Welding Fume Extractors

High-quality Extraction equipment will protect your employees and it is not costly. We are happy to discuss part exchanges on any extractors including  Nederman, Kemper and Plymovent that you may have to dispose of after a visit from the HSE.  We can also arrange the LEV and TExT certification on any fume extractor purchased from us and remind you of your obligation every 14 months to get re-tested.

Welding creates hazardous fumes that can be dangerous for the welder. So weld fume extractors are a must for a safe work environment. Certain fumes can cause cancer and other harmful, long-term effects. Reducing these risks wherever possible will improve your working conditions and employee satisfaction. Keep your welders safe from harmful welding fumes by reading HSE Safety Alert.

Why are welding fume extractors necessary?

Chemicals in the fumes given off when welding can cause all sorts of health issues. From irritation and bronchitis in the short term, to lung cancer and chronic respiratory problems after long exposure. Weld fume can also cause heart disease, skin diseases and other illnesses.
These chemicals cause problems because the fumes they give off are toxic. Some of these chemicals are cancer causing and include arsenic and nickel.
The ultraviolet radiation produced by these welding chemicals and those in the air (O2 and N2) releases other fumes also.
This can form ozone and nitrogen oxides which, after a large amount has formed, can be deadly.
Fume extractors for welding cut the risk by removing imposing fumes before inhalation. Reducing exposure to these chemicals lowers the chance of any serious medical conditions that could arise.
Such health and safety measures in the workplace can increase the strength and productivity of your workforce. In turn, reducing the current 160 hour average yearly sick leave of a welder.

Welding Fume Extraction Systems and Procedures

Every year, thousands of workers in Britain develop occupational diseases. Many of these are from breathing in certain dust, fume or other airborne contaminants at work.
Local Exhaust Ventilation (LEV), often called dust and/or fume extraction, remove these harmful particles. Thus cleaning the air before people breathe in these harmful substances.
Research shows that welders are at risk to a serious infectious disease from welding fumes. 

HSE review and publish guidelines to protect your workers. Take a look at the current guide for welding fumes here.

Ventilation problems

HSE suggest that for ambient indoor conditions, the volume of fresh air supply shouldn't fall below 0.28m³ per person per minute.
This rate of air exchange is natural in most circumstances.
In buildings where welding takes place, temperature control and airborne contamination are issues.
The quantity of fresh air required now increases.
The sole use of general ventilation for airborne pollutant control in welding is usually ineffective. This leads to expensive heat loss.
Airborne contaminant capture is more efficient as close to the source as possible. Local extraction is the principal recommended method of fume control in the welding industry.
The theory, types and application of local extraction are discussed at length in many publications.
For more detailed study, you can find these on Google.
This module deals with local extraction as an aspect of safety in welding. Topics include when it is needed, types of equipment available, and when local extraction alone may prove inadequate.

Fume hazards - What is fume?

The term welding fume relates to the minute particles emitted during fusion welding. Some gases are also generated or released, and these also form part of the 'welding fume'.
Fume extraction equipment captures polluted air containing both gases and particles. Thus the term 'fume' refers to any atmospheric pollution arising from the arc.

Hazards

All atmospheric contaminants are potentially detrimental to health. Some substances, particulate or gaseous, are more toxic than others. The Control of Substances Hazardous to Health Regulations (COSHH) require employers to assess the risks. From there, adopting measures to ensure that employees aren't exposed to unacceptable levels of hazardous substances at work.
The Health and Safety Executive (HSE) publishes a list of "safe" exposure limits for many substances. Entitled Occupational Exposure Limits EH40, this includes welding fume.
HSE recommends that for welding fume, suitable fume extraction should be in use. So reducing exposure in the workplace.
Below are the principles involved in selection and use of fume extraction equipment. Read in association with HSE's Guidance Note EH55 The Control of Exposure to Fume from Welding, Brazing and Similar Processes.

When is fume extraction equipment necessary?

