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Thermal degradation of water-based metalworking fluids (MWFs) produces carcinogen by-products. Since different additives have been used to eliminate hazardous material, the carcinogenic potential of two water-based MWFs was investigated in the lung epithelial cell line (A549). Two MWF types were studied in pure and on-used. The chemical content of all samples was assessed by gas chromatography–mass spectrometry (GC-MS). DNA damage of samples was evaluated in the doses range of 0.05–0.8 mg by comet assay. Comet images were analyzed with Open comet software. Amine borate and ethanolamine were found in B and C fluids respectively. Pyridazine compound by the potency of nitrosamine production was found in on-used C fluid. After using MWFs in the metal processing, a polycyclic component with bore central groups was produced in on-used B fluid. DNA damage of on-used fluid with boron component occurred at a level lower than ethyl amine-containing fluid. Moreover, the genotoxicity of air samples in B fluid was higher than C airborne samples significantly. More careful management have to be considered for the replacement of amine corrosion inhibitors with boron-containing chemical in MWFs. In conclusion design of a plan was required for the control of high-risk chemicals in the metal processing industry.

DNA breaks evaluation of two water-based metalworking fluids by an occupational exposure design