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Robotic Welding: Embracing the Benefits for a Safer and More Productive Future

Clean Air Industries on January 30, 2024

In today’s manufacturing landscape, the challenge of sustaining a skilled welding workforce is a common concern. The industry is grappling with a unique set of challenges: rapid growth, an aging workforce, and a scarcity of fresh talent, leading to a significant skills gap. The American Welding Society anticipates a shortfall of 360,000 skilled welding professionals by 2027, a reality that’s rippling through the industry, affecting morale and stretching resources thin. This is particularly impactful considering that half of all manufactured products require some form of welding.

Traditional recruitment methods alone are proving inadequate in meeting the demand for skilled welders necessary to maintain the high production levels required in today’s competitive market. Manufacturers are increasingly turning to a strategic blend of advanced technologies and robotic automation, complemented by human expertise, to address workforce shortages and enhance employee morale.

Robotic Welding: A Strategic Solution

The integration of robotic welding offers undeniable benefits, despite some manufacturers’ reservations. Robotic automation doesn’t replace the unique skills and experience of manual welders. Instead, it enables them to concentrate on more complex, creative, and problem-solving tasks.

Safer Operations

Welding poses significant health and safety risks to operators, resulting in the deaths of approximately 60 American workers annually. The National Library of Medicine (NIH) reports that 109,127 welding-associated ocular injuries occurred in the United States from 2010 to 2019. “Welder’s flash,” or burns to the eyes due to ultraviolet light emitted from certain welding operations, account for almost 6% of all workplace-related eye injuries in the American construction sector. In Canada, over one-fifth of all workers’ compensation claims related to eye injuries originate from professionals in the welding sector.

Other common injuries include electric shock, burns, and Manganism, a neurological disorder with symptoms resembling those of Parkinson’s disease, caused by chronic exposure to manganese. Robotic welding mitigates many of these risks, enhancing safety with controlled operations.

Enhanced Efficiency and Focus on High-Value Tasks

Robotic welding systems, typically featuring one or two arc welding robots equipped with advanced technology for seam tracking, can match the productivity of multiple welders. This allows human workers to focus on specialized or custom tasks, reducing monotony and the risk of burnout or ergonomic injuries.

Creation of New Roles for Skilled Welders

The adoption of robotic welding necessitates skilled personnel for operation and programming. Experienced welders, with their deep understanding of welding nuances, are ideally suited for these roles. Their expertise in welding techniques and quality control is invaluable in programming and overseeing robotic systems, leading to smoother integration and enhanced productivity.

Competitive Advantage

Robotic welding can significantly improve product quality, critical in maintaining a competitive edge. This technology not only meets high-volume demands but also supports long-term employee development over temporary staffing solutions.

Long-term Success with Automated Welding

In summary, the strategic integration of robotic welding is a forward-thinking solution to the skilled welder shortage, offering a blend of technological efficiency and human expertise, while providing for a far safer and healthier work environment – even more so when combined with an advanced fume control system. This approach not only addresses immediate production needs but also sets the stage for long-term success and competitiveness in the manufacturing sector.

Unlocking Workplace Safety and Efficiency: The Importance of Downdraft Tables in Manufacturing

Clean Air Industries on January 10, 2024

Imagine a bustling manufacturing facility, the rhythmic hum of machinery, and dedicated workers striving to meet production targets. In this scene, safety should never be an afterthought. Yet, accidents and health hazards can loom over even the most well-run operation.

In this blog post, we’ll delve into the world of downdraft tables, their invaluable role in manufacturing, and how they not only boost productivity but also help prevent injuries and illnesses. We’ll share compelling statistics and data to underscore their significance in maintaining a safe and healthy workplace.

The Vital Role of Downdraft Tables in Manufacturing

In the dynamic world of manufacturing, where efficiency and productivity are king, the health and safety of workers often hinge on the equipment used. Among these, downdraft tables play a pivotal role. These specialized workstations are designed to capture and contain harmful dust, debris, and fumes right at the source, before they can invade the breathing space of workers.

The Invisible Threat in the Air

According to the Centers for Disease Control and Prevention (CDC), an estimated 558,000 workers in the USA are exposed to hexavalent chromium, a common compound in manufacturing [1]. Prolonged exposure to hexavalent chromium can lead to serious health issues like lung cancer and chronic obstructive pulmonary disease (COPD). Downdraft tables are instrumental in mitigating these risks by providing a localized extraction and filtration system.

A Statistical Perspective on Workplace Health

The implementation of downdraft tables has shown a marked improvement in workplace health. A study by the Journal of Occupational and Environmental Hygiene revealed that the use of local exhaust ventilation, like downdraft tables, can reduce airborne contaminants by up to 95%. This reduction significantly lowers the risk of respiratory diseases, which account for about 24% of all work-related illnesses in the manufacturing sector [2].

Beyond Health: Enhancing Productivity and Quality

Downdraft tables not only safeguard health but also enhance overall productivity and product quality. By removing airborne contaminants, they provide a cleaner work environment, leading to fewer machine malfunctions and lower maintenance costs. Moreover, a healthier workforce is invariably more productive and less prone to absenteeism due to illness.

