Welding fume can cause cancer, including the fume produced when welding mild steel. The International Agency for Research on Cancer classified welding fume as carcinogenic to humans in 2017, and HSE followed with a safety alert in February 2019. For workshops, the practical message is that fume needs proper control, whatever metal you weld.
For regular indoor welding, this usually means local exhaust ventilation, or LEV, which captures fume close to the arc before it reaches the welder’s breathing zone. This guide explains how to choose extraction that suits your work, understand the airflow figures and set up the equipment so it provides effective protection in everyday use.
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In this guide:
When Welding Fume Extraction Is Needed
Before choosing equipment, consider how often you weld, how much fume the process produces and who could breathe it in. These factors determine the controls you need, with the following points providing a starting point for most fabrication workshops.
- All welding fume is a cancer risk, including mild steel fume. Controls therefore need to cover everyday steel fabrication as well as stainless steel and coated materials.
- Use suitable extraction for regular indoor welding wherever practicable. Capturing fume close to where it is produced helps protect both the welder and other people in the workshop.
- General ventilation supports fume control. It helps clear fume from the room, but an open door or wall fan is not a substitute for effective capture during routine arc welding.
- Add respiratory protective equipment where extraction cannot adequately control exposure. Suitable RPE is also needed for outdoor welding, where air movement makes capture less reliable.
- Choose RPE that suits the wearer and the work. Tight-fitting masks need a face fit test, and the sealing area must be free of facial hair. Select a suitable loose-fitting alternative where a reliable face seal cannot be achieved.
There are limited exceptions. For incidental welding carried out less than once a week and lasting less than an hour, HSE does not normally expect engineered fume controls, but suitable RPE, good general ventilation and protection for people nearby are still needed. Low-intensity resistance spot welding on clean, uncoated metal can usually be controlled with good general ventilation. These exceptions should be assessed against the actual job, rather than applied to routine fabrication work.
Types of Welding Fume Extractors
| Type | How it works | Best for | Watch out for |
|---|---|---|---|
| On-torch | A nozzle on the MIG torch captures fume close to the arc as the torch moves. | Long welds and large fabrications where an extraction arm would need frequent repositioning. | Check access, torch weight and compatibility with the extraction unit. Flow and nozzle position must suit the weld. |
| Portable or mobile unit | A movable filter unit captures fume through an arm or a suitable extraction hose and nozzle. | Small workshops, changing jobs and maintenance work. | Keep the capture point within reach of the fume as the welding position changes. |
| Wall or ceiling mounted arm | An arm serves a fixed bay and connects to a filter unit or ducted system. | Established welding bays where the work stays within the arm’s reach. | Check that the arm reaches every welding position and holds the hood where it is needed. |
| Downdraft bench | Extraction draws air down through openings in the work surface. | Small components and repetitive work that fit within the bench’s capture area. | Large parts can obstruct airflow. Use it for grinding only if the bench and collection system are suitable. |
| Welding booth | An enclosed work area combines extraction with screens around the welding operation. | Training bays and repeat production where the whole workpiece fits inside. | Allow enough space for the work and operator, and confirm that fume moves away from the breathing zone. |
| Centralised system | A duct network connects several workstations to a shared extraction and filtration unit. | Workshops with several permanent stations and a predictable workload. | The system needs to be designed and balanced for the stations that will operate together. |
👉 Browse mobile fume extraction units, extraction arms and hoods, bench top extraction and centralised systems.
On-Torch Fume Extraction
On-torch extraction keeps the capture point close to the arc as you move along the weld. That makes it particularly useful for long runs and large fabrications, where repeatedly moving an extraction arm can be awkward. Its effectiveness still depends on the joint, welding position and torch angle, so it needs to be set up for the work you are doing.
An extraction torch normally connects to a high vacuum unit, which draws a relatively small volume of air through the torch’s narrow passages. An extraction arm works differently, moving a much larger volume through a wider hood. Match the torch to the flow and suction pressure its manufacturer specifies, and check where the quoted flow is measured: the figure at the extraction nozzle may differ from the figure at the hose connection.
Setting Up Extraction Without Affecting the Weld
The aim is to capture fume while keeping the shielding gas around the weld pool. Incorrect extraction settings or nozzle position can disturb that gas shield and contribute to porosity. If porosity starts after fitting an extraction torch, check the whole setup before changing the suction, as gas leaks, draughts and torch position can produce similar symptoms.
