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More protection
at work

Optimal capture and
high filtration of welding fumes

More precision
in machine production

Extract
welding fumes economically

Less welding fumes
in the hall

Consider and eliminate
welding fumes comprehensive

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0043 7252 220 500

WELDING
WITHOUT
WELDING FUMES

Welding is the most important joining process for the permanent connection of two or more workpieces. No matter which welding method is used, one thing cannot be avoided: welding fumes, fine dust and emissions.  But the negative effects of welding fume emissions on employees, equipment and buildings can be prevented. After all, welding fumes are harmful to health and dangerous to humans because they can get into the lungs. This does not only affect the welder himself, but also the neighbouring machine operator on the automated welding machine. In addition, the welding fumes are distributed as so-called diffuse emissions in all work areas. This affects all professionals who are working in the hall.

 

This summary presents a comprehensive and compact overview of the hazards caused by welding fume emissions. But also how it is possible to ensure safe and legally compliant welding operations. Our recommendations are based on our decades of activity in the extraction and filtration of welding fumes and the in-hall air cleaning of welding halls. Some of our recommendations require some lead time. Others can be implemented immediately and directly. All in all, however, all these adjusting elements ensure one thing: more protection for the welding workplace, a potential improvement in welding quality and, last but not least a considerable reduction in energy costs.

 

INHALT

WELDING
THE MOST IMPORTANT JOINING PROCESS

Unter Schweißen versteht man ein Fügeverfahren zur dauerhaften Verbindung von zwei oder mehreren Werkstücken. Es gilt als das wichtigste Fügeverfahren. Mit Hilfe von Wärme und Druck entsteht eine unlösbare Verbindung zwischen den Bauteilen. Teilweise werden dabei auch Schweißzusatzstoffe verwendet.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WELDING FUMES
ARE A MIXTURE OF EMISSIONS

Welding fumes are not homogeneous emissions, but a heterogeneous mixture of fumes, dusts, gases and vapours that are generated during welding and emitted into the ambient air.

  • Fumes are understood to be a mixture of different fine and solid substances. Fumes are produced by the condensation of inorganic substances from the vapour phase, chemical reactions (e.g. oxidation) and incomplete combustion of organic material due to welding consumables, coatings and impurities. For fine dust to be perceived as fumes, it must be present in larger quantities.
  • Gaseous emissions and vapours are produced by the thermal conversion process of fuel gases, air, coating materials and impurities.
    • Ozone, for example, is created by the electric arc from the oxygen in the air.
    • Carbon monoxide is formed by incomplete combustion of fuel gases with inert gases.
    • Nitrogen oxides are formed by thermal processes from the nitrogen and oxygen in the air.
    • Phosgene, aldehydes and decomposition products are generated by working with coatings, oils or degreasing agents.

Danger to the workforce –
that's why welding fumes are dangerous

The hazards of welding fumes result on the one hand from the different ingredients of the emission mixture, and on the other hand from the fineness of the emission.

Generally speaking, welding fumes are a hazardous substance.
Therefore, there is a legal obligation to evaluate and take appropriate measures to protect workers from the hazardous substance.

Depending on the welding process, the welding material and the welding consumables, different types of welding fumes are produced. They differ greatly in their characteristics. That is why we categorise welding fumes according to their effect on humans: we distinguish between respiratory, toxic and carcinogenic welding fumes.

  • Respiratory and lung-damaging welding fumes
    This welding fume is mostly produced during the processing of metallic materials without alloys. For example, when welding iron, steel, magnesium or aluminium. In these processes, the welding fumes released contain metal oxides such as iron oxide or aluminium oxide. The hazard results from the amount of fumes that are released and the size of their fine dust particles. The exposure leads to impairment of the respiratory tract. The consequences are respiratory diseases such as bronchitis, narrowing of the airways, siderosis (iron storage disease) or fibrogenic reactions (connective tissue proliferation).
  • Toxic welding fumes
    Toxic welding fumes are said to occur when poisoning occurs due to exceeding a certain dose. Gases such as carbon monoxide, nitrogen oxides, ozone, but also oxides of copper, lead or zinc are classified as toxic. The toxic effect depends essentially on the concentration - a low concentration can cause mild poisoning or health disorders, a high concentration can be life-threatening.
  • Carcinogenic or cancer-causing welding fumes
    For carcinogenic and cancerogenic substances, there is no threshold value above which damage occurs. Even small amounts are thought to pose a serious risk. Special regulations therefore apply to welding fumes in this category. Carcinogenic substances include, for example, chromium(VI) compounds, nickel oxides or cobalt oxide. They arise in particular when welding alloyed steels (e.g. steel containing chromium and nickel).

