The Hidden UVC Hazard in Welding: Why Zinc Oxide Matters for Worker Safety

Most people associate UV radiation with sunlight — but some of the most intense UV exposure occurs indoors, in welding bays and industrial workshops.

Arc welding emits extreme levels of UVC radiation, the most dangerous and least understood part of the UV spectrum. Unlike UVA and UVB, which reach us from the sun, UVC is normally filtered out by the atmosphere. In industrial settings, however, it’s generated artificially — and can burn, damage, or even mutate skin cells within seconds.

UVC: The Unseen Threat

Ultraviolet rays affect the skin in different ways. UVB causes redness and surface burns, while UVA penetrates deeper, accelerating ageing and increasing cancer risk without visible warning signs. UVC, however, is far more energetic and damaging — capable of injuring skin cells and DNA almost instantly.

During welding, UVC exposure can exceed safe limits in as little as one or two seconds. Even brief contact can cause “arc burn,” eye inflammation, or long-term cellular damage that contributes to occupational skin cancers. Reflected UVC rays can also reach areas not directly under the arc, such as the sides of the face or neck, compounding the hidden risk.

Beyond PPE: The Case for Zinc Oxide Skin Protection

Welders and metalworkers are trained to wear helmets, gloves, and protective clothing — and these remain the first line of defence. But certain areas, like the lower face and neck, often remain partially exposed. That’s where non-nano zinc oxide-based protection can make a measurable difference.

Zinc oxide is unique among UV filters: it reflects and scatters UVA, UVB, and even UVC, offering the broadest spectrum coverage available. Unlike chemical filters, which absorb radiation and convert it to heat, zinc oxide forms a stable mineral barrier that shields the skin physically — and it doesn’t degrade or lose strength under light exposure. For welders and other high-risk workers, zinc oxide sunscreens are not a substitute for PPE — but they provide an important secondary layer of defence for exposed skin that can’t be fully covered by clothing or masks.

Technical Summary (Evidence-Based Overview)

Occupational research confirms that arc welding produces UVC radiation far above daily exposure limits, even at moderate distances.

Dr Chowdhury (2025) draws on data from multiple peer-reviewed sources and insights from Dr Denis Dudley to report that UVC intensity peaks around 270 nm, where both eye and skin injury can occur almost immediately.

Dr Chowdhury also highlights that non-nano zinc oxide is the only mineral UV filter proven to cover the full UVA and UVB spectrum and to significantly reduce UVC transmission under laboratory conditions.

While zinc oxide cannot replace helmets or protective clothing, its stability, non-absorption, and broad-spectrum performance make it a credible adjunct protection strategy for workers exposed to welding arcs or reflected industrial UV.

The Takeaway

UVC exposure during welding remains one of the most underestimated workplace hazards. PPE should always come first, but non-nano zinc oxide adds a vital final layer of defence for exposed skin.

As understanding of occupational UV risk grows, integrating zinc oxide protection into worker safety protocols is a simple, evidence-based step to help safeguard skin health — both in sunlight and under the arc.

Chowdhury, A. (2025, September 23). UV filters, UVC hazards and photoprotection: What everyone should know. Advance ZincTek. https://www.advancezinctek.com/post/uv-filters-uvc-hazards-and-photoprotection-what-everyone-should-know