- Start with the manufacturer’s extraction settings. Use the specified flow and suction pressure for the torch and hose arrangement, rather than adjusting the damper by how much visible fume remains.
- Check the shielding gas supply at the torch. Confirm that the flow suits the welding procedure, check for leaks and test the weld. Increasing gas flow without finding the cause can introduce turbulence rather than solve the problem.
- Set the extraction nozzle to the specified position. Its distance from the gas shroud affects both fume capture and shielding, so follow the torch manufacturer’s instructions when adjusting it.
- Keep the extraction openings clear. Remove spatter as directed in the manual, because blocked openings can reduce capture even when the unit appears to be running normally.
For other causes of weld defects, our guides to TIG welding defects and MMA welding problems explain the checks that apply to those processes.
👉 Browse on-torch fume extraction torches and spares and high vacuum units to find a compatible torch and extraction unit.
Key Features to Look For
| Feature | Why it matters | What to ask |
|---|---|---|
| Airflow at the hood | The flow available at the hood helps determine whether it can capture fume in the intended working position. | What flow in m³/h will the complete system maintain with the arm in use and the filter partly loaded? |
| Filter class and W3 approval | Tested filter performance helps you choose a suitable unit, but recirculation also depends on the process and complete installation. | What testing or certification supports the unit’s suitability, and what checks are needed before returning air indoors? |
| Automatic filter cleaning | A suitable cleaning system can maintain airflow and extend the life of a cleanable filter. | Does the filter need compressed air, and does cleaning take place during or between welding operations? |
| Filter cost and availability | Replacement intervals and cartridge prices can make a substantial difference to running costs. | What do replacement filters cost, and what service life is realistic for our materials and workload? |
| Arm reach and balance | An arm that moves easily and stays in place makes it easier to keep the hood close to the weld. | Can the operator position the hood comfortably, and will it stay there throughout the job? |
| Noise level | The unit needs to suit the working environment without making communication or routine use unnecessarily difficult. | What is the sound level in dB(A) at the operator’s position under normal working conditions? |
| Spark arrestor | Suitable spark protection reduces the hot particles reaching the filter, although it does not remove every fire risk. | What spark protection is included, and is the unit suitable for the processes we intend to use? |
| Airflow monitoring | An indicator or alarm helps operators recognise when airflow falls below the level required for capture. | What does the indicator measure, what is the acceptable range, and what should the operator do if the alarm activates? |
Choosing the Right Extractor
Start with the way work moves through your workshop. The five questions below will help you narrow down the options before comparing individual machines.
- Does the work come to the welder, or does the welder move around it? Fixed workstations often suit arms, benches or booths. Where the welding position changes, a mobile unit or on-torch extraction may be easier to keep close to the joint.
- What materials and processes do you use? Include coatings and consumables when discussing the hazards with the supplier, and ask how the proposed system will deal with both particles and gases, especially if air will return to the workshop.
- How many stations will run at once? Individual units can suit one or two bays, while several permanent stations may justify a central system. Compare installation and running costs for your workload rather than relying on a fixed number of stations.
- How large are the parts? Small components may fit within the capture area of an extracted bench. Large fabrications need enough arm reach, a suitable booth or on-torch extraction that follows the weld.
- How much welding will the unit handle? Occasional maintenance and continuous production place very different demands on filters, so consider the daily workload, cleaning arrangements and likely replacement intervals.
| Situation | Usual answer |
|---|---|
| One welder handling varied jobs in a small workshop | A mobile unit with an arm, or on-torch extraction where it suits the process. |
| A fixed bay with one or two welders | Wall mounted arms connected to a suitable static unit or ducted system. |
| Small, repetitive components | An extracted bench with a capture area that suits the parts. |
| Training or repeat production | A welding booth with suitable extraction and screens. |
| Several permanent stations | Compare a central ducted system with individual units, allowing for simultaneous use. |
| Large fabrications with the welder moving along the joint | On-torch extraction with a compatible high vacuum unit, where suitable for the weld. |
| Site work with limited power or space | Portable extraction where practicable, with a suitable power supply. Provide suitable RPE for outdoor welding and wherever capture is inadequate. |
Airflow and Capture Velocity
Airflow figures are useful only when they relate to effective fume capture. With an extraction hood, capture velocity means the air speed at the point where fume is produced. HSE gives a general comparison range of 0.5 to 1 metre per second for this type of capture, with higher speeds sometimes needed where draughts interfere. On-torch systems are assessed differently, using the manufacturer’s specified volume flow. In either case, the installation needs to demonstrate that it captures the fume.
