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Complete Guide for Welding Fume Extraction
What is welding fume?
Welding fumes are hazardous airborne particles and gases produced when metals are heated and fused during welding. These fumes, a complex mixture of metallic oxides, silicates, and fluorides, pose significant health risks if inhaled.
The exact components of welding fumes can vary depending on the welding process, the material being welded, and the coatings or contaminants on the materials if any. Common particles in welding fumes may include metal particles, oxides, flux and coatings, and gasses. Metal particles can include iron, chromium, nickel manganese, copper, aluminium, and other elements present in the base metal or filler material.
Depending on the material you are going to weld, the level of danger will vary. For instance, metals like cadmium, lead-coated steel, stainless steel, nickel, chrome, zinc, and copper are considered particularly dangerous to weld due to the highly toxic fumes they produce. For these types of metals, welding fume extraction units are mandatory to remove the danger and ensure that the welder is safe during the process.
| Substance | OSHA PEL (mg/m3) | NIOSH REL (mg/m3) | ACGIH TLV (mg/m3) | Notes |
|---|---|---|---|---|
| Total Weld Fume | 5 | 5 | 3 | respirable fraction |
| Aluminum & Aluminum Oxide | 15 (total), 5 (resp) | 10 (total), 5 (resp) | 1 | respirable particulate matter |
| Copper & Copper Oxide | 0.1 (fume) | 0.1 (fume) | 0.1 (fume) | fume |
| Manganese | 5 | 1 | 0.2 | |
| Nickel & Nickel Oxide | 1 | 1.5 | 0.5 | |
| Tungsten | 5 | 5 | 3 | respirable particulate matter |
| Zinc Oxide | 5 | 5 | 2 | respirable fraction |
What are the health risks from welding fumes?
Exposure to welding fumes poses severe health risks, including lung and kidney cancer, as confirmed by the International Agency for Research on Cancer and the HSE. Even mild steel welding fumes are now classified as carcinogenic, underscoring the necessity of effective welding fume extraction.
Inhaling welding fumes can cause immediate symptoms like nausea and dizziness and lead to acute illnesses while chronic diseases can gradually develop. The Health and Safety Executive (HSE) has estimated that 40-50 welders are hospitalised each year from breathing metal fumes at work.
Chronic effects from exposure to welding fumes develop gradually leading to serious diseases such as Chronic Obstructive Pulmonary Disease (COPD), Occupational Asthma, and Asphyxiation. Certain elements present in the welding fume such as hexavalent, chromium, nickel and cobalt, can increase the risk of respiratory diseases and other adverse health conditions.
HSE Regulations
Health and Safety Executive (HSE) is a regulatory body in the UK responsible for promoting and enforcing health, safety, and welfare in the workplace. HSE introduced new regulations after the scientific evidence highlighted the serious health risks associated with exposure to welding fumes, and the Workplace Health Expert Committee endorsed the reclassification of mild steel welding fume as a human carcinogen.
HSE regulations outline the necessary guidelines and requirements for controlling and managing welding fume exposure to protect workers. Recognizing that general ventilation does not provide adequate control, the HSE has issued new enforcement expectations applicable to all welding fumes, including those from mild steel.
HSE issued the directives that all indoor welding activities should ensure effective engineering controls such as Local Exhaust Ventilation (LEV) to control welding fumes arising from the welding process. In cases where engineering controls are not adequate to control all welding fume exposure then adequate and suitable respiratory protective equipment (RPE) is also required to provide the required protection.
For all outdoor welding, appropriate Respiratory Protective Equipment (RPE) is mandatory, and employers must ensure welders receive thorough training on its correct use. Given that no safe level of exposure to welding fumes has been identified, the HSE mandates that suitable control measures be implemented to protect workers, irrespective of exposure duration.
HSE has published numerous guidance sheets to help you in defining the appropriate controls. You can read HSE’s WL3: Welding Fume Control guidance that explains good control practices for various welding tasks.
Consequences of breaching HSE regulations
Failure to adequately protect workers from harmful welding fumes can lead to serious consequences. The HSE, may issue warnings, impose fines, or, in severe cases, pursue imprisonment for breaches of health and safety regulations.
LEV Testing
Employers are legally mandated to assess and protect their employees from hazardous substances like dust, fumes, and vapors. Where controls include a Local Exhaust Ventilation (LEV) system, regular maintenance and testing are essential, with a minimum requirement of testing at least every 14 months, to verify its effectiveness in providing the necessary protection.
You can read more about LEV testing on the HSE website: https://www.hse.gov.uk/lev/faqs.htm
What is Welding Fume Extraction?
Welding fume extraction is a critical process for safeguarding welders and those in the surrounding area by capturing and removing hazardous contaminants generated during welding. When metals are heated to high temperatures during welding, they release a complex mixture of gases, vapors, and particulates, all of which pose significant health risks. Effective welding fume extraction systems are essential for maintaining a safe working environment and complying with UK Health and Safety Executive (HSE) regulations.
The precise composition of welding fumes varies depending on several factors, including the welding process, the base metal being used, and the presence of any surface coatings. Typically, these fumes contain a range of harmful substances, including metallic oxides, silicates, and fluorides in particulate form, as well as hazardous gases such as carbon monoxide, ozone, and nitrogen oxides. Understanding the specific components of welding fumes is crucial for selecting the appropriate extraction system and ensuring adequate worker protection.