Measuring actual weld fume concentration helps to determine exposure levels. Whether that is of the welder or others working in the vicinity. It shows when levels are to exceed the Occupational Exposure Levels (OELs) allowed in EH40. This is when fume extraction is required.
BS EN ISO 10882 parts 1 & 2 Fume from Welding and Allied Processes gives methods for sampling and analysis. This is for both particulate and gaseous fume.
Yet there are many situations where experience shows that extraction is necessary to ensure safe working conditions.
For example, carrying out open-arc processes in a workshop environment or confined space. Including MMA, MIG, MAG, flux-cored, plasma welding, arc gouging and cutting processes, brazing and soldering etc.
The amount of fume generated and the toxicity hazards to welders depend upon a wide range of factors. These include:

• material type
• process parameters (increasing energy input to the process increases fume)
• duration and frequency of the actual process in operation
  
• operating position and location
• general ventilation and air movements in the area

As a general guide, any shop-based welder arcing on steel on a bench, or in the flat or downward position for more than two minutes in every ten with MMA or MIG at currents in excess of 170A is likely to need extraction.
Extraction is also needed to prevent general build up of fume in the workshop.
Like where many welders are working (even if individually), exposure shouldn't exceed low Time Weighted Average (TWA) concentrations.
The usual limiting OEL for welding steels is 5mg/m3, for the total fumes. For welding stainless steels and other alloys, the limiting safe OEL for one of the constituents may be so low that the total fume level has to be reduced.

Confused? Then why not let us visit, inspection and advise the most suitable welding fume extractor for your workshop and staff.

How to Reduce Exposure to Fume Hazards.

The questions for consideration are:

• Can an alternative joining process be devised or substituted that gives less fume?
• Can the welder be positioned so as to be remote from the fume?
• Can welding be arranged to take place within a fixed capture hood/booth system?

If the answers to the above are negative, then you will need local extraction (LEV). Filter masks and air-fed systems for the operator are last resorts, or usable as extra safeguards.

Fixed equipment or portable fan units?

You can move Portable fume extractor fans close to the arcing position. This reduces the length of the flexible hose required and ensures maximum efficiency. 
Mobile fume extraction filters are suitable for one operator. Though you can affix several arms fixed to a fan, allowing welders to work near to each other. This will reduce vacuum performance. Extraction filters need careful monitoring to ensure they have not become blocked. Thus rendering the extraction system ineffective and discharging polluted air into the workshop. 

Before purchasing, you should consider whether you need direct exhaust to the external atmosphere or to the shop via filter.

If Westermans International provide a quotation, we can also arrange an inspection of your workshop.
This means we can quote the type and numbers of dust and fume extractors needed to follow current regulations.

Disposal of fume dust collected by extraction system filters

Under current discharge of welding fume into the atmosphere is permitted; provided it does not cause a nuisance to others.
Welding is not a prescribed process that needs notifying to the Environment Agency.
But when welding fume is collected into a filter or another container, it is hazardous. People in the area are at risk if any dust is dislodged or allowed to escape into breathing zones.
This is particularly true when the welding fume contains significant levels of toxic dusts.
For example, hexavalent chromium, barium oxide (from self-shielding flux-cored wires) or copper oxide. There are other such substances that have low OELs quoted in EH40.
It is necessary to arrange and put in place a 'safe system of work' to cover the collection, removal and handling of the collected particle waste. You may need to provide appropriate PPE for operators collecting or transferring used filters to the safety of a sealed bag or container.

Legal requirements

Although all the requirements feature under the Health and Safety at Work Act Section 2, specific sections of COSHH also apply.
For example, under Regulation 7, employers must ensure employees exposure to fume is prevented or adequately controlled. Lots of useful information can be accessed from our Blog or the HSE as to the correct solution for you.
Again, we can arrange an inspection of your workshop and site to give safe and current advice.  You will also need to have these units LEV tested on site when first installed and every 14 months after that.  If we arrange this we will provide a certificate to prove compliance.

Welding and cutting

Welding fume extraction for sound, safe and efficient metal fabrication and cutting processes.
Welding and cutting fumes cause health problems and negatively affect production. The result is reduced capacity, re-occurring disturbances and eventually decreased profit.
Not only welders are at risk in unsafe environments.
The production equipment, as well as end products, are negatively affected from the lack of adequate safety measures.
Automated welding equipment such as robots, and the operators, can be subject to residual welding fumes and also need to be protected. Good safety and health is good business.
Benefits of having adequate fume and dust extraction systems in place include:

• Improve workplace environment
• Protect your workers health
• Protect equipment and processes
• Reduce production disturbances

All of these lead to improved staff retention and work rates, thus improving bottom line.