Combating Welding Fume Inhalation with More Efficient Means
10.03.2020
Welding Unalloyed Low-Carbon Steel: The Most Common Welding Method Today
Welding unalloyed low-carbon steel is the most common welding method today, essential for any industry that uses welding in its production process. Recent scientific evidence has shown that welding fume is carcinogenic. While we have yet to see the full consequences of this discovery, it is evident that in the future, there will be increased emphasis on the health and safety of welders and on methods to guarantee them.
How Is Welding Fume Generated, and What Does It Contain?
Welding fume is generated when metal is heated above its boiling point. The vapors created by this thermal process condense into fine particles, forming a plume. Since operators need to monitor the welding seam closely, they stay near the molten metal pool. This means that the fumes, particles, and gases enter the welder’s breathing zone.
Although different welding methods produce varying amounts of fume, all contain various concentrations of hazardous substances. Chromium, manganese, nickel, NO, and CO are among the most common and dangerous ones. Smaller particles are particularly hazardous as they tend to penetrate deeper into the lungs when inhaled and, along with gases, pose the greatest health risk.
Reclassification of Welding Fume from Carbon Steel as Carcinogenic
In April 2017, the International Agency for Research on Cancer (IARC) released new scientific evidence showing that fumes from welding carbon steel can cause lung cancer (and possibly kidney cancer) in humans. The immediate legislative outcome was that fumes from welding unalloyed steels were reclassified as carcinogenic in the United Kingdom by the Health and Safety Executive (HSE), an agency dedicated to workplace safety.
As general ventilation cannot adequately control emissions, the HSE issued a regulatory update requiring all businesses conducting welding activities to implement effective measures to prevent workers from being exposed to fumes. “Regardless of duration, HSE will no longer accept any welding activity conducted without adequate protection, as there is no known safe level of exposure.” (Source: www.hse.gov.uk)
Welding Fume Legislation Likely Under Development
Workplace safety legislation varies significantly between nations. However, in Europe, the European Union sets minimum requirements that member states must meet. These standards address various workplace factors, including air quality and limit values for hazardous substances. While many countries have had legislation meeting these requirements for years, the UK’s recent approach represents a significant step toward stricter regulations on welding carbon steel. Other countries, most recently Germany, have taken legislative steps that suggest stricter welding fume regulations may also be enforced in the near future.
Different Welding Processes Require Different Fume Extraction Systems
Source extraction (also known as capture at source) has proven to be the most effective method of collecting and removing fumes. This technical solution can be portable, stationary, centralized, or customized depending on the welding process and environment. Fume Eliminator is an example of a product that can be easily moved and transported within a factory or workshop for short-duration welding. Stationary devices—such as extraction arms, reels, or welding and grinding tables—remain the most common fume extraction methods and will continue to replace air recirculation systems for many welding operations.
Welding Health and Safety Standards Are Continuously Evolving
While it is challenging to predict future welding legislation, certain trends in industrial welding are apparent. Previously, most welding processes were designed for specific applications, but today it is much easier to design a welding process that combines features of multiple methods. This includes the possibility of performing complex movements and addressing parts with diverse configurations in a single production step—supported by customized source extraction—or creating a product through a 3D printing process.
We can also expect robotic welding to become increasingly common. To maintain a high level of cleanliness and quality, these welding robots also require fume extraction systems. Both the robot and the welding surface must be clean for the robot to perform its tasks with precision. Additionally, human workers will need to access these robots for maintenance and adjustments, meaning the air in robotic environments must be free from carcinogenic substances and other hazardous particles.
Both trends align with the development we are already seeing, where new generations of welders challenge old workplace cultures and demand safer, cleaner working environments.
Everyone Benefits When the Workplace Is Safe and Clean
Companies equipped with effective fume extraction systems quickly notice a difference, as their factories and workshops become visibly cleaner when fumes from the production process are properly extracted. Such workplaces result in healthier workers, fewer sick days, and prevention of early retirement. Businesses with safe and clean working conditions also tend to experience benefits such as higher productivity, improved product quality, and a greater likelihood of attracting and retaining highly skilled personnel.
