Welding fumes can cause serious health risks, but with proper controls like LEV systems and fume extraction systems, workplaces can protect workers effectively. This article explains the dangers of welding fumes and how to implement safe solutions.

What Are Welding Fumes and Why Are They Dangerous?

Welding fumes are airborne particles and gases created when metals are heated during welding. They contain harmful substances like metal oxides, gases (carbon monoxide, ozone), and toxic compounds. Inhaling these fumes can lead to:

  • Lung cancer.

  • Chronic respiratory diseases.

  • Kidney damage and other long term health issues.

Even short term exposure can cause dizziness or eye irritation.

HSE Regulations for Welding Fume Control

The UK's Health and Safety Executive mandates strict controls for welding fumes. Key rules include:

  • LEV systems (Local Exhaust Ventilation): Required for all indoor welding to capture fumes at the source.

  • RPE (Respiratory Protective Equipment): Must be used if LEV alone isn't sufficient, or for outdoor welding.

  • No “safe” exposure level: Controls are mandatory regardless of welding duration.

Failure to comply can result in fines, legal action, or shutdowns.

How LEV Systems Protect Workers

Local Exhaust Ventilation (LEV) systems capture fumes directly where they're generated. They work by:

  1. Extracting air near the welding point using hoods or arms.

  2. Filtering contaminants before releasing clean air.

  3. Reducing exposure to hazardous particles and gases.

LEV systems are more effective than general ventilation, which can't eliminate concentrated fumes.



Also Read: How Local Exhaust Ventilation Systems Protect Workers from Hazardous Substances



LEV Testing: Ensuring Your System Works

Regular LEV testing is legally required every 14 months. Testing involves:

  • Checking airflow efficiency and filter performance.

  • Identifying leaks or blockages.

  • Certifying the system meets HSE standards.

Without testing, even the best LEV system may fail to protect workers.

Choosing the Right Welding Fume Extraction System

Selecting a fume extraction system depends on your workspace and welding type:

  • Mobile extractors: Ideal for small workshops or outdoor use.

  • Fixed LEV systems: Best for high-volume indoor welding.

  • Combination systems: Pair LEV with RPE for maximum safety.

Consider factors like workspace size, materials welded, and HSE compliance.



Fume Extract System Plant Room

Consequences of Ignoring Welding Fume Safety

Ignoring HSE guidelines risks:

  • Worker health crises: Hospitalizations or chronic illnesses.

  • Legal penalties: Fines or prosecution for non-compliance.

  • Reputation damage: Loss of trust from employees and clients.

Final Tips for Safe Welding Practices

  1. Use LEV systems for all indoor welding.

  2. Test LEV systems annually to ensure effectiveness.

  3. Train workers on proper equipment use and risks.

  4. Combine LEV with RPE for outdoor or high-risk tasks.

By prioritizing fume extraction systems and LEV testing, workplaces can safeguard their teams.