Welding and brazing are critical processes in many industries, but they come with serious health risks. One of the most dangerous is exposure to welding fumes, fine airborne particles released during welding operations. Long-term exposure can cause respiratory diseases, metal fume fever, neurological damage, and even cancer. Investing in the right welding fume extraction systems is not only a legal requirement under COSHH but also an essential step in protecting your workforce and creating a safe, productive environment.
Why Welding Fume Extraction Systems Are Critical for Worker Health
Welding and brazing fumes often contain hazardous substances, such as:
- Hexavalent chromium from stainless steel, a known carcinogen
- Manganese from mild steel, linked to neurological damage
- Zinc from galvanized steel, has a high fume formation rate, increasing metal fume fever risk
- Copper fume, a reproductive toxin with multiple hazards
- Toxic gases, including ozone, nitrogen dioxide, and occasionally carbon monoxide
Symptoms can begin as eye irritation or a sore throat and progress to chronic respiratory conditions. The HSE classifies welding fume as a confirmed human carcinogen, and under COSHH regulations, employers are required to control exposure to as low as reasonably practicable.
Installing high-quality welding fume extraction systems is one of the most effective ways to ensure compliance and protect worker health.
Key Considerations for Choosing a Cost-Effective Fume Extraction System
Every worksite is unique, and designing a cost-effective fume extraction system requires assessment of:
- Types of materials being welded: Stainless and galvanized steel are more hazardous than mild steel.
- Size and shape of parts: Larger or oddly shaped items may need flexible extraction options like on-torch or portable systems.
- Welding frequency and duration: Continuous or high-volume operations require robust, often automated solutions.
- Ventilation and air movement: Poor airflow increases the importance of local extraction.
- Fire or explosion risks: Some fumes are flammable or explosive and require special safeguards.
A combination of methods may be ideal, for example, a mix of mobile flex arms and general ventilation.
When returning air to the workplace suitable continuous air quality monitoring systems should always be fitted. As recommended in the very recent HSE update. rr1224_recirculating LEVs- selection use guidance.
R&B Industrial specialise in providing compliant continuous monitoring systems.
Types of Welding Fume Extraction Systems
Local Exhaust Flexible Extraction Arms
These are best for light-duty applications and can be fixed or portable. They often include built-in filtration and are versatile across welding setups.
Advantages:
- Versatile as they can be positioned to capture fumes at the source for various welding positions and applications.
- Easy to manoeuvre, allowing the welder to adjust the hood as needed.
- Available in various lengths and configurations.
Disadvantages:
- Require the welder to frequently adjust the arm, which can be time-consuming, leading to the arm not being positioned correctly.
- Fume extraction is not effective if not positioned correctly.
- Can obstruct the welder’s reach and visibility if not positioned carefully.
- Require regular maintenance to ensure proper airflow; internal mechanisms can get clogged up with product.
Rear-Draught Welding Booths and Plenums
Rear-draught booths provide a large capture zone and are very effective for smaller workpieces. Units may have integrated filters or connect to a centralised system.
Advantages:
- Good for specific applications: Effective for capturing fumes when welding objects within the bench area.
- Less potential to draw fumes through breathing zone: When properly designed, it draws fumes away from the welder’s face.
- Less potential for operator misuse: due to the larger capture area there is no need to move any hoods.
- Several booths can be interconnected to a centralised system.
Disadvantages:
- Limited capture zone: Effective within a limited area. The welder and the workpiece need to be positioned close to the rear-draught opening.
- Can be obstructed: Large workpieces can obstruct the airflow and reduce effectiveness.
- Not effective for all welding positions: May not be as effective for welding positions where fumes are not directed towards the rear of the booth.
Overhead Welding Canopies
Ideal for robotic or automated welding processes. Canopies must be curtained on the sides to retain rising fumes effectively.
Advantages:
- Capture rising fumes: Effective for capturing fumes from automated welding processes, Laser / Plasma cutters, robots etc.
- Less obstruction of floor space: Do not take up valuable floor space.
- Multiple canopies could be joined into a single extraction system.
Disadvantages:
- Not suitable for manual / operator welding stations as fumes will likely be drawn through operator breathing zone.
- Requires height clearance: Require sufficient height in the workspace.
On-Torch Welding Fume Extraction
Perfect for large items like structural beams, with 50–70% capture efficiency when set up properly.
Advantages:
- Effective Fume Capture: Captures fumes directly at the source, maximizing removal of hazardous substances and minimizing the welder’s exposure.
- Consistent Performance: Extraction is always optimally positioned as it’s part of the torch, eliminating the need for manual adjustments.
- Improved Productivity: Welders don’t need to stop to reposition extraction devices, leading to more arc-on time.
- Reduced Airflow Requirements: Requires less air volume compared to other extraction methods, resulting in lower energy costs.
