Perfect Welding Blog
It’s an ordinary day in the workshop. Suddenly Frank, an experienced welder, feels a brief stabbing pain in his eyes and stumbles back. One moment of carelessness and he’s exposed his eyes to the arc. But how serious is arc eye, what can be done about it, and what consequences could a moment like this have?
Frank has been welding for many years, but on this particular day he was distracted. A quick glance to the side with his visor still open was all it took—a flash of light strikes his retina. The UV radiation from the arc takes effect and even before his shift has ended, Frank feels an unpleasant burning sensation in his eyes, which gradually intensifies.
The initial symptoms
Tears form in Frank’s eyes and he has difficulty seeing clearly; his eyes are also watery, red, and slightly swollen, and they become sensitive to light. Frank knows that he has to act now. But what exactly has happened?
The medical diagnosis
Frank consults the company doctor, who confirms his fears: keratoconjunctivitis photoelectrica, better known as “arc eye”. The intense UV radiation has damaged the cornea and conjunctiva of his eyes. “Arc radiation triggers an inflammatory reaction in the sensitive cells on the surface of the eye, which can lead to serious visual impairment if left untreated,” explains Dr. Diana Pöppl from the Austrian General Accident Insurance Institution (AUVA). Strictly speaking, UV radiation damages the sensitive cells of the cornea and conjunctiva. Epithelial cells in the cornea die, which leads to an inflammatory reaction in the surrounding tissue. This in turn exposes the nerve endings, which causes Frank to experience a painful burning sensation (source: DocCheck Flexikon).
Long-term consequences
Frank is lucky—after a few days of treatment with antibiotic eye drops and anti-inflammatory medication, his symptoms improve. But the company doctor warns him that repeated arc eye can lead to chronic inflammation and permanent damage to the cornea. In the worst case, there is even a risk of blindness!
Empirical studies and examples
Studies by the German Federal Institute for Occupational Health and Safety (BAuA) show that welders who regularly work without adequate protection have a significantly higher risk of eye injuries. In Germany, around 260,000 workers are professionally involved in welding, and almost one million across Europe. One illustrative example is the case of a welder who worked for years without wearing an adequate glare shield. He now suffers from chronic eye inflammation and a considerable deterioration in his vision. Welding is no longer an option for him, even when using the highest possible glare protection.
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, there were a total of 129,866 workplace accidents in 2023, a significant proportion of which involved eye injuries. AUVA has pointed out that many of these injuries could have been avoided by using suitable protective measures.
Medical opinions
Doctors highlight how important it is to treat burns caused by the arc immediately. “The symptoms must be taken seriously and treated quickly to avoid long-term damage,” explains Dr. Diana Pöppl. 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 keep the eyes closed and avoid rubbing them with the fingers, as this can make the inflammation worse. Contact lenses should be removed straight away,” she advises. Customary treatments include antibiotic eye drops and anti-inflammatory medication.
Protective measures
To avoid such accidents, welders should always wear suitable helmets with UV filters. Certified welding protection screens are also important to protect everyone in the vicinity of welding work. “Regular breaks and training are also advisable,” stresses Dr Pöppl.
Welding helmets are essential for the safety of welding specialists and Fronius offers helmets that are known for their quality and reliability. These include:
Fronius Vizor 4000 Professional: This helmet offers optimum protection and makes every welding task safer, more efficient, and more comfortable 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 recognized as an occupational illness under certain circumstances. The process of confirming this is conducted 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 recognized as a work-related illness if a clear connection can be established between the occupational activity and the illness; AUVA is responsible for the recognition process and for compensation payouts. Once again, specific figures for accident benefits associated with arc eye injuries are not published in detail.
What should you do if you suffer arc eye?
Franz Bichler, welding trainer at Fronius International, explains: “I, too, used to suffer with arc eye. I often underestimated the reflection of arcs from nearby walls when I was in the immediate vicinity of welding work.”
Back then, it was common practice among welders to wash their eyes with sterile saline solution and then apply cloths dipped in cold milk. Today, however, we know that this procedure is absolutely counterproductive as it increases the risk of inflammation, because arc eye causes small scars to form, which can easily become inflamed.
“I recommend consulting a doctor immediately, because you can’t take any risks with arc eye. I know welders who can hardly see anything when they carry out TIG welding, because they haven’t used sufficient protection for years and haven’t seen a doctor,” adds Bichler.
The good news is that injuries usually heal within 24 to 48 hours if treated correctly.
Repeated arc eye
Welders who suffer frequent arc eye will experience chronic eye problems over time, as mentioned earlier on, and will also become increasingly susceptible to further injuries. Over the years, arc eye can massively increase the risk of serious eye diseases such as cataracts.
Conclusion
Frank’s story serves as a warning to all welders: take the risk seriously and protect your eyes. If you do properly protect yourself during your work, you don’t need to worry—with the right protective measures and prompt medical treatment, long-term damage can be effectively avoided. Just stay alert and be sure to keep your eyes safe, because they are your most valuable tool.
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