Welding fume extraction systems play a vital role in mitigating the risks associated with exposure to these hazardous substances. By effectively capturing and removing welding fumes at the source, these systems minimize the exposure of welders and other personnel to harmful particulates and gases. This not only helps to prevent short-term health issues but also reduces the risk of long-term occupational diseases, creating a safer and healthier working environment that adheres to UK HSE standards.
What is Local Exhaust Ventilation (LEV)?
Local Exhaust Ventilation (LEV) is a crucial engineering control system designed to capture and remove welding fumes at their source, directly during the welding process. In the UK, the Health and Safety Executive (HSE) mandates LEV as a primary method for controlling welding fume exposure. LEV systems function by extracting fumes directly from the welding torch or the immediate work area, effectively preventing welders from inhaling harmful contaminants and minimizing their dispersion into the wider workspace.
A variety of LEV systems are available to suit different welding applications and workplace environments. These include mobile welding fume extraction units, on-torch fume extraction systems, and Welding Fume On Torch Extraction Packages. Selecting the appropriate LEV system requires a thorough risk assessment, considering factors such as the specific welding process, the materials being welded, the potential health effects of the fumes, and the typical exposure patterns within the workplace. Consulting HSE guidance and industry best practices is essential for making an informed decision.
What are mobile fume extraction units?
Mobile fume extraction units are standalone LEV systems that offer flexibility due to their high mobility, making them an ideal solution for every changing workplace. They are often mounted on wheels or skids for easy mobility within a workshop and welding workstations.
Fume extraction units are equipped with disposable filters or cleanable filters to remove contaminants and particulates from the extracted air. The filtration system inside the unit will typically consist of a mechanical filter such as HEPA (High-Efficiency Particulate Air) filter or other suitable filters.
Mobile fume extraction units utilize a built-in fan or blower to generate negative pressure, which draws welding fumes into the system through a capture hood or suction inlet. The capture hood or inlet is strategically positioned as close as possible to the welding activity to maximize fume capture at the source, preventing the spread of contaminants.
Typically, mobile fume extraction units are equipped with flexible, adjustable welding fume extraction arms. These arms allow for easy and effortless adjustment, enabling the operator to position the capture hood precisely where it's needed. Extraction arms are often extendable, providing a variable reach to accommodate different welding setups and work areas.
To optimize the performance of a mobile fume extraction unit, it's recommended to minimize cross-drafts in the welding area. This can be achieved by using welding curtains or screens to create a partial enclosure, preventing air currents from diverting fumes away from the capture hood and ensuring effective extraction. Adhering to manufacturer guidelines and HSE recommendations for positioning and usage is also crucial for maximizing the unit's effectiveness and maintaining a safe working environment.
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What are portable welding fume extractors?
Portable welding fume extractors are compact and lightweight fume extraction systems designed for localized control of welding fumes. These units are engineered for easy transport, allowing them to be conveniently carried to the immediate welding area, making them suitable for situations where mobility is paramount.
While portable fume extractors generally offer lower airflow capacity compared to mobile units, they are well-suited for temporary welding tasks, maintenance work, and low-to-medium duty cycle operations. Their size and portability make them a practical choice for smaller workshops, construction sites, repair shops, and other settings where welding is performed on a smaller scale or in confined spaces.
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What is On-Torch Fume Extraction?
On-torch fume extraction involves a specially designed welding torch with a fume extraction system directly integrated into the welding torch. It is also known as On Torch Fume Extraction or integrated fume extraction.
The on-torch system features a built-in extraction nozzle or suction chamber positioned close to the welding arc. This allows for the direct capture of fumes as they are generated. The extracted fumes are then drawn through a flexible hose or extraction tube to a fume extraction unit. This unit contains a fan to create suction and a filter system to remove contaminants before the air is either recirculated or exhausted.
To learn more check out On Torch Fume Extraction vs Mobile Fume Extraction.
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What is Respiratory Protective Equipment (RPE)?
Respiratory Protective Equipment (RPE) is a vital form of Personal Protective Equipment (PPE) designed to protect individuals from inhaling hazardous substances and airborne contaminants, including welding fumes. In the UK, the Health and Safety Executive (HSE) mandates the use of appropriate RPE in situations where Local Exhaust Ventilation (LEV) alone cannot adequately control exposure to these risks.
RPE encompasses respirators and breathing apparatus, both of which are designed to filter or supply clean air. Respirators utilize filters to remove contaminants from inhaled air and are available in two main types: non-powered and powered.
Dust masks & respirators rely on the wearer's breathing to draw air through the filter, while powered respirators use a motor to force air through the filter, providing a continuous flow of clean air.
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HSE recommends use of RPE where engineering controls are not adequate to control exposure to all welding fumes. Air fed welding helmets equipped with PAPR provide another layer of protection to the welder from welding fumes. Powered Air Purifying Respirator (PAPR) is a type of RPE commonly used in welding to protect the wearer from hazardous fumes, gasses, and particles generated during the welding process.