Workshop volume is relevant to general ventilation, which helps remove fume that escapes into the room. It does not tell you whether a hood or torch will capture fume at the weld. Treat the figures below as examples to help compare systems, and use the supplier’s design requirements for your installation.
| Extraction type | Typical flow | Notes |
|---|---|---|
| On-torch extraction | As specified for the torch and hose arrangement | Uses a relatively small volume at high suction pressure. Check whether the flow is quoted at the nozzle or connection. |
| Extraction arm, 160 mm | Around 800 m³/h on some designs | An illustrative figure, not a sizing rule. Confirm the required flow for the actual hood and arm. |
| Extraction arm, 200 mm | Around 1,000 to 1,200 m³/h on some designs | Check the flow available in use and the capture area it provides, rather than selecting by diameter alone. |
| Downdraft bench | Specified for the working area and required air speed | The size and position of the component affect airflow through the work surface. |
| Welding booth | Specified for the opening and extraction arrangement | The design must draw fume away from the welder across the intended working area. |
When comparing specifications, distinguish between fan free-air rating, measured without the resistance of the extraction system, and flow at the hood, which reflects the air actually reaching the capture point. Arms, ducting and filters all add resistance, so ask what flow the complete system can maintain as the filter loads with fume.
Setting It Up So It Actually Works
Even well-chosen extraction equipment depends on how it is used. A hood that starts close to the joint can soon be too far away as the work moves along the bench. Checking its position before welding, and moving it as the job progresses, helps keep the fume within reach of the extraction.
Keeping the Hood Close Enough
Airflow towards a hood weakens quickly as you move away from it. HSE’s practical guidance is to keep a movable hood within one hood diameter of the welding point, so a 200 mm hood should be no more than about 200 mm away. Use that as a positioning guide alongside the capture zone confirmed for your equipment; hood shape, airflow and draughts all affect its performance.
Keep the weld inside the hood’s effective capture zone throughout the job. Reposition the hood whenever the weld moves outside that area, and check that the rising fume enters it rather than drifting towards you. The distances in the diagram illustrate the effect of moving the hood away; they are not guaranteed capture limits for every system.
Positioning the Hood to Catch the Fume
- Position the hood to catch the rising fume. With a movable capture hood, this often means placing it just above and behind the arc, facing the plume. Check the recommended arrangement for the hood and joint.
- Keep your breathing zone out of the fume path. Arrange the work and hood so fume moves away from your face, rather than being drawn past it on the way to the extractor.
- Adjust the hood angle as well as its distance. A nearby hood can still miss the plume if its opening faces the wrong direction, so check both whenever you move it.
Managing Cross-Draughts
Draughts can push fume away from the hood before it is captured. When checking the setup, look at the air moving through the bay as well as the extractor itself, especially when doors are open or heating and cooling equipment is running.
- Check open doors and shutters for draughts that carry fume across the bay and away from the hood.
- Position cooling fans carefully so they do not disrupt capture or blow fume towards the welder or neighbouring workers.
- Check heaters and air conditioning outlets too, as their airflow can alter the plume’s path when they switch on.
- Consider other equipment nearby, including extractors and air intakes that change how air moves through the work area.
- Use welding screens where they help control draughts. Alongside protecting nearby workers from arc radiation, they can shelter the capture area, provided the arrangement still allows adequate ventilation.
Ducting and Installation
- Keep flexible hose runs as short as practical. Extra length increases resistance and can reduce flow at the hood, particularly if the hose sags or becomes kinked.
- Keep bends to a minimum and use the supplier’s recommended bend radius. A smoother route reduces the resistance the fan has to overcome.
- Use the duct size specified for the system. Reducing the diameter to squeeze it through a convenient route can leave the hood short of airflow.
- Have multi-station systems balanced during commissioning. Each branch needs its intended airflow, including when several stations operate together, so balancing should form part of the installation rather than an operator adjustment.