The Economic Impact of Improved Safety

Investing in downdraft tables is not just a health and safety measure; it’s a smart economic decision. The National Safety Council estimates that work-related injuries and deaths cost the U.S. economy $167 billion in 2021 alone [3]. By preventing such incidents, downdraft tables contribute to reducing these enormous costs.

A Call to Action for Safer Workplaces

The story of downdraft tables in manufacturing is one of silent guardianship. They stand as a testament to the fact that the best safety measures are often those that go unnoticed, seamlessly integrated into the daily workflow. As we continue to advance in industrial practices, let’s not forget the importance of such equipment in safeguarding the health and well-being of our workforce. After all, a healthy worker is the true backbone of any successful manufacturing operation.

Downdraft tables might seem unassuming, but their impact on manufacturing settings is profound. They not only shield workers from harm but also bolster production efficiency. As the statistics demonstrate, these tables are an investment in both the well-being of your workforce and the bottom line of your business.

Incorporating downdraft tables into your manufacturing facility isn’t just a safety measure; it’s a strategic decision to secure a healthier, more productive future. By doing so, you’re not only protecting your employees but also fortifying your company’s position in the competitive manufacturing landscape.

Remember, in the world of manufacturing, safety is not just a priority – it’s a responsibility. Downdraft tables, with their proven track record, are here to help you fulfill that responsibility with excellence.

References

  1. Centers for Disease Control and Prevention (CDC). “Occupational Exposure to Hexavalent Chromium” [Online]. Available: https://www.cdc.gov/niosh/docs/2013-128/pdfs/2013_128.pdf.
  2. U.S. Bureau of Labor Statistics. “Respiratory Conditions Due to Toxic Agents” [Online]. Available: https://www.bls.gov/.
  3. National Safety Council. “Work Injury Costs – 2021” [Online]. Available: https://injuryfacts.nsc.org/work/costs/work-injury-costs/.

Understanding Oil Mist and Oil Smoke: Applications, Health Risks, Safety Hazards, and Effective Solutions

Clean Air Industries on July 7, 2023

Oil mist and oil smoke in manufacturing facilities are primarily generated by industrial processes that involve the use of cutting fluids, such as machining, grinding, and milling. There are different types of cutting fluids that generate oil mist and smoke, including straight oils, soluble oils, semi-synthetic fluids, water-based fluids (composed of water, with additives for lubrication and rust prevention), and synthetic fluids. These fluids are used to cool, lubricate, and remove metal particles during the machining process. When these fluids come into contact with the hot surface of the workpiece, they vaporize and form an oil mist or smoke.

The difference between oil mist and oil smoke lies in the size of the particles. Oil mist consists of larger particles and is usually visible to the naked eye, while oil smoke consists of smaller particles and may not be visible.

OSHA Guidelines and Compliance

The Occupational Safety and Health Administration (OSHA) has set a permissible exposure limit (PEL) for oil mist at 5 milligrams per cubic meter of air for an 8-hour workday, 40-hour workweek. OSHA also has regulations regarding ventilation, the use of PPE, and other safety measures.

It’s important to note that specific regulations can vary depending on the type of oil being used, the specific processes in place at a facility, and other factors. Therefore, it’s crucial to consult with a safety professional or industrial hygienist to ensure compliance with all relevant regulations.

Applications Associated with Oil Mist

Oil mist is typically generated in manufacturing applications that involve the use of oil for lubrication or cooling. Here are some specific examples:

  • Metalworking: In processes such as drilling, milling, grinding, and turning, cooling lubricants are often used to reduce heat and friction. These lubricants can become aerosolized, creating an oil mist.
  • Machining: High-speed machining centers often use oil-based coolants, which can create a mist when they come into contact with the hot surface of the machined part.
  • Gear Manufacturing: Gear cutting, grinding, and hobbing processes often use oil-based coolants, which can generate oil mist.
  • Cold Forming and Forging: These processes often use lubricants to reduce friction and wear, which can generate oil mist.
  • Die Casting: Die casting machines often use oil-based lubricants to cool and lubricate the die, which can generate oil mist.
  • Spindles and Bearings: High-speed spindles and bearings often use oil-air or oil-mist lubrication systems, which can generate oil mist.
  • Heat Treatment: Quenching processes in heat treatment often use oil, which can generate oil mist.

Applications Associated with Oil Smoke

Oil smoke is typically generated in manufacturing processes that involve high temperatures and the use of oil-based lubricants or coolants. Here are some examples:

  • Metalworking: Processes such as grinding, turning, milling, and drilling often generate oil smoke when high-speed cutting tools come into contact with oil-based coolants or lubricants. The heat generated by the friction can cause the oil to smoke.
  • Heat Treatment: Processes like hardening, tempering, and annealing can generate oil smoke, particularly if oil quenching is used to cool the parts.
  • Die Casting: In die casting, molten metal is forced into a mold under high pressure. The high temperatures involved can cause any oil-based lubricants or release agents to smoke.
  • Welding: While welding itself doesn’t typically generate oil smoke, if the parts being welded are coated with oil or if oil-based anti-spatter agents are used, oil smoke can be generated.
  • Hot Forging: In hot forging processes, the high temperatures can cause oil-based lubricants to smoke.

In all these processes, it’s important to have proper ventilation and filtration systems in place to capture and remove oil mist and smoke from the air. This not only helps to protect the health and safety of workers, but also helps to maintain the quality of the finished products by preventing contamination.

