Introduction
Welding fume exposure can lead to serious health conditions like occupational asthma, lung cancer, and Parkinson’s disease. To protect welders, the Health and Safety Executive (HSE) has implemented legal exposure limits and control measures that workplaces must comply with.
In this blog post, we’ll break down the risks of welding fumes, explain HSE welding fume regulations, and discuss ways to meet the requirements through exposure reduction and proper respiratory protection.
The Dangers of Welding Fumes
Welding produces a complex mixture of airborne contaminants in the form of gases, fine particles, and metal oxides. Fumes are generated when the intense heat of the welding arc vaporizes base metals and filler materials.
The fumes contain over 100 different substances including manganese, chromium, nickel, cadmium, fluorspar, zinc and copper. Many of these particulates are linked to:
- Lung cancer
- Asthma and bronchitis
- Metal fume fever with flu-like symptoms
- Respiratory tract irritation
- Immune system damage
- Nervous system disorders like Parkinson’s disease
Repeated exposure to the toxins in welding fumes puts welders at high risk of developing permanent respiratory issues and other chronic health problems over time.
HSE Legal Exposure Limits
To protect welders from dangerous concentrations of airborne contaminants, the HSE has set legal limits on welding fume exposure:
- Total inhalable fume exposure must not exceed 5mg/m3 over an 8-hour period
- For manganese and chromium VI, levels should stay below 0.5mg/m3 over 8 hours
It is the employer’s duty to ensure their welding workspace and processes adhere to the prescribed limits. This may require implementing suitable exposure controls and providing proper respiratory protection.
Recommended Exposure Control Measures
The HSE recommends a hierarchy of fume control measures to reduce welding exposure:
- Source extraction – Extractors and LEV systems that capture fume at the arc source. This is the most effective exposure control.
- General ventilation – Diluting and dispersing fume with fans and open doors/windows. Provides only limited control.
- Respiratory protective equipment (RPE) – Using respirators to filter the air inhaled by welders. Required in tandem with other controls.
- Proper selection of welding process and materials – Some processes like laser and ultrasonic welding minimize fume. Special low-fume rods are also available.
- Separating the welding area – Using screens, curtains and extraction booths to isolate welding and contain fumes.
- Job rotation – Rotating welders between high and low exposure tasks to limit exposure duration.
- Training – Educating welders on risks and correct use of exposure controls. Ensures proper adherence to minimize fume.
Fume extraction systems like mobile or centralised extractors, or on-gun extraction torches, provide the best source control. They should be supported by general ventilation and PPE respirators where needed.
Respiratory Protection for Welders
Even with exposure controls, achieving HSE compliance usually requires providing suitable RPE for welders. Powered respirators coupled with the correct filter cartridges reliably bring fume exposure down to acceptable levels.
Key factors in RPE selection:
- Filters that remove the specific welding fume particulates like chromium and manganese
- Sufficient assigned protection factor (APF) rating of at least 20
- Fit testing to ensure a tight facepiece seal
- Proper maintenance and filter replacement schedule
Selecting the Right Fume Extraction System
Welding produces harmful fumes containing toxic particles and gases that can cause severe respiratory diseases, cancer, metal fume fever, and nervous system damage over time. To protect the wellbeing of welders, the Health and Safety Executive (HSE) has set legal exposure limits on the levels of manganese, chromium and general fumes in welding workspaces. It is the employer’s responsibility to implement adequate controls like fume extraction systems and protective respirators to adhere to these prescribed limits.
The HSE recommends a hierarchy of exposure control methods including source capture systems close to the weld, general ventilation, using safer materials, isolation screens, job rotation, and proper training. Extraction systems provide the best protection by capturing fumes at the welding point before they disperse into the air. This should be supported by powered respirators fitted with appropriate filters to control the personal exposure of welders when needed. A combination of engineering and PPE controls is necessary to reduce all welding fume exposures below 5mg/m3 over an 8 hour shift to comply with regulations and minimize health risks.
Conclusion
Left uncontrolled, welding fume exposures frequently exceed safe limits and put welders at significant long-term health risk. Employers must implement adequate exposure controls and respirators that adhere to HSE regulations. Fume extraction, ventilation, PPE, and other measures should all be utilized to properly protect workers from the hazards of welding fumes.