- Make the equipment easy to use where welding takes place. Allow for access, noise and arm movement so the hood can be positioned without interrupting the work unnecessarily.
Filter Types and Applications
| Filter stage | Removes | Best for |
|---|---|---|
| Spark arrestor | Reduces the sparks and hot particles reaching later filter stages. | Processes that can carry hot particles into the extractor, using the protection specified for that unit. |
| Pre-filter | Collects coarser particles before they reach the main filter. | Suitable systems handling coarser dust as well as welding fume. It does not make an unsuitable unit safe for grinding. |
| Main cartridge | Collects fine fume particles, which may contain chromium or nickel compounds. | Welding-fume filtration, with the required efficiency confirmed for the application. It does not remove gases. |
| Activated carbon | Can remove specified gases or vapours when the media and operating conditions are suitable. | Applications with identified gas hazards, where the supplier confirms performance and a replacement schedule. Carbon is not a universal solution for welding gases. |
| HEPA | Captures fine particles to a defined efficiency. | Systems that require this level of particle filtration. Suitability for recirculation depends on the whole installation, not the HEPA label alone. |
Recirculate or Discharge?
Returning filtered air to the workshop can reduce heating losses, but the system must be suitable for the contaminants it collects. Particle filters do not remove welding gases, so the decision needs to consider the process, filter performance and quality of the returned air, rather than the filter label alone.
- Look for tested particle-separation performance. W3 certification from the German IFA is useful evidence of a unit’s ability to filter welding fume, including fume from high-alloy steels. It supports equipment selection but does not, on its own, establish that recirculation is suitable for a UK installation.
- Confirm that returning air indoors is suitable for your process. The COSHH assessment needs to address residual particles and gases, with appropriate filtration and checks. If adequate control cannot be demonstrated, use a properly designed outdoor discharge and account for replacement air and heating losses.
- Choose the outdoor discharge position carefully. Exhaust air needs to disperse safely without re-entering through doors, windows or ventilation intakes, or exposing people nearby.
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Common Welding Fumes and Hazards
Although all welding fume needs to be treated as a cancer risk, the metal, consumable and coating affect the other hazards involved. The table below highlights what to consider when choosing capture, filtration and any additional controls. It is a starting point for the assessment, rather than a filter specification for every job.
| Material welded | Main constituents | Specific hazards | Filtration |
|---|---|---|---|
| Mild and carbon steel | Iron oxides and manganese, depending on the consumable and material. | Cancer risk from welding fume; manganese exposure can also affect the nervous system. | Capture fume at source and use filtration suitable for the process and intended discharge. |
| Stainless steel | Chromium compounds, including hexavalent chromium, and nickel compounds. | Cancer risk, with some constituents also capable of causing respiratory sensitisation. | Use suitable high-efficiency particle filtration and assess any proposal to return air indoors. |
| Galvanised and zinc-coated | Zinc oxide as well as fume from the steel and consumable. | Zinc oxide can cause metal fume fever, alongside the other risks from welding fume. | Effective capture and suitable particle filtration, with additional controls where needed. |
| Aluminium | Aluminium oxide particles; the arc can also generate ozone gas. | Respiratory irritation and ozone exposure. Metallic dust from grinding presents a separate fire or explosion risk. | Control particles and ozone appropriately; particle filters do not remove ozone. Assess metal-dust collection separately. |
| Nickel alloys | Nickel compounds and other constituents depending on the alloy, which may include chromium. | Some compounds can cause cancer or respiratory sensitisation. | Choose particle filtration and any gas controls to suit the alloy, consumable and process. |
| Painted, primed or coated steel | Depends on the coating and how it breaks down when heated. | May include lead, hazardous gases or vapours, and isocyanates from some coatings. | Identify the coating and remove it from the weld area where appropriate, controlling exposure during removal too. |
Check painted and coated material before you start welding. Heating a coating can release hazardous substances, and some older paints contain lead. Identify the coating and remove it from the weld area where appropriate, using a method that also controls the dust or vapour produced during removal.
Your Legal Duties in Brief
Alongside choosing the equipment, you need arrangements for using, checking and maintaining it. The main UK duties to account for are:
- Assess and control exposure under COSHH. Include everyone who may be affected, from the welder to nearby workers and the people who maintain the extraction equipment.
