Multiple Ways to Reduce the Risks of Welding Fumes

Welding fume extraction is essential to protect workers and maintain a clean environment. Source capture—extracting fumes directly at the point of welding—is always the most efficient and safest method. On top of that, various additional measures can help reduce fumes and lower exposure risks.

There are many systems that help remove welding shop fumes, such as downdraft tables, extraction arms and hoods, filter systems, fans, or systems that control the background concentration of welding fumes in the workshop. In this article, we explore different ways to reduce the risks associated with welding fumes.

Adjusting Work Conditions

Changing how and where welding tasks are performed is one of the simplest ways to reduce exposure:

• Avoid welding in confined or enclosed spaces whenever possible.
• Modify the welding sequence to position the welder out of the direct fume path.
• Consider seated welding setups—these often reduce exposure near the welder’s face.
• Use turntables to reposition the workpiece so fumes naturally rise away from the breathing zone.

Design Jobs to Require Less Welding

Depending on the task, there are many ways to reduce the amount of welding needed—and with it, the amount of fume generated:

• Use cold-joining methods like mechanical fasteners (bolts, rivets) or advanced adhesives. These are increasingly common in automotive and industrial applications.
• Choose thinner-gauge materials where possible, reducing weld passes and power demands—both of which lower fume output.
• MIG brazing, in some cases, can offer similar structural performance to full-penetration welds but with less fume. Most modern machines support this.

Modify Fabrication Techniques

Production methods can also help minimize exposure:

• Use automated or self-guided welding machines where appropriate to reduce manual welding and grinding.
• Apply ceramic backing or inert gas backing to minimize root weld grinding. Note: inert gases may require extra safety precautions to avoid asphyxiation risks.

Use Low-Fume Welding Techniques

Some welding processes naturally produce fewer fumes:

• TIG welding emits the least fume, although it releases ozone and nitrogen oxides, which can be irritating.
• MIG and MAG generate more fume; stick welding (MMA) and flux-cored arc welding produce the most.
• Where possible, automate welding using methods like submerged arc welding, “hot wire” TIG, or electron beam welding to reduce fume and improve consistency.

Resistance welding is another low-fume alternative. For example, in shipbuilding, fairing brackets can be attached with stud welding instead of manual arc welding, reducing both fume generation and cleanup time.

Optimize Shielding Gas

Using the right shielding gas mixture can significantly reduce fume levels:

• High amperage and long duty cycles increase fume emissions and reduce weld quality.
• Ask your gas supplier for the optimal shielding gas mix to maintain performance and minimize fumes.

Shielding gas optimization is a quick win that improves weld quality and lowers overall fume exposure.

Frequently Asked Questions

What is welding fume extraction and why is it important?

Welding fume extraction is the process of capturing and removing harmful fumes directly at the source. It protects welders from breathing in toxic metal particles and helps remove welding shop fumes from the workspace, improving overall air quality and safety.

How can I reduce exposure to welding fumes at work?

To limit fume exposure:

• Use local exhaust ventilation (LEV) like source extraction arms.

• Choose low-fume welding methods such as TIG or MIG brazing.

• Improve general ventilation in the shop.

• Position work to keep fumes out of the breathing zone.

What do workplace safety regulations say about welding fume extraction?

In the U.S. and Canada, employers must control exposure to welding fumes under workplace health and safety laws. If welding fume extraction at the source is technically feasible, it’s often mandatory.

Check guidelines for your country:

• USA (OSHA): Welding, Cutting and Brazing Standards

• Canada (CCOHS): Welding - Fume Extraction

Is source extraction mandatory during welding?

Yes. In most countries, if source extraction is technically possible, it’s legally required. It's the most effective way to remove welding shop fumes and protect worker health.

What is the best way to extract welding fumes in confined spaces?

Use mobile welding fume extraction units with flexible arms. These systems are designed to work in tight or enclosed spaces and allow precise fume capture without obstructing movement.

How can I ensure my workshop complies with welding fume safety standards?

• Install welding fume extraction systems at every weld station.

• Use certified filters and ventilation.

• Train workers on proper use.

• Monitor air quality regularly.

• Document all safety procedures and maintenance.