Introduction: Little information is present regarding health impact of copper and zinc exposure among metal die casting workers in Egyptian foundries. Aim of work: 1-To measure blood levels of zinc and copper among the studied groups, 2- To measure the prevalence of respiratory hazards among exposed workers and their impact, 3-To identify other health problems due to copper and zinc exposure such as anemia and respiratory disorders, and lastly 4- To correlate such problems with blood levels of zinc and copper. Material and Methods: A comparative cross-sectional study was conducted among 60 male workers, 30 of them were the exposed group involved in processes like melting. The other 30 were chosen from the administrative departments in the same foundry as the reference group. All workers were interviewed using questionnaire for occupational history, respiratory and other symptoms. Blood samples were taken to measure serum copper and zinc, hemoglobin (Hb), and white blood cells counts (WBCs). Ventilatory functions were assessed too. Results: The study showed no significant difference in the blood levels of zinc and copper among the studied groups. However, symptoms related to copper and zinc toxicity were significantly more prevalent among the exposed group, like respiratory symptoms, symptoms regarding skin, throat and eye irritation, metallic taste in the mouth and exhaustion. Symptoms suggestive of metal fume fever including flue like symptoms, arthralgia, fever, and leukocytosis were more prevalent among the exposed workers, but without significant difference. There was no significant correlation between copper and zinc blood levels and other findings such as; Saint George Respiratory Questionnaire scores, Peak Expiratory Flow Rate scores, mean Hb, and WBCs level. Conclusion: Although there was no significant difference in blood levels of zinc and copper among the studied groups, exposed workers were complaining of different symptoms, one of which was respiratory symptoms that had a significant impact on their social and psychological functioning.