Client Overview
Our client operates within the metal fabrication sector, carrying out MIG and TIG welding of mild and stainless-steel fabrications in their main production area.
As an existing customer, they required an upgraded extraction system to improve fume control across multiple welding bays and ensure compliance ahead of an upcoming ISO audit.
The Challenge
The client’s existing setup presented several operational and compliance issues:
- Inadequate flexible droppers that prevented correct hood positioning
- Only 4 existing extraction arms in place with a requirement for 8
- Requirement to control hazardous welding fumes, including:
- Manganese
- Nickel
- Chromium
- Ozone
- Need to meet strict Workplace Exposure Limits (WELs)
- ISO audit deadline requiring full commissioning documentation by a specific deadline
The system needed to extract from all welding stations simultaneously while ensuring adequate capture velocities for safe control of the hazardous welding fumes.
Our Solution
We designed and installed a new 8-bay welding fume extraction system, incorporating both upgraded and reused components to deliver a cost-effective solution.
Key elements included:
- Reuse of 4 existing extraction arms
- Supply and installation of 4 additional extraction arms to replace ineffective droppers
- Integration of existing ductwork where suitable (as per colour-coded layout drawings)
- Installation of a new 11kW centrifugal fan positioned on the mezzanine floor
- Design airflow to allow all 8 arms to operate simultaneously
- Calculated capture distances:
- 150mm @ 1m/s (higher toxicity fumes)
- 240mm @ 0.5m/s (lower toxicity fumes)
- Approximately 3000 m³/hr of general ventilation, supplied via three high-level extraction louvres
- Installation of airflow indicators (8 Chevrons), calibrated at commissioning
- Intermediate inspection doors fitted for maintenance access & internal ductwork inspection
The project was delivered within a 3-day installation window, including system strip-out, with commissioning completed in one day to meet the audit timeline.
The Results
The completed system delivered effective source capture across all eight welding bays, significantly improving hood positioning and operator usability while ensuring compliance-ready performance aligned with Workplace Exposure Limits (WELs).
In addition to controlling hazardous welding fumes at source, the system enhanced general ventilation throughout the fabrication area, creating a cleaner and safer working environment.
The installation was fully commissioned with all required documentation supplied ahead of the company’s ISO audit, providing a robust, compliant, and future-proofed LEV solution tailored to Finest Fabrication’s operational needs.
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