     

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Welding fumes are very fine

The sizes of the welding fume particles have a different effect on the human body. The smaller the particles are, the deeper they can penetrate the human respiratory tract. Another possibility is therefore to distinguish the welding fumes by their size:

  • Inhalable particles
    Particle sizes of less than 10 micrometres are inhaled.
  • Pulmonary particles
    Particles of approximately 2.5 micrometres in size penetrate into the lungs.
  • Alveolar particles
    Particles of about 1 micrometre penetrate into the bronchial branches of the lungs.
  • Ultrafine particles
    Particles smaller than 0.1 micrometres can no longer be retained by the respiratory organs. They enter the bloodstream.
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The effect
of the welding
process

The welding process and the materials used, in addition to the additives, have a direct influence on the type of welding fumes that are produced.

The following list provides an overview of the most common welding processes and the associated composition of welding fumes.

Welding process Welding fume quantity Emission rate [mg/s]
Gas welding, friction stir welding, TIG, submerged arc welding, resistance spot welding Low < 1
Laser welding without filler metal Low 1 to 2
MIG/MAG (energy-optimised inert gas welding) medium 1 to 4
MIG (general) medium 2 to 8
Manual arc welding high 2 to 22
MAG (solid wire), flux-cored welding with inert gas, laser welding with filler material high to
MAG (flux cored wire), flux cored welding without inert gas, oxyacetylene flame cutting, arc spraying very high > 25

Source: DGUV

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Regulations and legal provisions

Over the years, numerous limit values have been imposed for welding. Depending on the country and the type of underlying pollutant, the limit values vary greatly. In particular, the legislator addresses the health risk and differentiates between occupational exposure limits (OEL), technical reference concentrations (TRC) and acceptance or tolerance concentrations.

The following table gives an overview of the most common welding-relevant limit values.

Limit value Category Germany Austria
General dust limit value OEL 1,25 mg/m³(A) 5 mg/m³ (A)
Welding fume OEL 1,25 mg/m³ (A) 5 mg/m³ (A)
Chromium(VI) compounds TRC, Acc., Tol. 0,001 mg/m³ (E) 0,01 mg/m³ (E)
Cobalt and carcinogenic cobalt compounds (cobalt(II) oxide (CoO)) TRC, Acc., Tol. 0,0005 mg/m³ (A)  0,1 mg/m³ (E)
Carcinogenic nickel compounds (nickel(II) oxide (NiO)) TRC, Acc., Tol. 0,006 mg/m³ (A) 0,05 mg/m³ (E)
Manganese and its inorganic compounds (for example MnO, Mn3O4) OEL 0,02 mg/m³ (A) 0,05 mg/m³ (A)
Nitrogen(II) oxide (NO) OEL 0,5 ppm 
0,95 mg/m³ 		 0,5 ppm 
0,96 mg/m³ 
Fluorides (sodium fluoride (NaF), calcium fluoride (CaF2), sodium calcium fluoride (NaCaF3)) OEL 1 mg/m³ (E) 2,5 mg/m³ (E)
Carbon monoxide OEL 30 ppm 
35 mg/m³ 		 20 ppm
23 mg/m³ 


E ...  respiratory Fraction
A... alveolar Fraction

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Reduction of
danger sources

For welding work on metallic materials, the employer is obliged to prepare a risk assessment. It must be carried out before the welding work is started. The results of the analysis must be assessed and documented. This also includes suitable protective measures to avoid or reduce the risk from the welding fumes.

