HEALTH & SAFETY
Conversion There is no need to change your current working set-up in order to implement fume extraction. You can use the same processes, protocols and systems you were previously using for your MIG/MAG welding torches and seamlessly integrate fume extraction. A general rule is that the higher the
Galvanised steel
Galvanised steel is another hazardous material where it is important to extract the harmful welding fumes produced during the welding process. When zinc is welded, for example, it releases zinc oxide fumes that can cause fume metal fever like exposure to manganese, copper or beryllium does, and damage the respiratory system. Other metals such as lead, that can be used like zinc as a coating on certain metals, can even damage the central nervous system.
Aluminium When aluminium is welded, aluminium
oxide is released, which can lead to respiratory and lung disease when inhaled. In the worst case, aluminium pneumoconiosis can occur. As so-called A-dust, these particles get into the lung alveoli and change lung tissue, even shrinking the tissue affected. Lung cancer can be a long-term consequence of this. In addition, an increased amount of ozone is produced during the welding of aluminium under UV radiation; this is also harmful to health. Often, aluminium is welded with
push-pull torches, because the wire is very malleable when compared with steel wire. There are no push-pull torches with integrated welding fume extraction available yet, but they can be ideally equipped with a fume extraction kit such as the fume extraction kit from Abicor Binzel. This is simply clamped to the torch neck so that the fumes can be extracted at their source. A further alternative for extraction
when a push-pull torch is used is the xFUME FLEX extraction system, the flexible extraction arm of which can be positioned above the welding process.
36 / WELDING WORLD MAGAZINE - ISSUE 02 - MARCH 2024
amperage used, the more harmful are the welding fumes emitted into the ambient air. Accordingly, during some welding processes more fumes are produced than during others. It is necessary to purchase new equipment to implement fume extraction. Ideally, you need a fume extraction system and a fume extraction torch in order to achieve the best possible solution with extraction at the source. If welding fume extraction at the source
is not an option for you, systems with extraction arms offer a further solution. Ideally, the welding fume extraction system should get as close as possible to the source to prevent the welding fumes from spreading. The closer welding fume extraction is to the ‘source’ the better. Professional respiratory masks can
provide additional protection and supplement an extraction arm. When choosing a respiratory mask, care must be taken that it has been approved for the European market. For this to be guaranteed, it must have CE certification and an EC Declaration of Conformity. Respiratory masks are personal protective equipment (PPE) and belong to category 3. Usually, half-masks, powered air- purifying respirators (APR) and supplied- air respirators (SAR), that are independent of the ambient air, are considered when dealing with welding fumes. When using these respiratory masks,
remember that cartridges and filters have to match the respective pollutant they are protecting against and have
to be changed periodically. However, respiratory devices are usually a last resort solution and, according to the European Centre for Disease Control (ECDC), should be used when fume extraction torches and systems are not feasible.
Options There are different options available
for extracting welding fumes. A basic distinction can be made here between two extraction systems: high vacuum systems and low vacuum systems. The terms high vacuum systems and
low vacuum systems refer specifically to the static pressure. In a high vacuum system, there is a low volume flow at higher static vacuum. Since static pressure and air speed are higher, a large hood or bracket is not required for a high vacuum system. You are closer to the source of fume generation than with ventilation by a large hood at low pressure. With a low vacuum system, there
is a high volume flow at lower static pressure. In terms of fume extraction during welding, this means that larger quantities of air have to be moved.
Central fume extraction Stationary systems are more or less
maintenance-free for the welders themselves, servicing is the responsibility of the plant management. This means welders have more time for welding. Performance is reliable and stable. Central fume extraction stations almost always have a larger motor and filter that has to be changed less frequently. The fume extraction torch is simply connected to the central system and work can begin. Even if you have a large plant with more than 40 mobile welding stations, there is a system available that can accommodate these requirements. In addition, there is also less noise for the welders since the extraction system is further away. The disadvantage of central extraction
systems is that a high initial investment is required. These systems require a lot of upfront capital because of the work involved in getting the system up and running and the consultation required to introduce the system. The high operational costs have to be considered, too, since the circulation of large air masses consumes a considerable amount of energy.
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