented many of these injuries.

Medical opinions

Arc eye injuries are no laughing matter; an eye specialist requires immediate and professional assistance. “The symptoms must be taken seriously and treated quickly to avoid long-term damage. Injuries usually heal within 24 to 48 hours if treated correctly,” explains Dr. Diana Pöppl from AUVA. Typical signs of arc eye include redness, watery eyes, a feeling that something is in the eyes, and sensitivity to light. “The first thing to do is to remove contact lenses and keep the eyes closed, without rubbing them with the fingers, as this can make the inflammation worse,” she advises before continuing, “customary treatments include antibiotic eye drops and anti-inflammatory medication.”

Repeated arc eye

Repeated arc eye can lead to chronic inflammation, permanent damage to the cornea, and increased likelihood of further injuries. There is also a risk of cataracts and, in the worst case, even blindness.

Protective measures

To avoid accidents, welders should always wear suitable helmets with UV filters. Certified welding protection screens are also essential to protect everyone present near welding work. “Regular breaks and training are also advisable,” stresses Dr. Pöppl.

As welding helmets are essential for the safety of welders, it pays to invest in quality and reliability—for example, with a helmet from Fronius:

• Fronius Vizor 4000 Professional: This helmet offers ideal levels of protection and makes every welding task safer, more efficient, and more straightforward for the welder.
• Fronius Vizor Crystal: With its unique anti-glare technology, this helmet offers crystal-clear vision and optimum protection.

Recognition as a work-related illness and pension payments

In Germany, eye injuries caused by UV radiation, including arc eye, are recognised as a work-related illness under certain circumstances. The process is confirmed by conducting by the employers’ liability insurance associations, which are also responsible for paying pensions in the event of permanent damage. However, exact figures for pension payments made due to arc eye injuries are not publicly available.

In Austria, eye injuries caused by welding work can also be recognised as a work-related illness if a clear connection between the occupational activity and the illness can be established. AUVA is responsible for the recognition process and for compensation payouts. Specific figures for accident benefits associated with arc eye injuries are unavailable for detailed publishing.

What other hazards lie in waiting for welders?

The dangers of the arc are not just restricted to arc eye and burns. Various other factors also have to be considered:

1. High temperatures: An arc can reach several thousand degrees Celsius, resulting in serious burns.
2. Electrical dangers: The high electrical current generated by the arc can be dangerous in the event of direct contact.
3. Welding spatter: The high temperatures may cause metal spatter, which can also result in burns.
   

To offer protection against all these dangers, wearing suitable personal protective equipment (PPE) is vital.

Appeal to companies

The safety of welding specialists must be the highest priority. Companies must protect their employees and provide them with the best protection equipment. This includes top-quality welding helmets, protective screens, and regular training sessions. Timely breaks are also required to safeguard employees’ health. Fronius supports metalworking companies with a comprehensive range of personal protective equipment that meets the highest safety standards and makes the working day safer for all welding personnel.