The following order of priority must be used in the assessment:

  • Substitution
    Substitution is the replacement of the welding process with another, lower-emission process. If it is possible to use different welding processes, the one that releases the least amount of welding fumes should be selected (see table above on welding processes and welding fumes).
  • Ventilation protection measures
    This includes technical protection measures such as the extraction and filtration of welding fume emissions by means of extraction and filter systems or the provision of ventilation solutions.
  • Organisational protective measures
    Organisational protective measures include instruction of workers and general occupational health care.
  • Individual protective measures
    Individual protective measures include, for example, personal protective equipment such as the wearing of respiratory protection or the use of ventilated welding helmets.
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Kappa in-hall air cleaning system
for manual and
robot welding

Kappa table extraction
for manual welding

Kappa suction hood extraction
for robot welding

Kappa suction arm extraction
for manual welding

Efficient capture
and removal of
welding fumes

Ventilation measures are usually unavoidable during welding. They ensure that welding fumes and fine dust are captured, removed and filtered. In order for this to be done as efficiently as possible, a large number of influencing factors need to be assessed. These include the welding process, the materials welded, the type of workplace, the size of the workpiece and the manufacturing infrastructure. As a result, the solutions are as individual as the requirements themselves.

 

One way of classifying the available solutions is to group them according to their proximity to the emission source, i.e. the welding itself:

Welding fume extraction
at the source of generation

When welding fumes are collected at the source, welding fumes and fine dust are extracted as directly as possible and close to the welding workplace. If the local proximity and position of the extraction device is not consistently maintained, the collection effect is drastically reduced.

We distinguish between the following solutions in terms of the type of collection:

WELDING FUME EXTRACTION
WITH WELDING TORCH

With torch extraction or gun extraction, the welding fume emissions are captured and extracted directly at the welding torch. Extraction nozzles are installed on the welding torch for this purpose, to which an extraction hose is connected. It is combined with the hose assembly of the welding machine. Either a filter unit is installed at the end of the extraction hose or the extraction hose leads to a central filter unit via high vacuum piping. Manufacturers of welding torches often offer integrated extraction solutions for their products. Existing units can be retrofitted with collection kits.

 

 

 

 

 

 

 

 

Experiences and effect

  • The operation and the degree of collection is highly dependent on the welder, after all, the handiness of the welding torch is influenced by the extraction nozzle and extraction hose and sometimes impairs the visibility for the welder.
  • The welding position also has a big effect on the collection rate.
  • Secondary fumes cannot be collected with torch extraction.
  • Extraction directly on the torch is not possible for all welding processes.
  • Torch extraction is particularly recommended for welding work where alternative extraction solutions are difficult to use. For example, when welding in boilers.
  • A suction performance of 100 m³/h is usually required for torch extraction.
  • Due to the high resistance of the extraction hose, high vacuum extraction with a negative pressure of over 15,000 Pa is necessary.
  • The torch extraction system can achieve a collection rate of 70% when properly designed and used.

WELDING FUME EXTRACTION
WITH WELDING SHIELD


With welding shield extraction, the welding fume emissions are collected directly with a shield and extracted. An extraction hose is once again connected to the welding shield. Either a filter unit is installed at the end of the extraction hose or the extraction hose leads to a central filter unit via high vacuum piping. The importance of welding shield extraction has decreased significantly in recent years. This is mainly due to the new types of welding shield, which are no longer hand-held but worn directly on the head and actively adapt to the welding process and the prevailing brightness.

 

 

 

 

 

 

 

Experiences and effect

  • The operation and the degree of collection is highly dependent on the welder. The handiness of the welding shield is affected by the suction nozzle and the suction hose and sometimes impairs the welder's field of vision.
  • The welding position also has a huge effect on the rate of collection.
  • Secondary fumes cannot be collected with the welding shield extraction system.
  • Welding shield extraction is not possible for all welding processes.
  • A suction performance of 200 m³/h is usually required for extraction.
  • Due to the high resistance of the extraction hose, high vacuum extraction with a negative pressure of over 15,000 Pa is necessary.
  • Welding shield extraction can achieve a collection rate of up to 60% when properly designed and used

WELDING FUME EXTRACTION
WITH SUCTION ARM

Welding suction arms are still widely used for collection and extraction during welding. The welding fume emissions are collected by positioning a suction arm as close as possible to the emission source. A suction arm normally consists of suction pipes or suction hoses, articulated or swivel joints for correct positioning and a suction funnel. The suction funnel ensures an even distribution of the suction effect and ideally protects against the penetration of foreign bodies. Optional integrated lighting or various switches provide improved comfort.