Health Risks and Safety Hazards

Inhalation of oil mist and oil smoke can lead to respiratory problems, skin irritation, and eye problems. Long-term exposure can lead to more serious health problems like occupational asthma and other lung diseases.

Some of the primary safety hazards include:

  • Fire: Oil mist is flammable and can ignite if it comes into contact with a heat source or spark, leading to fires or even explosions in extreme cases.
  • Slips and Falls: Oil mist can settle on floors and other surfaces, creating a slip hazard.
  • Equipment Damage: Over time, oil mist can accumulate on machinery, electronic components, and other equipment, leading to damage and maintenance issues.

To eliminate these risks, it’s essential to use oil mist and oil smoke collection systems. These systems work by drawing in the contaminated air, filtering out the oil particles, and then releasing the cleaned air back into the environment. The collected oil can then be recycled or properly disposed of. Air purification systems for oil mist and oil smoke collection work by using filters to capture the oil particles. The best systems are efficient, reliable, and easy to maintain. They should also be capable of handling the volume of air in the manufacturing facility.

Creating a Spark: The Importance of Welding Booths in Schools for a Hands-On Learning Experience

Clean Air Industries on June 22, 2023

In a world increasingly dominated by technology and digital learning, the importance of hands-on experiences cannot be overstated. And when it comes to vocational skills, welding is undoubtedly one of the most valuable and versatile. That’s where welding booths come into play. These specially designed spaces provide students with a safe and controlled environment to learn the art of welding, allowing them to ignite their creativity and passion for craftsmanship. But the benefits of welding booths extend far beyond the development of technical skills. By working in these dedicated spaces, students also cultivate a sense of discipline, attention to detail, and problem-solving abilities. In this article, we will explore why welding booths are crucial in schools, how they enhance the learning experience, and the long-term impact they have on students’ futures. So, let’s dive in and discover how creating a spark in the form of welding booths can ignite a lifelong love for hands-on learning.

Benefits of Hands-On Learning in Welding

Welding is a practical skill that requires hands-on experience to master. By providing students with the opportunity to engage in hands-on learning, welding booths offer numerous benefits. Firstly, hands-on learning allows students to apply theoretical knowledge in a practical setting, bridging the gap between classroom learning and real-world application. This experiential learning approach helps students develop a deeper understanding of the subject matter and enhances their critical thinking skills.

Secondly, hands-on learning in welding booths promotes creativity and innovation. When students have the freedom to experiment and explore their ideas, they become more confident in their abilities and are more likely to think outside the box. This fosters a spirit of innovation and problem-solving, essential skills for success in the ever-evolving world of welding.

Lastly, hands-on learning in welding booths instills a sense of pride and accomplishment in students. As they see their creations come to life, students gain a sense of ownership and a feeling of achievement. This boosts their self-esteem and motivates them to continue pursuing their passion for welding.

In summary, hands-on learning in welding booths is vital for students as it allows them to apply theoretical knowledge, promotes creativity and innovation, and fosters a sense of pride and accomplishment.

Importance of Welding Safety in Schools

When it comes to welding, safety should always be the top priority. In schools, where students are learning the fundamentals of welding, it is crucial to create a safe training environment that minimizes the risk of accidents. Welding booths play a vital role in ensuring the safety of students by providing a controlled space for them to practice their skills.

Welding booths are equipped with safety features such as ventilation systems, fire-resistant materials, and proper lighting. These features help prevent the accumulation of harmful fumes, reduce the risk of fire, and ensure optimal visibility during welding operations. Additionally, welding booths are designed to contain sparks and prevent them from spreading, further enhancing the safety of students and the surrounding environment.

By emphasizing the importance of welding safety in schools and providing dedicated welding booths, educational institutions demonstrate their commitment to the well-being of their students. This not only instills a culture of safety among students but also prepares them for a career in welding where safety practices are of utmost importance.

Types of Welding Booths and Their Features

Welding booths come in various types, each with its own unique features and benefits. The choice of welding booth depends on factors such as the size of the school, the number of students, and the specific welding techniques being taught. Let’s explore some common types of welding booths and their features:

1. Standard Welding Booths: Standard welding booths are the most basic type and are suitable for schools with limited space or a smaller number of students. They provide the necessary safety features such as ventilation, fire-resistant materials, and proper lighting. Standard booths are often modular, allowing for easy installation and customization.

2. Multi-Station Welding Booths: Multi-station welding booths are designed to accommodate multiple students simultaneously. These booths feature individual workstations equipped with welding equipment and safety measures. Multi-station booths promote collaboration and peer learning, allowing students to observe and learn from each other’s techniques.

3. Advanced Welding Booths: Advanced welding booths are ideal for schools that offer advanced welding techniques or specialized training. These booths may include additional features such as integrated exhaust systems, advanced safety controls, and computerized monitoring. Advanced booths provide students with a more immersive and technologically advanced learning experience.

4. Mobile Welding Booths: Mobile welding booths are designed for schools that require flexibility in their welding programs. These booths are portable and can be moved to different locations within the school or even taken off-site for field trips or community outreach programs. Mobile booths offer convenience and versatility without compromising on safety and functionality.

