Why Welding Fume Control Matters

Welding fume is a significant occupational hazard welders face that requires immediate action. With 2024 came the Workplace Exposure Standard Update, which lowered the limit from 5mg/m³ to 1mg/m³, businesses are required to adopt effective control measures to protect their welders. A scientific study conducted confirms that extended exposure to welding fumes increases the risk of lung cancer and other deadly respiratory diseases which makes it imperative employers implement robust fume control solutions.

Understanding the risks of Welding Fume

Welding fume is classified as carcinogenic, meaning it poses severe long-term health risks, which include lung cancer, and chronic respiratory conditions. Given these dangers, all employers must review and update their risk management procedures to ensure compliance with safety regulations. The key to mitigating these risks is selecting the right combination of engineering control, PPE, and administrative efforts to ensure compliance.

 

Hierarchy of Controls For Welding Fume

 

According to the hierarchy of control, the most effective way to reduce welding fume exposure include:

1. Elimination and Substitution – Use alternative welding methods or materials that produce fewer fumes.
2. Engineering Controls – Implementing Local Exhaust Ventilation (LEV) systems, such as on-gun extraction and portable fume extraction units which help capture and remove welding fumes directly from the source.
3. Personal Protective Equipment (PPE) – High-quality welding helmets with integrated powered air-purifying respirators (PAPR) provide superior respiratory protection compared to disposable or reusable half-mask respirators.
4. Administrative Efforts – Proper workplace training, routine equipment maintenance, and fume exposure monitoring.

The Role Of PPE in Welding Fume Control

 

When other control measures cannot completely mitigate welding fume exposure, PPE becomes essential. The two primary types of respiratory protection for welders include:

1. Welding Helmets with Integrated Power Air Respirators

• Provides an assigned protection factor of 50, significantly reducing fume exposure.
• Offer a steady flow of filtered air, improving comfort and reducing heat build-up.
• Do not require fit testing or a clean-shaven face unlike half-mask respirators.
• Long-term cost savings due to less frequence filter replacements.

1. Half Mask Respirators

• Provide an APF of 10, offering less protection than PAPR systems.
• Require fit testing and a clean-shaven face for effectiveness.
• Can cause discomfort due to heat and negative pressure seals
• More frequent filter changes lead to higher long-term costs.

Engineering Controls: LEV Systems

 

Properly installed Local Exhaust Ventilation (LEV) systems effectively capture and remove welding fumes. The three most practiced LEV options include:

 

1. On-Gun Fume Extraction

• Captures fumes directly as the source.
• Provides mobility as it follows the welders movement.
• Newer models are lightweight and do not interfere with shielding gas.

2. Portable LEV Systems

• Flexible and cost-effective for mobile welders
• Can be moved around the workshop for localized fume extraction

3. Fixed LEV Hood Capture Systems

• Effective in dedicated welding stations
• Best suited for large-scale industrial environments

 

Scientific Research on Welding Fume Control

 

A 2022 study published in the Safety Journal compared the effectiveness of fume control methods. The findings showed that

• PAPR Welding Helmets reduced exposure by at least 99.96% making them the most effective form of protection.
• On-gun fume extraction removed up to 98% of welding fumes proving 33% more effective than fixed LEV systems.
• LEV systems should always be used alongside PPE for comprehensive protection.

Employer Responsibilities in Welding Fume Control

Under Australian and New Zealand Work Health and Safety Laws, employers must ensure welders are protected from harmful fume exposure. 

 

Key responsibilities include:

• Conducting air monitoring if exposure levels are uncertain.
• Providing PPE at no cost to employees.
• Offer proper training on the use and maintenance of PPE and LEV systems.
• Ensuring compliance with updated exposure standards.

Practical Steps For Welding Fume Protection

To minimize welding fume exposure, businesses should:

1. Equip welders with PAPR helmets to maximize respiratory protection.
2. Install LEV systems to extract fumes at the source.
3. Train workers on proper fume control practices.
4. Monitor air quality regularly to ensure compliance.
5. Use alternative materials and processes where possible to reduce fume generation.

For more information on welding fume control solutions, contact Gentronics today.