- Cooling Effect: Airflow through the torch can help cool it, potentially extending consumable life.
Disadvantages:
- Will not extract all harmful / hazardous fumes; generally, capture efficiency is 50 – 70% if setup correctly.
- Weight and Bulk: Some welders find on-torch extraction torches heavier and bulkier than standard torches, potentially causing fatigue. However, newer models are addressing this issue.
- Potential for Shielding Gas Disruption: If not designed or used correctly, it can disrupt the shielding gas flow, leading to weld defects (porosity). Modern torches and proper usage minimize this risk.
- Maintenance: Like any equipment, on-torch extraction systems require regular maintenance, including filter changes.
- Not Suitable for All Applications: May not be ideal for all welding positions or confined spaces.
Portable Welding Fume Extractors
Ideal for mobile work or less frequent welding tasks. These units are mobile, self-contained, and flexible.
Advantages:
- Portability and Flexibility: The main advantage is their mobility. They can be easily moved to different welding locations within a workshop or even to different job sites.
- Lower Initial Cost: Generally, they have a lower initial investment compared to more complex, fixed, or on-torch extraction systems.
- Ease of Installation: Installation is usually simple, requiring only a power source.
- Versatility: Suitable for various perhaps less frequent welding processes and applications, or in a small workshop.
- Energy efficiency: Air is returned back to workplace providing no loss of conditioned / heated air.
Disadvantages:
- Manual Positioning Required: The welder must position the extraction arm correctly, which can be time-consuming and may lead to inconsistent fume capture if not done properly.
- Less Efficient Capture: They may be less effective at capturing fumes, when compared to welding benches etc, especially if not positioned optimally.
- Space Requirement: They take up floor space and may obstruct movement in tight workspaces.
- Must ensure correct filters are fitted to ensure clean air is returned to workplace.
- Maintenance: Regular filter replacement and maintenance are necessary.
- Limited Capacity: May not be suitable for heavy-duty, continuous welding operations with high fume generation.
Centralised Extraction Systems
Best suited for large workshops with multiple welding bays. These systems provide powerful fume extraction from several points, using ductwork and central filtration.
Advantages:
- Scalable and efficient for large sites.
- When combined with SmartAIR, can deliver extremely energy-efficient extraction.
- Long-term cost savings with ROI in under 12 months in some cases.
SmartAIR and Integrated Automation
To improve energy efficiency and ease of use, SmartAIR automation activates fume extraction when:
- A welding arc is struck
- A PIR sensor detects operator presence
- A robot begins welding
- An operator steps on a pressure mat
- A manual switch is activated (e.g., on the flex arm hood)
This ensures extraction systems operate only when needed, making them a cost-effective fume extraction system solution. Return air to workplace systems can be seamlessly fitted with particulate or VOC monitoring systems, ensuring air quality is safe.
Filtration Options for Welding Fume Extraction
Choosing the right filtration is essential for system performance and safety:
- Dry filtration systems: Common for general welding. Can include powder dosing or dry scrubbers to inert particles and prevent fires.
- Dry scrubbing: Works well for oily fumes, preventing filter blockages.
- Wet scrubbers: Ideal for sticky, flammable, or explosive fumes.
- Spark arrestors: Prevent flammable particles from igniting in filters.
- Return air systems: Recycle clean air into the workspace, reducing heating costs.
Filter media selection depends on the specific fume type, required efficiency, and flame-retardant properties.
Legal Responsibilities and COSHH Compliance
UK law requires all employers to assess welding fume risks and implement control measures “as low as reasonably practicable” (ALARP). This includes:
- Providing suitable engineering controls, such as LEV systems
- Performing regular health surveillance for exposed workers
- Maintaining and testing extraction systems for continued effectiveness
Failing to comply can result in substantial fines, reputational damage and more importantly, serious health consequences for your staff.
Why Cost-Effective Fume Extraction Systems Make Long-Term Sense
While it may be tempting to choose the cheapest option upfront, poorly designed systems often result in higher long-term costs through:
- Frequent maintenance or breakdowns
- Poor capture efficiency
- Non-compliance penalties
- Higher energy bills due to inefficient design
Cost effective fume extraction systems strike the right balance between upfront investment and ongoing performance, protecting your team and your bottom line.
How R&B Industrial Can Help
At R&B Industrial, we offer end-to-end solutions for welding fume extraction. From initial site assessments to full system design, installation, and COSHH LEV testing, we help you stay compliant and protect your workforce.
Our systems are built to last, tailored to your exact needs, and backed by experienced engineers who understand the practical challenges faced by manufacturers, metalworkers, and fabricators.
Talk to Our Experts Today
If you’re looking to improve air quality, reduce health risks, and ensure compliance with COSHH regulations, R&B Industrial is here to help. Get in touch with us for a tailored consultation on welding fume extraction systems and explore how we can deliver cost effective fume extraction systems that suit your specific needs.