Humidity and Ventricular Fibrillation: When Wet Welding can be Fatal

Arc welding is generally considered very safe electrically. There have been electrocution cases with welders in high humidity environments. When dry, the flux coatings tend to have sufficient electrical resistance to limit the current below that required for the induction of VF (ventricular fibrillation).

We tested 4 welding electrodes for resistance in both dry and wet conditions. To estimate the cardiac current density - in a worst-case scenario - we used a 20k element finite-element bioimpedance model with 1 cm of skin and fat along with 1 cm of muscle before the heart of 5 cm dimensions. Between the heart and a metal plate we assumed 5 cm of lung and 1 cm of skin and fat.

Welding electrode flux is highly resistive when dry. However, when saturated with moisture the resistance is almost negligible as far as dangerous currents in a human. The FEM model calculated a current density of > 7 mA/cm² on the ventricular epicardium with a source of 80 V at the welding rod.

In conditions of high humidity, a supine operator, in contact with a coated welding electrode to the precordial region of the body can be fibrillated with the AC open-circuit voltage. Most reported DC fatalities were probably due to pseudo-DC outputs that were merely rectified AC without smoothing.