WORKPLACE SAFETY
WHAT TO LOOK FOR IN A WELD FUME EXTRACTION SYSTEM
By Nicolas Van der veken,
product manager at Donaldson
W
elding fumes are a mixture of gases and particles that can contain metal oxides and various gases (such as nitrogen oxides or carbon monoxide, depending on the process). Metal particles in weld fumes are 50 to 75 times smaller than the width of a human hair, making them extremely easy to inhale. Exposure to these metal oxides and gas byproducts is widely recognised as a significant hazard for welders. Every facility has a different level of risk, driven by the following factors:
Type of welding process; Base and filler metal used;
Space layout and number of workstations; Implementation of PPEs; and Air movement and ventilation.
Exposure levels can be greatly reduced by effective workspace ventilation. Considerations for ventilation should include:
Local exhaust ventilation (LEV) – also called fume extraction for indoor welding;
Only welding in confined spaces that have proper ventilation; and
Use of natural drafts and positioning the work to avoid exposure where there is no mechanical ventilation.
However, simply relying on natural or forced-air fan ventilation using a fan, opening a window, or even welding outside may not provide adequate protection for operators, particularly in situations
where fume concentrations are high. Fume extraction systems are generally considered more effective for proper ventilation. This equipment draws in contaminated air, filters out particulates and exhausts filtered air outdoors or possibly back indoors. Any particles that settle out in the extractor are collected in waste containers.
In the UK, the Health and Safety Executive (HSE) requires all welding operations to use LEV solutions that capture fumes near the source and draw 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.
FUME LIMITS
Directive 98/24/EC sets minimum requirements for protecting workers from risks related to chemical agents at the workplace but it does not provide specific numerical exposure limits for individual substances, including welding fumes. Instead, it mandates the establishment of occupational exposure limit values (OELVs) and biological limit values. Indicative OELVs (IOELVs) are established by the European Commission, based on scientific evaluation. Binding OELVs (BOELVs) are set through EU legislation (by the European Parliament and the Council, on a Commission proposal). Employers must assess operational risks, implement preventive measures and ensure exposure is minimised. Regular monitoring of chemical agents is required, with immediate action if limit values are exceeded. Fire safety measures, compliant equipment and emergency procedures are essential. Employers must inform and train workers, provide access to safety data sheets and ensure clear identification of hazardous substances. Under the Directive, health surveillance is
16 WINTER/SPRING 2026 | INDUSTRIAL COMPLIANCE
mandatory for workers exposed to chemical agents with binding biological limit values, with derogations from prohibitions allowed in special circumstances. The employer must also review and update risk assessments.
Directive 2004/37/EC establishes occupational exposure limit values for certain carcinogens and mutagens. However, it does not explicitly provide specific numerical limits for welding fumes. Instead, the directive categorises welding fumes containing carcinogenic substances as hazardous and outlines general principles for their prevention and control. Employers must assess the risks associated with exposure, implement preventive measures and ensure exposure is minimised to the greatest extent technically feasible.
WELD FUME VOLUME CONSIDERATIONS
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 (e.g., 24/7 operation or full-shift welding) is likely to generate higher fume volumes. This 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 fume extractor, which can be turned on and off depending on demand.
LOCATION CONSIDERATIONS
When assessing fume generation points and evaluating what your facility layout permits regarding equipment placement, a commonly effective approach involves removing contaminants as near as possible to their origin. Source-level
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