The Council of the European Union has formally adopted revised workplace safety legislation introducing stricter limits on workers’ exposure to potentially dangerous chemicals, including substances used in battery manufacturing, metal production and the chemical industry.

The decision, announced on Monday, 19th October, completes the Council’s approval of the sixth revision of the EU’s Carcinogens, Mutagens and Reprotoxic Substances Directive. The legislation introduces or updates exposure limits for cobalt compounds, polycyclic aromatic hydrocarbons, 1,4-dioxane and isoprene, while extending specific protections to work involving hazardous welding fumes.

According to the Council’s announcement, the measures could prevent approximately 1,700 cases of lung cancer and 19,000 other work-related illnesses across the European Union over 40 years.

New exposure limits for industrial substances

The legislation addresses chemicals encountered in industries that remain important to European manufacturing and industrial employment.

Cobalt and its inorganic compounds are used in several industrial applications, including certain battery technologies, metal processing and specialist manufacturing.

Exposure to cobalt-containing dust and fumes can occur during production processes, particularly where workers handle powders or undertake activities that generate airborne particles.

Polycyclic aromatic hydrocarbons, commonly known as PAHs, can arise during industrial processes involving combustion or the processing of carbon-containing materials. Workers in parts of the steel, aluminium and carbon industries may encounter these compounds.

The new legislation also covers 1,4-dioxane, a chemical used in industrial production processes, including applications connected with chemical and textile manufacturing.

Isoprene was added to the revised framework during negotiations between the Council and European Parliament. The substance is used in the manufacture of synthetic rubber and other industrial products.

Exposure limits establish the maximum permissible concentration of specified hazardous substances in workplace air, subject to the measurement methods and averaging periods laid down in the legislation.

Employers must also apply wider preventive measures, which can include replacing hazardous substances where technically possible, improving ventilation, containing industrial processes and monitoring workplace exposure.

Welding fumes brought within revised framework

One of the significant changes concerns welding fumes, which can contain hazardous substances depending on the materials and processes involved.

Welding is used extensively in construction, automotive production, shipbuilding, infrastructure maintenance and the manufacture of industrial equipment.

Workers may be exposed to mixtures of particles and gases produced when metals are heated, melted or joined.

The revised directive adds relevant welding fumes to the list of substances, mixtures and industrial processes subject to specific requirements under EU occupational safety legislation.

This is particularly relevant where the fumes contain substances classified as carcinogenic, mutagenic or harmful to reproduction.

The legislation does not prohibit welding. Instead, it establishes a clearer legal framework for assessing and reducing occupational exposure.

European institutions have also recognised the need for additional practical guidance to assist employers in applying the new provisions across industries using different welding technologies and materials.

The agreement reached by Parliament and Council in June included provisions addressing protective equipment and the conditions under which it should be used.

Industry granted transition periods

The legislation was negotiated against concerns that some manufacturers would require substantial investment to comply with the revised exposure limits.

Industrial employers may need to install extraction systems, improve ventilation, adapt production equipment or introduce additional monitoring arrangements.

For certain substances, the final compromise therefore includes transitional periods intended to give affected sectors time to make the necessary changes.

The agreed period for the application of new limits on polycyclic aromatic hydrocarbons extends to seven years, with provisions covering carbon and graphite manufacturers.

This was one of the modifications introduced during negotiations to balance occupational health requirements with the technical constraints facing individual industries.

The agreement also provides for regular breaks for workers required to wear personal protective equipment and clarifies how those measures interact with existing EU legislation.

Protective equipment remains part of the safety framework, although the directive also recognises the importance of preventing exposure through engineering controls and improved working practices.

Health and economic implications

The European Commission estimates that more than 2.5 million workers could be exposed to the substances or processes covered by the revision.

Occupational illnesses can produce substantial costs for workers, employers and public health systems, including treatment expenses, sickness absence, reduced productivity and long-term disability.

The Commission previously estimated that the updated legislation could generate up to €1.16 billion in healthcare savings over the coming decades.

These figures are projections derived from assessments of expected exposure reductions rather than outcomes already achieved.

Their accuracy will depend on how effectively Member States implement the legislation and how consistently employers comply with the new requirements.

The measures also form part of the EU’s broader programme to reduce workplace exposure to substances associated with cancer and other serious illnesses.

Two years for national implementation

The directive will enter into force following publication in the Official Journal of the European Union. Member States will then have two years to transpose its provisions into national law.

National authorities will remain responsible for inspections and enforcement, while employers will need to assess which new requirements apply to their operations.

For businesses operating across several EU countries, the revised framework is intended to provide more consistent standards, although national enforcement arrangements may differ.

The practical effects will be most apparent in industrial workplaces where airborne chemical exposure remains a routine occupational risk. Compliance will require manufacturers to examine their production processes before the new requirements become enforceable.