Welding Fume Extraction: Different Ways to Reduce Welding Fume Risks

Using effective welding fume extraction is the safest and most efficient way to protect welders from hazardous fumes. Source extraction systems remove fumes where they're created and help to reduce welding fumes in the entire workshop.

There are many systems that extract welding fumes, such as downdraft tables, extraction arms and hoods, filter systems, fans or systems to control the background concentration of welding fumes in a workshop. In this article, we outline various solutions to lower the risks associated with welding fumes.

Changing Working Conditions to Reduce Welding Fumes

Modifying the working environment is one of the simplest ways to reduce exposure:

• Avoid welding in confined or enclosed spaces when possible.
• Adjust the welding sequence to keep the welder out of the direct fume path.
• Let welders work seated if possible; it helps reduce fume exposure near the face.
• Use turntables to reposition the workpiece and guide fumes away from the welder.

Redesigning Jobs to Minimise Welding

Certain job designs help reduce welding fumes from the start:

• Use cold jointing techniques like bolts, rivets, or industrial adhesives.
• Consider friction stir welding; it produces minimal to no fume.
• Choose thinner gauge materials, which require less power and fewer weld passes.
• Try MIG brazing where suitable, as it generates less fume than full-penetration welding.

Many modern welding machines support brazing functions, so no need for major equipment changes.

Improving Production Techniques

• Use automated welding or self-guided weld profilers where possible.
• Reduce manual grinding by designing parts that don't need it.
• Apply ceramic backing tiles or inert gas backing techniques to avoid root pass back-gouging (ensure proper ventilation when using inert gases).

Choose Low-Fume Welding Techniques

Different welding methods produce different fume levels:

• TIG welding produces the least fume but does release ozone and nitrous oxide.
• MIG and MAG emit more fumes.
• MMA (stick welding) and flux-cored welding create the most fume.

Automated welding methods such as submerged arc, hot wire TIG, or electron beam welding can be cleaner and more efficient. Resistance welding is another good option; for example, using stud-welded bolts instead of arc-welded brackets in shipbuilding significantly reduces fume generation.

Optimise Shielding Gas to Reduce Welding Fumes

• High current and long duty cycles increase fume production.
• Choose shielding gases designed to reduce fume and improve weld speed and quality.

Speak to your gas supplier about the best shielding gas mix for your application.

Frequently Asked Questions

What is welding fume extraction and why is it important?
Welding fume extraction removes hazardous particles at the source, protecting welders and keeping workshop air clean.

How can I reduce exposure to welding fumes at work?
Use source extraction systems, choose low-fume welding processes, improve ventilation, and ensure proper work positioning to limit fume exposure.

What do workplace safety regulations say about welding fume extraction?
Most countries require employers to control exposure to welding fumes by law. If technically feasible, source extraction is mandatory. See official guidelines for your region:

• Welding: Fume Control

• Ireland (Health and Safety Authority): Welding Safety
• Australia (Safe Work Australia): Welding processes – managing risks
• India (DGFASLI – Ministry of Labour): Safety in Welding and Cutting (navigate to publications or safety guidelines)

Is source extraction mandatory during welding?
Yes – in most countries, source extraction is legally required if it’s technically possible. It’s the most effective way to protect workers from dangerous welding fumes.

What is the best way to extract welding fumes in confined spaces?
Mobile fume extractors with flexible arms are ideal for tight or enclosed areas. They ensure targeted fume removal without blocking movement.

How can I ensure my workshop complies with welding fume safety standards?
Install source extraction at every welding station, use approved ventilation systems, train your staff, monitor air quality, and document all safety procedures.