Welding Fume

Control Measures

Employers should always consider whether it is possible to eliminate the health risks associated with welding. Alternatives to welding may include cold joining techniques using mechanical fasteners (bolts, rivets etc.) or adhesives.

Where welding cannot be eliminated consideration should be given to the following:

• reducing the amount of welding taking place
• using welding consumables that produce less fume
• using a welding process that produces less fume
• making sure the metal has been properly cleaned and prepared
• automating or mechanising the process or job
• using other engineering controls such as Local Exhaust Ventilation

Effective management and administrative control measures are also important. Some examples include the provision of a dedicated area for welding thereby minimising exposure to other workers in the workplace.

The hierarchy of control places the use of personal protective equipment as the least preferable control measure in terms of overall priority. In most cases however a combination of control measures will be required to ensure adequate control of welding fume.

Local exhaust ventilation
Where it has not been possible to eliminate the need for welding, or substitute the welding technique with a less hazardous one, other engineering controls including Local Exhaust Ventilation (LEV) may be necessary to remove the fume at source.

A range of LEV is available depending on the size of the workpiece being worked on and range from extracted benches to on-torch extraction systems to moveable capture hoods. It is important to ensure that extraction systems are suitably designed for the welding process taking place.

In some cases the provision of LEV may not be reasonably practicable e.g. when welding at height or outdoors. Under such circumstances suitable respiratory protective equipment (RPE) may be required for relevant employees.

Where LEV is used, employers should ensure that employees are trained on how to operate the equipment and that it has been suitably maintained and thoroughly examined so as to ensure it is performing as intended. Further information on LEV systems is available within HSE guidance entitled Controlling airborne contaminants at work: A guide to local exhaust ventilation (LEV) HSG258.

Respiratory Protective Equipment (RPE)
The following guidelines should be followed when using RPE to control welding fume:

• RPE with a UK Standard Assigned Protection Factor (APF) of at least 20 will normally be required e.g. FFP3.
• For work not expected to exceed one hour, a FFP3 tight-fitting disposable mask or reusable half-mask with a P3 filter may be adequate to control fume particulate.
• Particulate filters will not protect workers from welding gases that may be contained within the fume.
• Workers must have had a face-fit test to ensure tight-fitting respirators fit properly and be clean shaven for this type of respirator to work effectively.
• Workers should be trained to use, check and clean the respirator.
• The filters or disposable respirators should be changed regularly.
• The equipment should be stored in a clean, dust-free place such as a container.
• If any defects are found, or the respirator does not fit, is dirty or its filter is old, it should be replaced.

Further information relating to the measures that should be considered in order of priority can be found within BOHS guidance entitled Welding Hierarchy of Control.

More detailed industry guidance on controlling the risks associated with welding fume, as well as other activities such as cutting and surface preparation is available as part of HSE’s COSHH essentials task related guidance.

Further guidance on appropriate control measures can be accessed using the BOHS Welding Fume Control Selector Tool. This web-tool is designed to complement the information on the Breathe Freely campaign website developed by BOHS for the manufacturing sector.