No matter the type of welding booth chosen, it is essential to ensure that it meets industry standards and regulations to guarantee the safety and well-being of students.

Setting up a Welding Booth in a School

Setting up a welding booth in a school requires careful planning and consideration. Here are some steps to follow when setting up a welding booth:

1. Assess the Space: Evaluate the available space in the school and identify an area suitable for the welding booth. Consider factors such as ventilation, access to electrical outlets, and proximity to other classrooms or workshops.

2. Ensure Proper Ventilation: Adequate ventilation is crucial in a welding booth to remove harmful fumes and ensure a safe working environment. Install a ventilation system that meets industry standards and regulations.

3. Choose the Right Welding Equipment: Select welding equipment that is suitable for the skill level and techniques being taught. Consider factors such as power requirements, durability, and ease of use.

4. Install Safety Measures: Implement safety features such as fire-resistant materials, proper lighting, and safety shields. Ensure that the booth is equipped with fire extinguishers and first aid kits.

5. Train Staff and Students: Provide comprehensive training to staff and students on the safe use of the welding booth and equipment. Emphasize the importance of following safety protocols and provide ongoing supervision and support.

By following these steps, schools can create a safe and functional welding booth that enhances the learning experience for students.

Best Practices for Using Welding Booths in Schools

To maximize the benefits of welding booths in schools, it is essential to implement best practices for their use. Here are some recommendations:

1. Safety First: Prioritize safety at all times. Ensure that students and staff are aware of and follow safety protocols, including the use of personal protective equipment (PPE) such as welding helmets, gloves, and safety glasses.

2. Supervision and Support: Provide adequate supervision and support to students during welding activities. Assign qualified instructors or supervisors who can guide students, answer questions, and address any safety concerns.

3. Regular Maintenance: Conduct regular maintenance checks to ensure that the welding booth and equipment are in good working condition. Inspect ventilation systems, electrical connections, and safety features to identify and address any issues promptly.

4. Encourage Collaboration: Foster a collaborative learning environment by incorporating group projects or team-based activities in the welding curriculum. Encourage students to share their knowledge and skills with their peers, promoting a sense of camaraderie and teamwork.

5. Document Learning Outcomes: Keep track of students’ progress and learning outcomes through regular assessments and documentation. This allows educators to identify areas of improvement and tailor the curriculum to meet the specific needs of each student.

By implementing these best practices, schools can ensure that welding booths are utilized effectively, resulting in a more enriching and rewarding learning experience for students.

Incorporating Welding Booths into the Curriculum

Integrating welding booths into the curriculum is crucial for providing students with a comprehensive learning experience. Here are some ways to incorporate welding booths into the curriculum:

1. Structured Lesson Plans: Develop structured lesson plans that align with the learning objectives of the welding program. Break down the curriculum into modules or units and design activities that allow students to practice their skills in the welding booth.

2. Real-World Applications: Include real-world applications of welding techniques in the curriculum. For example, students can work on projects that simulate industry scenarios, such as building structural components or fabricating artistic sculptures.

3. Guest Speakers and Industry Visits: Invite guest speakers from the welding industry or organize visits to local welding shops or manufacturing facilities. This exposes students to real-life welding practices and provides them with insights into potential career paths.

4. Certification Programs: Offer certification programs in collaboration with industry partners or professional welding organizations. These programs provide students with recognized credentials, enhancing their employability and opening doors to further career opportunities.

By integrating welding booths into the curriculum, schools can ensure that students receive a well-rounded education that prepares them for a successful career in welding.

Training and Certifications for Welding in Schools

To ensure the quality and relevance of welding education in schools, it is essential to provide training and certifications for both students and instructors. Here are some training and certification options:

1. Student Certifications: Offer certification programs specifically designed for students. These certifications validate their skills and knowledge in specific welding techniques and can be a valuable addition to their resumes.

2. Instructor Certifications: Provide opportunities for instructors to obtain certifications in teaching welding. These certifications ensure that instructors have the necessary expertise to deliver high-quality instruction and maintain industry standards.

3. Continuing Education: Encourage both students and instructors to engage in continuing education programs to stay updated with the latest advancements in welding technology and techniques. This can be achieved through workshops, seminars, or online courses.

4. Collaboration with Industry Partners: Partner with local welding businesses or organizations to offer apprenticeship programs or internships. These programs provide students with hands-on experience and exposure to real-world welding practices.

By investing in training and certifications, schools demonstrate their commitment to providing students with a comprehensive and industry-relevant education in welding.

Funding Options for Purchasing Welding Booths

Acquiring welding booths for schools can be a significant investment. Fortunately, there are several funding options available to support the purchase of welding booths. Here are some potential funding sources:

1. Government Grants: Explore government grants and funding programs specifically designed for vocational education or career and technical education. These grants often prioritize the acquisition of equipment, such as welding booths, that enhance hands-on learning experiences.

2. Private Donations: Seek support from local businesses, corporations, or philanthropic organizations that have an interest in promoting vocational education. Many companies have corporate social responsibility programs or foundations that provide grants or donations to educational institutions.

3. Partnerships with Industry: Establish partnerships with local welding businesses or industry associations. These partnerships can provide financial support, equipment donations, or access to discounted prices for welding booths.

