a line art cartoon of a welder in workshop full of clouds of fumes

Welding is an essential process in many industries, but it also creates harmful welding fumes that can cause health problems for workers if they are not properly controlled. In the UK, employers have a legal responsibility to protect their employees from exposure to welding fumes under the Control of Substances Hazardous to Health Regulations 2002 (COSHH). Failure to comply with these regulations can result in legal action being taken against employers.

One of the most effective ways to control exposure to welding fumes is through the use of welding fume extractors. These devices remove harmful fumes and gases from the air, reducing the risk of respiratory problems and other health issues.

The benefits of using welding fume extractors are numerous. Firstly, they provide a safe and healthy working environment for welders, protecting them from exposure to hazardous fumes. Welding fume extractors can also help to increase productivity, as workers are less likely to suffer from health problems that could cause them to take time off work.

In addition to protecting workers, welding fume extractors can also help companies to comply with UK health and safety law. As mentioned earlier, employers have a legal responsibility to protect their employees from exposure to welding fumes. By using welding fume extractors, companies can ensure that they are meeting these legal requirements and avoiding potential legal action.

Another benefit of using welding fume extractors is that they can be tailored to meet the specific needs of a particular welding application. For example, some extractors are designed to be used in confined spaces or in areas with limited ventilation. Others are designed to be used with particular welding processes or materials. This means that welders can be confident that they are using the right equipment to control fumes and protect their health.

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Types of Fume Extractors

Fume extractors come in different types, and the choice of the type depends on the application, the location of the welding operation, and the volume of fumes produced. In this article, we will discuss the three main types of welding fume extractors: portable extractors, stationary extractors, and centralized extractors.

Portable fume extractors are designed to be moved easily from one location to another. They are compact, lightweight, and easy to maneuver, making them ideal for welding applications that require flexibility and portability. Portable extractors are available in different sizes and configurations, ranging from small, handheld units to larger units that can be mounted on carts. They are typically equipped with high-efficiency filters that can remove up to 99.97% of fumes and particulate matter from the air.

Stationary fume extractors are designed to be installed in a fixed location, such as a welding booth or a manufacturing facility. They are typically larger than portable extractors and are designed to handle high volumes of fumes and particulate matter. Stationary extractors are available in different configurations, such as wall-mounted units, ceiling-mounted units, and floor-mounted units. They are typically equipped with a range of features, such as automatic filter cleaning, variable-speed fans, and multiple filter stages.

Centralized fume extractors are designed for larger manufacturing facilities that require multiple welding stations. They are connected to a network of ductwork that collects fumes and particulate matter from each welding station and transports them to a centralized location for filtration. Centralized extractors are typically installed in a separate room or area of the facility and are designed to handle high volumes of fumes and particulate matter. They are typically equipped with a range of features, such as automatic filter cleaning, variable-speed fans, and multiple filter stages.

Features to Look for in a Welding Fume Extractor

When selecting a welding fume extractor, there are several features to look for to ensure that it is effective and efficient. In this article, we will explore the key features to consider when choosing a welding fume extractor.

  1. Airflow and Suction Power

One of the most important features to consider when selecting a welding fume extractor is its airflow and suction power. These two factors will determine how effectively the unit can capture and remove fumes from the air. A good extractor should have a high airflow rate and strong suction power, allowing it to remove fumes quickly and efficiently.

  1. Filtration System

The filtration system is another critical feature to consider when selecting a welding fume extractor. The unit should have a high-quality filter that can effectively remove fumes and other harmful particles from the air. Look for a filter that is designed specifically for welding fumes and has a high MERV rating (minimum efficiency reporting value).

  1. Noise Level

The noise level of a welding fume extractor is an important consideration, particularly if you will be using it in an indoor environment. Look for a unit that operates quietly, so as not to cause distractions or disturb others in the vicinity.

  1. Size and Weight

The size and weight of the welding fume extractor are also important considerations, particularly if you will be using it in different locations or need to move it frequently. A lightweight and compact unit will be easier to transport and maneuver, while a larger unit may be more stable and offer better performance.

  1. Mobility

Finally, consider the mobility of the welding fume extractor. Some units come equipped with wheels, making them easy to move around, while others may be designed for stationary use. If you will be using the extractor in different locations, look for a unit that is easy to transport and set up.

Factors to Consider When Choosing a Welding Fume Extractor

  1. Type of welding process

The type of welding process being used will impact the type of fume extractor required. For example, MIG welding produces a large amount of smoke and particulate matter, whereas TIG welding produces less. The type of welding process will also affect the required airflow rate and the type of filter required.

  1. Size of the workspace

The size of the workspace will determine the required airflow rate of the fume extractor. A larger workspace will require a higher airflow rate to effectively capture and remove fumes and particulate matter.

  1. Number of welders

The number of welders working in the workspace will also impact the required airflow rate. A larger number of welders will require a higher airflow rate to effectively capture and remove fumes and particulate matter.

  1. Type of materials being welded

Different types of materials produce different types of fumes and particulate matter when welded. For example, welding stainless steel produces hexavalent chromium, which is a carcinogen. The type of materials being welded will affect the required airflow rate and the type of filter required.

  1. Local regulations and standards

Local regulations and standards may dictate the required airflow rate and type of filter required for a fume extractor. It is important to research and comply with any relevant regulations and standards to ensure a safe and healthy workspace.

As a rough guide, the following table gives an idea of extraction airflow rates for MIG and TIG welding

Size of WorkspaceNumber of WeldersAir Flow Rates for MIG WeldingAir Flow Rates for TIG Welding
Small1-21000-1200 CFM800-1000 CFM
Medium2-41200-1500 CFM1000-1200 CFM
Large4-61500-2000 CFM1200-1500 CFM
Extra Large6+2000-2500 CFM1500-2000 CFM

Maintenance and Safety Tips

In order to ensure the safe and effective operation of a fume extractor, regular maintenance is required. Here are some maintenance tips to keep your fume extractor working at peak performance:

  1. Keep the filter clean: The filter is the heart of the fume extractor and needs to be kept clean in order to function properly. The filter should be cleaned or replaced according to the manufacturer’s instructions.
  2. Check the suction: The suction of the fume extractor is what draws in the hazardous fumes and particles. Over time, the suction can become weaker, which reduces the effectiveness of the fume extractor. Check the suction regularly and adjust it if necessary.
  3. Replace the motor brushes: The motor brushes are responsible for powering the fume extractor. Over time, the brushes can become worn and will need to be replaced. Check the manufacturer’s instructions for the recommended replacement interval.
  4. Check the hoses and connections: The hoses and connections that lead from the fume extractor to the welding torch can become clogged or damaged over time. Check the hoses and connections regularly and replace them if necessary.

Conclusion

Welding fume extractors are a crucial safety feature for any workspace where welding is performed. Selecting the right extractor involves considering the type of welding process, workspace size, number of welders, materials being welded, and local regulations.

Regular maintenance practices, such as cleaning the filter, checking the suction, replacing motor brushes, and inspecting hoses and connections, can help keep the fume extractor functioning effectively. Implementing these maintenance and safety tips will ensure a safe and healthy workspace for workers and compliance with legal regulations.