SAFETY & HAZARDOUS AREAS
FROM SPARKS TO SAFETY: HOW WELD FUME EXTRACTION SYSTEMS PROTECT WORKERS
Nicolas Van der veken, from
Donaldson
Nicolas Van der veken, Product Manager at Donaldson, discusses ways in which to optimise welding fume extraction from the workspace
elding fumes are a mixture of gases and particles that can contain metal oxides and various gases, and exposure is widely recognised as a significant hazard for welders. Exposure levels can be greatly reduced by effective workspace ventilation. However, relying on natural or forced-air fan ventilation may not provide adequate protection.
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The Health and Safety Executive requires all welding operations to use local exhaust ventilation solutions that capture fumes near the source, drawing them away from the welder's breathing zone and into a filtration system. The filtration system removes the hazardous substances from the fumes, and the clean air is then returned to the work area. The key is to equip a facility with filters designed to support consistent ventilation performance and help reduce downtime. When choosing a weld fume extraction system, it is important to assess the duty cycle and the expected particulate load a fume extractor must manage. For example, continuous or long-duration welding may call for continuously operating extractor units that have self-cleaning functions, and for long- lasting filters to help reduce downtime. Robotic welding will also produce substantial fume volumes and may require comparable system capabilities. Alternatively, for manual welding, where weld stations are used only on an intermittent basis, an appropriate option may be a small mobile
10 MARCH 2026 | PROCESS & CONTROL
fume extractor, which can be turned on and off depending on demand.
Source-level extraction equips individual weld stations with dedicated collection hoods and articulating arms, which are designed to capture emissions directly at their point of creation.
However, certain spatial limitations may make this impractical, so general ventilation can serve as an alternative solution, with an ambient collector drawing fumes from the wider workspace rather than from each station. The frequency with which you modify your operational layout also represents another consideration. General ventilation may not need to be reconfigured when you change your layout, maintaining its effectiveness regardless of workspace reconfiguration, whereas source extraction must be repositioned alongside the welding apparatus it serves.
Filtration equipment considerations The choice of filters to be used in an extraction system is important. For example, pleated filters are easy to change and provide maximum particle-holding capacity in a compact footprint. As the filter media traps dust on the surface, a fume collector with a self-cleaning function, where compressed air pulses the filters clean during operation, will extend filter life. There are also specific filters that are designed for sub-micron weld fumes. Most collectors include a differential pressure
indicator that can assist in identifying basic maintenance needs, such as potential filter issues or change-outs. As pressure drop increases, the system must work harder to pull air through the filters. So, monitoring your collector’s differential pressure readings can support more informed operational decisions. If differential pressure is at the high end, the equipment’s self-cleaning function turns on and uses compressed air to pulse dust off the filters. When pulsing no longer restores normal differential pressure, the filters should be replaced. Using a remote monitoring service can quickly identify and flag these incidents for quick action. If you believe your filters are delivering shorter life than you expected, it may be time to evaluate and upgrade the filter media in your extractor.
Noise exposure is another important consideration, particularly since welding activities often include grinding. A pulsing unit positioned close to operators may contribute to noise levels, but the use of appropriate ducting often means that the collector can be located outside the main work area to help reduce exposure. Also, smaller individual collectors can sometimes be configured to pulse only at the end of the working day, which may further limit noise during operations. Industrial hygiene professionals can help you to identify applicable exposure limits, collect air samples, review your processes and support you in developing your risk management strategy. Air quality experts can support you with monitoring emissions, or you can use a particulate monitor to test the discharged air. When it comes to the extraction system, an industrial filtration expert can assist you in selecting filtration equipment that effectively supports dust and weld fume collection as a part of a broader engineering control strategy. Once installed, monitoring and maintenance are critical for system performance, which supports filter replacement at the appropriate times to optimise weld fume extraction. *This information is provided for general guidance only and should not be considered legal, regulatory, or technical advice.
Donaldson
www.donaldson.com
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