4. Fundraising Events: Organize fundraising events within the school or the local community to generate funds for purchasing welding booths. These events can include auctions, raffles, or sponsorships.

It is essential to research and explore multiple funding options to find the most suitable and sustainable solution for acquiring welding booths for schools.

Conclusion: The Impact of Welding Booths on Student Learning

Clean Air Industries Welding Booth for Vocational TrainingWelding booths play a crucial role in schools by providing students with a safe and controlled environment to learn the art of welding. They not only develop students’ technical skills but also foster creativity, innovation, and problem-solving abilities. Welding booths create a hands-on learning experience that bridges the gap between classroom theory and real-world application, preparing students for successful careers in welding.

By emphasizing the importance of welding safety and implementing best practices for using welding booths, schools can ensure that students receive a comprehensive and safe learning experience. Integrating welding booths into the curriculum, providing training and certifications, and exploring funding options further enhance the impact of welding booths on student learning.

In a world where technology continues to advance, the need for hands-on experiences in vocational skills like welding becomes even more critical. Welding booths create a spark of passion and ignite a lifelong love for hands-on learning, empowering students to pursue fulfilling careers in welding and related fields. So, let’s continue to create sparks and build a future where hands-on learning thrives in schools.

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Why Weld Fume Extraction Is So Important

Clean Air Industries on June 10, 2023

You might not think much about the air you breathe. But what you might not know is that welding can produce fumes that are harmful to your health. That’s why it’s important to have a welding fume removal system in place.

A welding particulate removal system eliminates the fumes and smoke produced by welding operations and protects workers from the hazards of exposure to those fumes. If you’re a welder, it’s important to understand the dangers of welding fumes and take steps to protect yourself from them.

What is Welding Fume?

Welding fumes are created when metals are welded together. The fumes contain several dangerous chemicals, including lead, mercury, chromium, and cadmium. Exposure to these fumes can cause several health problems, including cancer, respiratory problems, and damage to the nervous system.

That’s why having a good weld smoke extraction system is crucial. It’s not enough to vent the fumes to the outside world. You need a system that captures and filters all the dangerous chemicals in the fumes. This is the only strategy to ensure your workers are safe from the dangers of welding fumes.

The Dangers of Welding Fumes

Welders often breathe in weld fumes without realizing the dangers they’re facing.

Weld fumes can be particularly dangerous for welders who don’t have proper welding fume suction equipment. Inhaling weld fumes can lead to serious health problems, including lung cancer.

That is why having welding fume extractors are essential in the workplace. A good welding air quality system will remove welding fumes from the air, ensuring welders can breathe safely.

Several different welding exhaust systems are available on the market, so choosing one that’s right for your needs is important. 

Make sure to research and choose a system that effectively removes welding fumes from the air. By removing these fumes from the work area, you’re protecting the health of your welders and ensuring they can work safely and comfortably.

Domestic and International Standards for Welding Fume Removal

Fume suction device for welding

There are domestic and international standards for controlling weld fumes, and your weld fume extraction system should meet or exceed these standards. The Occupational Safety and Health Administration (OSHA) is the regulating body in the United States, and have established standards related to welding, cutting and brazing. This is to ensure that the fumes are filtered as effectively as possible and that your safety is always the top priority.

Types of Welding Fume Removal

You should be aware of types of weld fume extraction systems. It’s important to consider whether you’re using manual welding or robotic welding, the size of your workspace, and the specific hazards associated with a particular job. Below, are the most popular weld fume extraction systems:

  • Portable or mobile fume extraction systems are small and easy to move between workspaces. Portable fume extractors (also known as weld fume vacuums) are great for localized welding operations and can be set up quickly to extract fume before it has a chance to spread.
  • Stationary fume extractors: Not only does it keep your workspace safe in a fixed spot, but it also helps improve the air quality so you can breathe easier, as well as helping reduce unpleasant odors that come with working with some materials.
  • Extraction arms: These are fixed systems with an arm extending over the work area and use compressed air to capture fumes as they rise up. This type of system is best for larger operations where a lot of welding occurs simultaneously.
  • Centralized fume extraction systems are larger systems that simultaneously capture fumes from multiple welding stations. They’re perfect for factories with a lot of daily welding activity.

No matter the type of system you choose, it’s important to ensure that it has all the necessary components—including filters—to prevent hazardous particles from entering your breathing air

Welding Fume Removal Solutions for the Workplace

When it comes to welding fume removal, you have a few options. The first is local exhaust ventilation (LEV), which can draw hazardous fumes away from the work area. However, this only works if the equipment is set up correctly and properly maintained.

Another solution is an enclosure such as a weld cell or welding booth, which would completely close off the space to isolate the welding process from the rest of your workspace. This option may be more practical in certain settings because LEV requires a large amount of air movement and may only be feasible with certain constraints.

You’ll also want to make sure that you’re investing in personal protective equipment, such as proper welding helmets, respirators and safety glasses, for anyone working with the welding process – this way, any fumes that may remain can be filtered out before they enter their lungs or eyes.

And finally, make sure you stock up on air purification systems that can remove toxins like ozone, formaldehyde, and other volatile organic compounds (VOCs) in your workspace atmosphere. Doing so will help ensure that your welding environment is safe and clean for everyone who spends time there.