- There is no single workplace exposure limit for welding fume as a whole. Because it can cause cancer, exposure must be reduced as low as reasonably practicable. The general dust figures in EH40 are not a safe target for welding fume.
- Check the limits for individual substances as well. Constituents such as manganese, nickel compounds and hexavalent chromium have their own workplace exposure limits, which must also be met.
- Arrange a thorough examination and test of LEV at least every 14 months. A competent person must carry it out, and the reports must be kept for at least five years.
- Train people to use and check the system. Explain hood positioning, airflow indicators and fault reporting, and keep records of checks and maintenance at the intervals set for the equipment and work.
👉 For exposure limits, monitoring, statutory testing and record keeping in full, see our guide to welding ventilation standards and LEV compliance.
Maintenance and Safety
| When | Check |
|---|---|
| Every shift | Before use, check the airflow indicator, hood and hose condition, and that the arm holds its position. Make sure extraction is running and correctly placed. |
| Weekly | Record a visual check of the system. Inspect the spark protection and collection bin, emptying or cleaning them at the intervals specified for the unit and workload. |
| Monthly | Review pre-filter condition, filter-cleaning operation and joints or seals. Follow the manufacturer’s schedule if checks are needed more often. |
| By condition | Replace filters at the manufacturer’s stated limit, or sooner if damaged. Follow the approved cleaning method for cleanable filters and confirm that airflow recovers. |
| Every 14 months at most | Arrange a thorough examination and test by a competent person, and address any defects identified. |
Aluminium and Magnesium Dust: an Explosion Risk
Fine metallic aluminium and magnesium dust can present a fire or explosion risk. This is particularly relevant to grinding and other processes that produce metal dust, rather than aluminium oxide fume alone. Collecting combustible dust together with hot particles or sparks can create a dangerous mixture inside the extractor.
- Keep aluminium and magnesium dust separate from steel welding and grinding waste. Use a collection arrangement designed for the particular metal and process, rather than sharing a general-purpose extractor.
- Have combustible-dust risks assessed before choosing equipment. DSEAR may apply, and the appropriate collection, ignition prevention and explosion protection measures need specialist advice.
- Control dust accumulation in the unit and around it. Follow the manufacturer’s collection and emptying procedure, with intervals suited to how quickly waste builds up.
Changing and Disposing of Filters
- Isolate the unit and follow its filter-changing procedure. Collected fume can become airborne during handling, so use the specified containment method, suitable RPE and gloves according to the risk assessment.
- Contain the used filter as you remove it. Follow the recommended bagging or sealed-container method so dust is not spread while the filter is carried through the workshop.
- Arrange disposal for the waste the filter contains. Filters carrying hazardous substances may need to be treated as hazardous waste, so confirm the classification and disposal route before putting them in a general waste container.
- Do not blow a removed filter clean with an airline. That releases collected dust back into the workplace. Use only the enclosed cleaning system or maintenance method specified by the manufacturer.
👉 Browse respirator masks and air-fed face shields for tasks where extraction needs to be supplemented with suitable respiratory protection.
Fume Extractor Troubleshooting
| Symptom | Likely cause | What to do |
|---|---|---|
| Weak suction at the hood | A loaded filter, blocked or damaged hose, closed damper or another airflow restriction. | Follow the manual to check the airflow path, filter and collection bin. Restore the required flow before relying on the extractor. |
| Fume still reaching the welder | The hood is outside its capture zone, faces the wrong way, or is affected by a draught. | Reposition and angle the hood, check nearby airflow and keep the breathing zone out of the plume. Seek help if capture remains inadequate. |
| Porosity after fitting on-torch extraction | Disturbed shielding gas, incorrect nozzle position, gas leaks or another change in the torch setup. | Check the specified extraction flow, nozzle position and gas delivery. Do not lower extraction below its required flow to hide the problem. |
| Arm will not hold position | Loose or worn joints, or an issue with the arm’s balance mechanism. | Adjust it according to the manual, or have worn parts replaced so the hood stays in position. |
| Unusual noise or vibration | Fan imbalance, worn components or another mechanical fault. | Stop using the unit and arrange inspection by a competent person before a fault causes further damage. |
| Smoke escaping from the housing | A possible internal fire, overheating or a failure of the filter or seals. | Stop work, isolate the unit if safe and follow the site fire procedure. Do not open a unit that may be burning; have it inspected before reuse. |
| Filter blocking unusually quickly | More dust than the unit is designed for, an unsuitable filter arrangement or failed cleaning. | Check that the unit suits the process and dust load, and inspect its cleaning system. Use only manufacturer-approved filters and modifications. |
| Unit will not start | A supply fault, open interlock or protective trip. | Follow the manual’s checks and have electrical faults investigated by a competent person. Do not bypass interlocks or repeatedly reset an unexplained trip. |
Welding Fume Extraction FAQ
Do I need fume extraction for welding mild steel?
