Safely collect and extract welding dust, fume and smoke from industrial processes
Capturing the dust, smoke and fumes generated during welding presents a unique challenge. Workplaces differ individually in layout and as such the system design should meet the specific requirements, this can require using various capturing techniques for the contaminated air. Sometimes it is sufficient to use simple flexible arm and capture hood, or more often is the case that bespoke extraction hoods may be needed around manual working areas or to contain the fumes generated in automated and robot welding cells or maybe high level ambient extraction. In some countries you may need additional HEPA filtration to permit recirculation of the air into the workplace or even to extract to atmosphere so there are many local variants of indoor and outdoor environmental guidance to consider.
Health problems from welding fumes and smoke
There are many significant risks of long term health effects of operatives due to the complex and variable mixtures of gases and particulates produced by the different types of welding MIG, MAG, TIG or laser welding for example:
- Metal dust particles in welding fumes are a leading cause of eye irritation, upper respiratory infections, coughs and headaches.
- Manganese in welding wire causes weakness, fatigue and headaches. Chronic overexposure leads to “manganism” which causes neurological and neurobehavioral problems.
- Hexavalent chromium (hex chrome) is a carcinogenic substance produced when welding stainless steel and other metals that contain chromium. Overexposure can cause upper respiratory damage, eye and skin irritations, rashes, allergies, contact dermatitis, sinus irritation, nosebleeds, stomach and nose ulcers, chest tightness, wheezing and shortness of breath. Long-term exposure can cause lung cancer and injury to the eyes, skin, liver and kidneys.
- Zinc oxide is produced when welding galvanized steel. Exposure can cause “metal fume fever,” a short-term illness with severe flu-like symptoms. It can potentially be confused with regular influenza and often goes undiagnosed.
We recommend consulting an expert when selecting and dimensioning the right dust and fume extraction system to ensure you are getting the appropriate and reliable separating solution for your application. The particle characteristics, airflow, and loading rates, which can greatly vary depending on the application, must be taken into consideration. Camfil APC with our experience and range of state-of-the-art filtration products are able to assist you in finding the solution that is most effective for your facility.
Why should I install an extraction system to remove welding dust and fumes from my production?
- Respiratory Health — A well-designed and maintained dust and fume collection system prevents respiratory problems and keep facilities in compliance with current air quality requirements.
- Maintenance — The equipment that fabricating plants currently use has reached a new level of sophistication. Controls and other computerized systems are more sensitive than the machinery of 10 or 20 years ago. If welding fumes are not managed properly, electronic controls can fail, shutting down operations and requiring emergency repairs. This causes production downtime, frustration and costly losses in productivity.
- Energy Savings — In cold climates and with a secondary police filter system installed, you can significantly reduce your energy costs by recirculating the filtered air back into the workplace and lowering the need for costly makeup air.
Application-specific extraction solutions - we will be happy to advise you!
Quantum Series – compact extraction system for welding dust and fume with small to medium air volumes
The Quantum Series separators is designed to handle all kind of welding dust, fume and smoke and includes three collector sizes from 1,500 – 5,500 m³/h. An integrated spark arrestor as well as an improved filter design and cleaning system ensure the necessary process reliability. Thanks to its small footprint, the separator can be integrated perfectly into the production environment. The large maintenance door and simple filter change make the plug-and-play devices particularly easy to maintain.
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Gold Series X-Flo – dry dust collector for welding applications with bigger air volumes starting from 5.500 m³/h
The modular-designed Gold Series X-Flo dust collection system is a reliable solution for capturing and separating dust and fume from welding applications where larger air volumes above 5,500 m³/h are required. The cross-flow technology used in combination with a unique baffle configuration creates a uniform airflow that extends the life of your filter cartridges and reduces the overall operating costs.
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Zephyr III – mobile extraction system for capture and extraction of welding fumes
The Zephyr III is ideal for industrial process contamination, source capture, and any production facility requiring periodic dust collection at various locations. The Zephyr III is a portable air cleaner for capturing welding fumes, grinding dusts, soldering fumes, and other airborne particles.
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