Benefits of a Good Welding Fume Extraction System

A man enjoying clean air

Welding smoke extractors are designed to keep people safe, but their benefits go beyond this. A good welding fume removal system can provide several other benefits, including better air quality and productivity.

The air quality of the workplace will be improved since welding fumes are removed from the environment before they have a chance to accumulate. Removing these contaminants will reduce the risk of health problems associated with breathing them in. In addition, fume extractors can also filter out smoke and dust particles which can also cause health problems.

In terms of productivity, having a fume removal system for welding in place increases welders’ visibility, making it easier for them to do their job accurately and quickly. With proper ventilation and smoke removal, welders will be able to breathe much more clearly which will lead to a happier, healthier, and more efficient workplace. With a good welding fume removal system, there is no need for welders to take multiple breaks, and this helps increase productivity levels for the whole team.

Conclusion

In short, welding smoke and fumes are dangerous, and welding fume extraction is important. If you’re welding without proper ventilation, you’re putting yourself at risk for serious health problems during daily welding processes. Welding air purification systems can help protect you from these dangers, and they’re worth the investment.

A Shortage of Skilled Welders in America

Clean Air Industries on April 18, 2023

According to the U.S. Bureau of Labor Statistics (BLS), as of September 2022, there were approximately 428,000 welders, cutters, solderers, and brazers employed in the United States, with the manufacturing sector accounting for 64% of those jobs.

The median age of welders in the United States is 39 years old, with about 26% of welders being over the age of 55, and 18% being under the age of 25.

The majority of welders are male, with only 3% of welders being female.

Shortage of skilled welders

There is currently a shortage of skilled workers in the welding trade. The American Welding Society (AWS) has predicted a shortage of about 314,000 welders by 2024.

This shortage is due to a combination of factors, including:

  • an aging workforce with many skilled welders nearing retirement,
  • low numbers of new entrants to the field,
  • an increased demand for welding skills in a variety of industries, including manufacturing, construction, and energy production.

Efforts to fill the void

Manufacturing companies are taking a variety of measures to attract skilled welders in light of the shortage, including:

  • Offering competitive wages: Companies are offering higher wages to attract skilled welders, as the demand for these workers continues to grow.
  • Providing training programs: Many companies are offering on-the-job training programs to help workers acquire the necessary skills to become welders.
  • Offering sign-on bonuses and other incentives: Some companies are offering sign-on bonuses, relocation assistance, and other incentives to attract skilled welders.
  • Improving working conditions: Companies are improving working conditions to attract skilled welders, such as providing better safety equipment including OSHA-compliant fume extraction systems, comfortable work environments, and flexible work schedules.
  • Collaborating with trade schools and vocational programs: Some companies are collaborating with trade schools and vocational programs to help train the next generation of welders, and to attract students to the field.
  • Increasing use of automation: Manufacturing companies are also investing in automation to help fill the gap created by the shortage of skilled welders. This includes using robotic welding equipment, which can help improve efficiency and reduce the need for human welders.

Overall, manufacturing companies are taking a wide range of measures to attract skilled welders, as this shortage continues to be a major challenge for the industry.

Welding Helmets Explained

Clean Air Industries on April 4, 2023

Because welding is a risky profession, a welder wears a welding helmet at all times to protect their head, face, and eyes from UV rays, infrared light, and heat. For any welder, it is like their shadow – an extension of themselves.

There are various types of welding helmets available, each with its own advantages and disadvantages. There are also many factors to consider when deciding which type of helmet is right for you. Here are some of the most common types:

Passive welding helmet

This type of helmet is the simplest and the most affordable option available. It has a fixed shade lens that is typically a #10 shade. This helmet offers basic protection and is suitable for welding tasks that do not require precision or intricate work.

Pros: Passive welding helmets are affordable and straightforward to use. They are also durable and require minimal maintenance.

Cons: The fixed shade lens may not provide adequate protection for certain welding tasks, and it can be challenging to see through the helmet in low light environments.

Auto-darkening welding helmet

This type of helmet has a lens that automatically darkens when the welder strikes an arc, providing instant protection from harmful UV and IR rays. Auto-darkening helmets come in different shade ranges and are suitable for various welding tasks.

Pros: Auto-darkening helmets offer better visibility and are more convenient to use than passive helmets. They allow the welder to see clearly during setup and positioning and switch between tasks more quickly.

Cons: Auto-darkening helmets are more expensive than passive helmets, and they require batteries or a power source to operate. They are also heavier than passive helmets and can be uncomfortable to wear for extended periods.

Respirator welding helmet

This type of helmet has a built-in respirator that protects the welder from hazardous fumes and particles that are released during welding. It is suitable for welding tasks that produce a high concentration of fumes and particles.

Pros: Respirator welding helmets provide excellent protection against harmful fumes and particles, and they eliminate the need for a separate respirator. They are also convenient to use and can be adjusted to fit the welder’s face.

Cons: Respirator welding helmets are more expensive than other types of welding helmets, and they can be heavy and uncomfortable to wear for long periods. They also require regular maintenance and replacement of the filter cartridges.

Powered air-purifying respirator (PAPR) welding helmet

These helmets have a built-in PAPR system that provides filtered air to the welder. This allows the welder to work in environments with high levels of fumes and other hazardous particles. The main advantage of PAPR helmets is their superior protection, but they tend to be the most expensive and bulky option.