For regular indoor mild steel welding, suitable extraction is normally needed to control fume close to its source. Mild steel fume can cause cancer, just like other welding fume. HSE allows limited exceptions for certain occasional or low-fume tasks, as explained earlier in this guide, but these still need an assessment and effective controls.
How close does the extraction hood need to be?
HSE advises keeping a movable hood within one hood diameter of the welding point, so about 200 mm for a 200 mm hood. Also follow the capture zone confirmed for your system, because hood design, airflow and draughts affect the result. Move the hood as needed to keep the weld within that zone.
What airflow do I need for welding fume extraction?
Use the flow specified for the complete extraction system. A large extraction arm may need around 1,000 to 1,200 m³/h, while an on-torch system uses much less air at higher suction pressure. The torch manufacturer’s flow requirement is the relevant check for on-torch extraction. For an arm, ask for flow at the hood and evidence of effective capture, rather than choosing by fan rating alone.
Can I recirculate filtered air back into the workshop?
It can be suitable if the complete installation controls the contaminants adequately. W3 certification is useful evidence of welding-fume particle separation, but it is not a blanket UK approval to recirculate air. The assessment must also consider gases, which ordinary particle filters do not remove, and the quality of the returned air. Ask the supplier to confirm suitability for your process.
Why did my welds go porous after fitting on-torch extraction?
The extraction may be disturbing the shielding gas, but check for other causes too, including gas leaks, draughts and torch position. Confirm the manufacturer’s extraction flow and nozzle position, then check gas delivery and weld quality. Do not reduce extraction below the required flow simply to remove porosity; ask the supplier for help if you cannot achieve effective capture and a sound weld together.
How often does LEV need testing?
Welding LEV normally needs a thorough examination and test by a competent person at least every 14 months, with reports retained for at least five years. This is separate from routine checks and maintenance. Follow the schedule for your equipment, record the work and act on defects when they are found.
Is a fume extractor enough on its own, or do I still need a mask?
Suitable RPE is needed where extraction cannot adequately control exposure and for outdoor welding. Tight-fitting masks require face fit testing and a clean-shaven sealing area. Confined-space work needs a separate assessment and safe system of work: a filtering mask or powered filtering helmet cannot protect against oxygen deficiency.
Can I use the same extractor for welding and grinding?
Only use a shared extractor if its manufacturer confirms that it is suitable for both processes and the materials involved. Grinding adds coarse dust and hot particles, so the unit needs the specified filtration and spark protection. Metallic aluminium or magnesium dust requires a dedicated, suitably designed collection arrangement; it should not be mixed with steel welding or grinding waste.
Final Thoughts
Good extraction starts with equipment that suits the job, then depends on keeping it close enough to capture the fume and maintaining the airflow as filters become loaded. Before buying, think through how the operator will position it, check it and move it during a normal shift. Those everyday details are what make the system practical to use.
- Choose controls around the welding task. For routine fabrication, plan effective capture at source alongside the general ventilation and RPE the work requires.
- Compare performance at the capture point. Ask what flow the complete installation can maintain and how its effectiveness will be demonstrated during commissioning.
- Make positioning part of the job. Keep the weld within the verified capture area and move the hood as the work progresses.
- Allow for ongoing costs. Compare filters, electricity, any compressed air, servicing and testing as well as the purchase price.
- Plan maintenance and statutory testing from the start. Keep the records together and arrange the next thorough examination before the 14-month maximum interval expires.
👉 Welding fume extraction · On-torch extraction · Arms and hoods · Replacement filters · PPE and RPE
If you need help choosing, tell us what you weld and where. Include the process, materials, number of welding stations and typical workload so we can help you compare suitable equipment.
