OBJECTIVE This work was intended to clarify the extent of exposure of workers occupationally exposed to N-nitrosodiethanolamine (NDELA), a carcinogenic nitrosamine, while working with aqueous metalworking fluids (MWFs) formulated with ("nitrite-formulated") or without ("nitrite-free") nitrite and to study the relationships between the nitrite and NDELA content of the MWFs as well as between the concentration of NDELA in MWFs and in urine. METHODS Pre-shift and post-shift urine samples from 100 workers directly exposed to MWFs in 15 factories were analysed for NDELA with chemiluminescent detection (TEA) according to a previously described analytical procedure. The method was also applied to eight indirectly exposed workers and to 48 unexposed subjects. The NDELA and concentrations in 84 fluids used by the workers were also determined. RESULTS No detectable NDELA could be observed in the control group. The mean post-shift NDELA excretion in workers exposed to "nitrite-formulated" and "nitrite-free" MWFs were 44.6 and 0.4 microg/l, with maxima of 277 and 2.7 microg/l, respectively. According to the correlation between the nitrite and NDELA concentrations in "nitrite-free" MWFs, there is a low probability of fluids exceeding 5 mg/l NDELA when the nitrite content does not exceed 20 mg/l. The NDELA concentrations in the fluids and urine were found to be highly correlated, particularly after correction for creatinine (r=0.917 in post-shift samples). Cutaneous contact probably contributes, at least in part, to the overall body uptake of NDELA: CONCLUSIONS Due to clear evidence of urinary NDELA excretion in workers exposed to contaminated MWFs, and despite a lack of knowledge of the human risk following NDELA exposure, levels of NDELA in MWFs should be kept as low as possible. NDELA fluid concentrations of less than 1 mg/l must be considered as the objective to be attained, even if the limit of 5 mg/l is temporarily satisfactory and consistent with a nitrite limit of 20 mg/l that is easy to verify with inexpensive colorimetric tests. "Nitrite-formulated" fluids, still sometimes used, should be prohibited. Meanwhile, the material safety data sheets (MSDS) of commercially available products should be clearly labelled to indicate their nitrite content.