Pros: PAPR welding helmets provide welders with superior protection from fumes, dust, and other hazardous particles. The helmet has a built-in PAPR system that filters the air and provides fresh, clean air to the welder, reducing the risk of inhaling harmful substances. Additionally, PAPR welding helmets are designed to be more comfortable for the welder to wear for extended periods. The helmet is usually lighter and more balanced than other types of welding helmets, and the PAPR system reduces the need for the welder to wear a separate respirator.

Cons: PAPR welding helmets are generally more expensive than other types of welding helmets due to the additional features and equipment required for the PAPR system. Furthermore, they can be bulkier and heavier than other types of welding helmets, which can be uncomfortable for some welders, especially when working in tight spaces. PAPR systems can also be noisy, which may be distracting or uncomfortable for some welders.

Grinding & welding helmet

This type of helmet has a clear lens that is suitable for grinding and other non-welding tasks. It is a versatile option for welders who need to switch between welding and grinding tasks frequently.

Pros: Grinding welding helmets are versatile and convenient to use, and they offer excellent visibility during grinding tasks. They also protect the welder’s face from flying debris.

Cons: Grinding welding helmets are not suitable for welding tasks that require a darker shade lens, and they are typically more expensive than passive helmets.

Overall, the choice of welding helmet depends on the welder’s needs and the type of welding tasks they perform. It is essential to choose a helmet that provides adequate protection and comfort while also fitting within your budget.

Benefits Of Weld Fume Extraction In The Workplace

Clean Air Industries on March 1, 2023

Many employees all across the world spend the majority of their days at work. Therefore, it is the responsibility of business owners to make sure that the working environment is conducive to being safe and comfortable for their employees. A safe workplace is crucial for every employee’s productivity, health, and increased staff effectiveness on the job.

Especially in high-risk industries like mining and manufacturing, workplace safety should be a top priority. These industries use the welding process quite frequently, exposing everyone in the zone to harmful fumes which can affect the respiratory system and adversely impact their health and safety.

Particulate matter of hazardous metals like aluminum and lead and gases like argon, nitrogen, hydrogen fluoride, and carbon monoxide can be detected in welding fumes. Long-term exposure to these fumes can cause a number of cancers, including lung, throat, and urinary tract cancer.

Employers are accountable for the workplace environment, safety precautions, and how machine operations are carried out. Observing the regulations set forth by OSHA, AWS, and NIOSH, you can guarantee the health and safety of your personnel.

Fume extraction systems are an excellent solution for such workplace issues, particularly in the manufacturing industry. If your work is more welding-oriented and involves the production of hazardous fumes, consider investing in a suitable welding fume extractor.

What Is A Welding Fume Extractor?

Weld fume extraction systems are tools utilized to remove welding fumes produced when working with metals used in welding applications. The use of a vacuum mechanism is to suck the fumes from the source of production such that the toxic fumes do not get an opportunity to escape into the welding room or other functioning areas.

This equipment is usually made for industrial purposes. Fixed suction systems are mainly designed and conceptualized by industry-leading companies in accordance with the needs of the customer to create a perfect plan for extracting the Welding sparks and smokewelding fumes through the insertion of airflow pipes that will filter the air to purify and reuse in the same environment.

Additionally, a number of different designs are available for the assembly of the mechanical arms that provide the suction depending on their length and the perimeter of the surface where the welding process will take place.

Applications Of Welding Fume Extraction Systems

Every job that requires welding or the creation of small particles and toxic fumes can use a fume extraction system.

Methods Of Weld Fume Extraction

An efficient fume extraction system will protect workers from health hazards by keeping dangerous fumes below the prescribed levels. Select a welding fume extraction system manufactured and designed to meet your work-specific requirements.

This diversity of requirements is why we have different fume extraction methods that can fit different needs. The five most prevalent techniques are as follows:

1. Portable welding fume extractor

Portable weld fume extractors have a filter fitted inside a frame with casters. It consists of a snorkel or an arm attached to a blower. It requires the snorkel to be placed at the center to be effective. Therefore, as the object being welded moves, the arm must be moved too. It also requires frequent filter changes.

2. Self-contained downdraft tables

In a self-contained downdraft table, the filters are placed inside the table, and the blower pulls air from the environment. This technique has the minimum installation requirements and costs just as much as a portable welding fume extractor. Self-contained downdraft tables are the safest solution for welding and grinding purposes.

3. Empty downdraft tables

These rely on the operations of a central fume and dust collector to take the collected air away from the operator into an external collector. They are not ducted and do not need power. One major strength of this technique is that empty downdraft tables are highly customizable and flexible but bring on a lot of additional expenses in installation and scalability.

4. Central fume and dust collectors

Empty downdraft tables are ducted to central fume and dust collectors. They do not need much maintenance as filters will typically only require an annual change although this will vary depending on the type of metal being welded, and the presence of oil on the metal surface.

5. Hanging ambient air cleaners

Hanging ambient air cleaners work as a secondary cleaning system to remove the leftover residues of harmful fumes after the primary solutions. The units are typically installed 12-14 feet above the ground, either suspended from the ceiling or mounted on a wall. Generally, they are an affordable and quick solution.

