WLD/Hazards/TBT-WLD-007

Welding Fume Extraction and LEV

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Welding Fume Extraction and LEV

Toolbox Talk Record

Ref: TBT-WLD-007  |  Issue: 1  |  Date: March 2026
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What?

  • Welding fume is a complex mixture of metal oxides, gases, and fine particles generated during welding.
  • The International Agency for Research on Cancer (IARC) classifies all welding fume as carcinogenic to humans.
  • Mild steel welding fume is now classified as a Group 1 carcinogen, not just stainless steel fume.
  • Local exhaust ventilation (LEV) captures fume at source before it reaches the welder breathing zone.
  • LEV systems include on-torch extraction, mobile fume units, fixed extraction arms, and downdraft benches.
  • General ventilation alone is not sufficient to control welding fume exposure to safe levels.
  • COSHH 2002 requires employers to prevent or adequately control exposure to hazardous substances including fume.
  • LEV systems must be examined and tested by a competent person at least every 14 months.
  • RPE is required in addition to LEV where fume exposure cannot be adequately controlled by extraction alone.
  • Welding on coated, painted, or galvanised steel generates additional toxic fumes requiring extra controls.

Why?

Prevent cancerWelding fume is a confirmed human carcinogen. Without extraction, welders face significantly increased lung cancer risk.
Legal requirementHSE issued enforcement expectation EH40 stating LEV or RPE must be used for all welding — general ventilation is not enough.
Lung diseaseBeyond cancer, welding fume causes occupational asthma, metal fume fever, pneumonia, and chronic obstructive pulmonary disease.
Do Don't
  • Use LEV at the point of welding for every welding task, every time.
  • Position the extraction nozzle as close to the arc as practicable.
  • Check the LEV system is working before starting any welding operation.
  • Wear RPE in addition to LEV where fume exposure remains significant.
  • Ensure LEV systems are examined and tested at least every 14 months.
  • Use on-torch extraction where available for MIG and flux-cored welding.
  • Increase extraction controls when welding coated, painted, or galvanised steel.
  • Keep your head out of the fume plume even when extraction is operating.
  • Report any reduction in extraction performance or damaged ducting immediately.
  • Attend health surveillance including lung function testing when required.
  • DON'T weld without LEV or RPE in place — general ventilation is not enough.
  • DON'T position the extraction nozzle too far from the welding arc.
  • DON'T assume mild steel welding fume is safe; it is now classified carcinogenic.
  • DON'T block, kink, or obstruct LEV ducting or extraction hoses.
  • DON'T rely solely on RPE when LEV extraction is reasonably practicable.
  • DON'T weld on painted or galvanised surfaces without additional fume controls.
  • DON'T switch off extraction to reduce noise or because it feels draughty.
  • DON'T ignore symptoms such as coughing, breathlessness, or metallic taste.
  • DON'T skip LEV maintenance inspections or ignore the 14-month test interval.
  • DON'T eat, drink, or smoke in areas where welding fume may be present.

See also: Welding Safety Awareness (Comprehensive) | RPE Selection and Face Fit Testing
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