Why Welding-Fume Controls Are Essential

Exposure to welding fumes can cause occupational asthma, lung disease and cancer. This includes fumes produced when welding mild steel.

Under the Control of Substances Hazardous to Health Regulations (COSHH), employers must assess the risks and introduce effective controls. Welding should not be undertaken without suitable exposure-control measures, regardless of how short the task may be.

Use Local Exhaust Ventilation to Capture Welding Fumes

Local exhaust ventilation (LEV) is one of the most important controls for indoor welding. It captures hazardous fumes close to the point where they are produced, preventing them from spreading into the welder’s breathing zone or around the workplace.

Types of Welding-Fume Extraction

Suitable LEV equipment may include:

• On-torch extraction systems
• Fume-extraction welding guns
• Portable extraction units
• Moveable extraction arms
• Fixed extraction hoods

Position Extraction Equipment Correctly

Before welding begins, the extraction hood or nozzle must be positioned close enough to the weld to capture the fume effectively without interfering with the work.

Poor positioning is one of the most common reasons for LEV failing to protect a welder. The extraction should be repositioned whenever the welding location or working angle changes.

Provide Effective General Ventilation

Good general ventilation helps prevent welding fumes from accumulating within the workplace. Depending on the risk assessment, this may involve:

• Using suitable mechanical ventilation systems
• Maintaining safe airflow through the work area
• Using fans without disturbing the operation of the LEV
• Opening doors or windows where it is safe and appropriate

General ventilation must not be relied upon as the only control for indoor welding fumes. Suitable engineering controls, normally LEV, should be used to capture the fumes at source.

Use Suitable Respiratory Protective Equipment

Where LEV does not adequately control exposure, or where using LEV is not reasonably practicable, workers must be provided with suitable respiratory protective equipment (RPE).

RPE may include:

• An FFP3 disposable mask for suitable short-duration tasks
• A reusable half-mask fitted with a P3 particulate filter
• A powered air respirator with an appropriate welding visor
• Supplied-air respiratory equipment where required by the risk assessment

For longer-duration arc-welding work, powered or supplied-air equipment that combines respiratory, eye and face protection may provide the most suitable option. The selected equipment must provide an appropriate level of protection against the particular fumes and gases produced.

Face-Fit Testing and Facial Hair

Tight-fitting RPE must be face-fit tested for the individual wearer. The wearer must also be clean-shaven wherever the mask seals against the face. Even a small amount of facial hair can prevent an effective seal.

RPE must be worn correctly throughout the task. It must also be inspected, cleaned, maintained and stored in accordance with the manufacturer’s instructions.

Controlling Welding Fumes Outdoors

LEV is not normally effective for outdoor welding because changing air movement can disrupt the extraction. Welders working outdoors should therefore use suitable RPE selected through the risk assessment.

Choose Welding Methods That Produce Less Fume

Where reasonably practicable, employers should consider alternative joining techniques or welding processes that generate less fume.

For example, TIG welding generally produces less particulate fume than MIG or MMA welding. However, the process may still produce hazardous gases, including ozone, so appropriate controls remain necessary.

The chosen process must be suitable for the materials, working conditions and required quality of the completed weld.

Keep Your Head Out of the Welding-Fume Plume

Welders should avoid placing their heads directly above the weld. Hot fumes naturally rise and may be inhaled if the welder leans over the work.

Adjust the working position and extraction equipment so that the fume is drawn away from the breathing zone. Good posture and correct LEV positioning work together to reduce exposure.

Maintain and Test Welding-Fume Extraction Equipment

LEV and other control equipment must remain effective throughout their working lives. Employers should ensure that:

• Workers check the extraction before use
• Hoods, ducts and hoses are inspected for damage or blockages
• Filters are cleaned or replaced when required
• Airflow indicators and warning systems operate correctly
• Defects are reported and repaired promptly
• LEV systems receive the legally required thorough examination and testing

Records of examinations, testing, servicing and repairs should be retained in accordance with legal requirements and the organisation’s safety procedures.

Maintain Good Housekeeping

Good housekeeping supports the effective control of welding fumes and other workplace hazards. Keep welding areas organised, remove waste safely and store welding consumables correctly.

Do not allow waste, equipment or materials to obstruct extraction units, airflow routes or access to emergency equipment.

Key Welding-Fume Safety Points

• All welding fumes are hazardous and can cause lung cancer.
• Use suitable engineering controls, normally LEV, for indoor welding.
• Position extraction close enough to capture fumes at source.
• Do not rely on general ventilation alone.
• Use suitable RPE where engineering controls cannot adequately control exposure.
• Face-fit test all tight-fitting RPE and ensure wearers are clean-shaven around the seal.
• Use suitable RPE when welding outdoors.
• Maintain, inspect and test all exposure-control equipment.
• Keep the welder’s head away from the rising fume plume.