Why Is Welding Fume Hazardous?

Welding processes first appear to be safe. Simply uses heat to join two or more metal components, right? But several risks are involved, many of which are directly connected to the air you breathe. Welding fumes are hazardous due to the welding particles they contain, which are the source of airborne contaminants, such as:

  • Carbon Dioxide
  • Ozone
  • Sulfur Dioxide
  • Nitrogen Oxides
  • Lead
  • Aluminum Oxides

If you are unsure how these chemicals affect you, let us list the problems for you. Long and short-term exposure to these chemicals is linked to a number of health issues, including:

  • Throat Cancer
  • Lung cancer
  • Respiratory issues
  • Nervous system damage
  • Vision problems
  • Acute Pneumonia
  • Fume fever

Welding fumes contain carcinogenic chemicals in high amounts that might result in malignant tumors in the body. As understood from the discussion above, these compounds have a harmful effect on the human body, both mentally and physically. In general, a number of variables, including genetic predisposition or environmental effects and personal immunity, influence the risk of developing cancer. This is why we do not have an exact quantified count of the impact these substances can have. However, there is evidence that the risk of cancer rises with increasing exposure to these dangerous compounds in welding fumes.

Many studies have discovered that welders have a higher chance of developing lung cancer because of long hours of exposure.

What To Consider Before Choosing A Fume Extractor

To maintain exposure at or below an acceptable level, it’s crucial to consider the work conditions, practices, and risks in the welding applications in your facility before beginning to choose a welding fume extraction system. Man welding Weld fumes extraction systems need to be placed correctly and used with necessary guidelines based on the specific requirements of the space in order to ensure effectiveness.

When buying a welding fume extractor, you can ask yourself the following questions for a better idea of which type of fume extractor will work for your office.

  • What is the size of your workshop or office where the welding process will happen?
  • How much welding is likely to take place?
  • What government-suggested regulations need to be met?
  • Does the filter meet your application requirements?
  • Is the fume extractor system flexible?
  • Is the fume extractor system friendly for operators?
  • Does the equipment meet the required level of airflow?

Benefits Of A Welding Fume Extractor

One of the best methods that guarantee safety in industrial environments through low exposure to hazardous fumes is to have fume extraction systems in the workplace. Employees can have efficient productivity in a safe working environment. Listed below are more such advantages linked to the operation of a fume extraction system in the workplace.

Improved Air Quality

Many offices in high-risk industries have poor air quality. It could harm your health if you or your employees spend most of the day in such a setting. However, you may enhance the quality of air and make your workplace healthier for everyone by using a weld fume extractor. The fume extractors function by collecting all of the fumes produced throughout the welding and manufacturing operations and releasing them into the air.

Improved Worker Productivity

Workers typically perform better when they are comfortable and in good health. Because a weld fume extractor minimizes welding fumes, you may give your staff a healthier working environment. Additionally, the team will take fewer days off, ultimately saving you money.

Improved Employee Morale

As they say, happy employees are productive employees. Your employees will immensely appreciate the safety precautions you take since they will see that you are concerned about their welfare. That can significantly improve everyone’s mental health and foster a positive work environment. This will be a step towards a better employer-employee relationship and building trust.

Reduced Absenteeism

A healthy workforce is directly related to a healthy workplace and lower absenteeism. As production increases, truancy will be lower, which is crucial for any organization. The majority of businesses are supposed to provide medical insurance for their staff members. If the workplace is unsafe and unsanitary, the expenses of treatment and medication for staff members as a result of the absence of a fume extraction filter could be quite high.

Healthier Work Environment

We all know that welding processes produce dangerous gases. Every welding procedure has some amount of fumes, and these gases can do a lot of harm if not handled carefully. Installing welding fume extractors in the welding area helps to ensure that all gases are quickly taken away from people before they can affect employees physically. The smaller the particles, the more dangerous they are. Fume extractors are essential to every welding sector for this reason.

Superior Weld Quality

The constant presence of fumes has an impact on the weld quality. The welds may become porous if the fumes are not sufficiently removed, resulting in weak and brittle joints. However, since a fume extractor will eliminate all dangerous vapors, you can enhance the weld quality.

Prevention of Corrosion

A number of corrosive gases are released in the office air during welding. These pollutants can also harm the surfaces and equipment in the office. Using a weld fume extractor in the workplace can be helpful in preventing metal pieces from corroding. Many industrial-grade fume extractors can assist in reducing corrosion.

Equipment Longevity

As mentioned above, the equipment used at work can also are impacted by the fumes created by welding. The equipment may be damaged and have a shorter lifespan due to the corrosive nature of welding fumes. Due to a fume extractor’s ability to eliminate corrosion, you can prolong the life of the machinery.

Conclusion

The benefits of fume extraction systems at a workplace are not restricted to workers only; they also benefit the company. In addition to reducing risks of illnesses, workers in a safe and healthy atmosphere will also be more attentive and energized. Additionally, workers have a tendency to be more self-assured in their surroundings at work, which benefits the people around them.

Employers must understand that even while a fume extraction system may appear to be unnecessary, the consequences of not having one will cost more. Therefore, it is only wise to install a fume extractor and watch your workers progress, as does your company.