What are welding fumes?

Welding fumes are a mixture of very fine solid particles and gases produced during welding processes and other hot-work operations. Their composition is not constant – it depends on the welding method, the type of metal being welded, filler materials, surface coatings and process parameters.

Depending on the technology used, the fumes may contain, amongst other things:

• metal particles and oxides, such as iron or manganese;
• chromium and nickel compounds, particularly when working with stainless steel;
• gases and reaction products, including ozone and nitrogen oxides under certain process conditions;
• fine and ultrafine particles, which can penetrate deep into the respiratory system.

Therefore, not all welding processes should be treated in the same way. A risk assessment should take into account the specific working method, the material, the consumables used, coatings and the ventilation conditions on site.

How can welding fumes affect health?

Inhaling welding fumes can put a strain on the respiratory system, eyes and skin. The nature and level of risk depend on the concentration of pollutants, the duration of exposure, the type of process and the effectiveness of the protective measures in place.

It is important to note that the risk is not limited to the welder alone. People working near the workstation may also be at risk if the fumes spread throughout the workshop and are not effectively captured at source.

Effects of short-term exposure

In the event of inadequate ventilation or an incorrectly positioned extraction system, symptoms may occur indicating irritation caused by airborne contaminants. These include, amongst others:

• irritation of the eyes, nose and throat;
• coughing, a feeling of breathlessness or respiratory discomfort;
• headaches, weakness or feeling unwell;
• reduced visibility in the welding area due to lingering fumes.

These symptoms should not be ignored. They should serve as a warning to check the source of emissions, the extraction settings, the efficiency of the ventilation system and the protective measures in place.

Risks of long-term exposure

Regular exposure to welding fumes may be associated with a risk of more serious health problems. In practice, particular attention is paid to respiratory diseases, including occupational asthma, and to the cancer risk associated with exposure to welding fumes.

When welding materials containing chromium or nickel, a particularly thorough risk assessment and exposure control are essential. Manganese compounds present in some fumes may also require attention to be paid to potential neurological effects in the event of long-term, uncontrolled exposure.

The risk depends on the actual working conditions; therefore, it cannot be reliably assessed solely on the basis of the type of equipment. Measurements, occupational risk assessment, the condition of the installation and the operator’s working practices are all important factors.

How does a welding fume extraction system reduce exposure?

A welding fume extraction system reduces the worker’s exposure to contaminants by capturing fumes close to the welding arc before they spread throughout the workstation and the workshop. Depending on the type of solution, this may be an extraction arm, an extraction system integrated into the torch, an extraction table, a mobile unit or a centralised system.

An effective system can:

• reduce the amount of fumes in the worker’s breathing zone;
• limit the spread of contaminants to other workstations;
• improve visibility during welding;
• help keep the work area clean;
• facilitate compliance with the requirements arising from risk assessments and health and safety regulations.

For the system to be effective, the nozzle or arm must be correctly positioned in relation to the source of fumes. Even an efficient unit will perform poorly if the extraction point is too far away, is positioned on the wrong side of the airflow, or if the filter is worn out.

Workstation with and without extraction

Health and safety and organisational responsibilities

The employer should identify hazards, assess occupational risks and implement measures to limit exposure to harmful factors. In the case of welding work, this means, amongst other things, the proper organisation of the workstation, effective ventilation and the selection of personal protective equipment appropriate to the process.

Local exhaust ventilation is a technical measure of great importance, but it does not exempt the employer from the obligation to monitor its operation. The system should be maintained, periodically inspected and used in accordance with the manufacturer’s instructions. The formal requirements and the scope of measurements must always be determined for the specific workplace and in accordance with the applicable regulations.

Is local exhaust ventilation alone sufficient?

Welding extraction is a fundamental element of collective protection, but in many situations it should form part of a broader safety system. Protection should be organised in accordance with the hierarchy of risk control measures.

• select welding technology and materials so as to minimise emissions wherever possible;
• use local extraction and adequate general ventilation;
• maintain the correct positioning of the arm, nozzle or torch with the extraction system;
• use respiratory protective equipment where required by the risk assessment;
• provide training, instructions and equipment inspections;
• do not weld materials with unknown or unremoved coatings without first carrying out a risk assessment.

How should extraction be selected to protect health?

The selection of an extraction system should begin with an analysis of the process, rather than simply comparing fan capacities. The most important criteria are:

• the welding method and type of material;
• the number and layout of workstations;
• frequency and duration of work;
• the ability to position the extraction point close to the source of fumes;
• the type of filtration suited to the contaminants and maintenance procedures;
• noise, mobility, access for maintenance and the running costs of the filters;
• the possibility of expanding the system as the plant grows.

Filters are selected according to the type of pollutants and the technical solution. Not every process requires the same type of filtration, and the recirculation of treated air may be subject to additional conditions. If in doubt, it is advisable to consult the system supplier and a health and safety specialist regarding the design.

Summary

Welding fumes pose a significant occupational hazard, which is why exposure control should be standard practice at every welding workstation. Local exhaust ventilation reduces the amount of contaminants in the operator’s breathing zone and also helps to protect people working nearby.

The best results are achieved when the extraction system is selected to suit the process, correctly installed, regularly maintained and supplemented by ventilation, work organisation and appropriate personal protective equipment. This approach improves working conditions and helps to reduce health risks in the long term.