Typical suction arms cover a working area with a radius of one to four metres. With a corresponding extension, working radii of up to eight metres are possible. The diameter of the suction arms for welding applications is usually 160 millimetres.

 

 

 

 

Experiences and effect

  • The operation and the degree of collection is highly dependent on the welder. The welding fumes can only be captured if the suction arm is positioned correctly.
  • The welding position also has a big effect on the collection rate.
  • In the case of changing working positions and short welding points distributed over large workpieces as well as very long welding seams, suction arms are often impractical. Especially because the suction arm has to be repositioned manually all the time.
  • Secondary fumes can be collected with suction arms.
  • A welding fume extraction system with suction arms makes sense for locally fixed welding workplaces with recurring welding work and for smaller workpieces.
  • For welding fume extraction via suction arms, a suction performance of 1,000 m³/h is usually required.
  • Due to the low resistance of the suction arms, low-vacuum suction with a negative pressure below 5,000 Pa is used.
  • Welding fume extraction with suction arms can achieve a collection rate of up to 70% when properly designed and used.

More information
on the Kappa suction arms

Welding fume extraction
in the surrounding area

When collecting welding fumes and fine dust in the vicinity of the welding process, the welding emissions are not collected directly, but at least in the immediate proximity of the welding process and removed.

We distinguish between the following solutions:

WELDING FUME EXTRACTION
WITH EXTRACTION TABLE

Welding tables are work tables on which the workpiece is placed and processed. They ensure the collection of the released welding fumes via integrated table suction. They are equipped with a downward suction device (table suction) as standard. Optionally, the welding tables can also be equipped with a rear wall extraction or a side wall extraction. Usually, extraction tables also have a drawer in which coarse particles are collected. Depending on the requirements, a wide variety of options are available, such as support frames made of wood or plastic, height adjustability or lighting.

Typical welding tables cover a working range of one to three metres and have a working depth of around 0.7 metres. Ideally, the working height of the welding tables can be adapted to the requirements.

 

 

 

 

Experiences and effect

  • The operation and the degree of collection is highly dependent on the welding requirements and the workpiece.
  • Secondary fumes can be collected with welding table suction.
  • Welding fume extraction via the welding tables is particularly useful at locally fixed welding workplaces with recurring welding work and for smaller workpieces.
  • For welding fume extraction via welding tables, a suction performance of 1,200 m³/h per metre of working width is usually required for pure table suction and 2,200 m³/h per metre of working width for combined table and rear wall extraction.
  • Welding fume extraction with welding table can achieve a capture rate of 70% if properly designed and used.

More information on
Kappa welding tables

WELDING FUME EXTRACTION
WITH EXTRACTION WALL

Extraction walls ensure that welding fumes are collected across a wide area. The workpiece is placed in front of the extraction wall - usually on a work stand. The rear wall ensures an even extraction effect over the entire wall surface.

Typical extraction walls have a modular design and cover a working range of one to several metres and a height of 0.5 to two metres.

 

 

 

 

 

 

 

 

 

Experciences and effect

  • The operation and the degree of collection are highly dependent on the welding requirements and the workpiece.
  • Secondary fumes can be collected with welding wall extraction.
  • Welding fume extraction via welding walls is particularly suitable for locally fixed welding workplaces with recurring welding work and for small to medium-sized workpieces.
  • For welding fume extraction with an extraction wall, a suction performance of 2,500 m³/h per square metre of extraction wall is usually required.
  • Welding fume extraction via wall can achieve a collection rate of up to 70% when properly designed and used.

WELDING FUME EXTRACTION
WITH SUCTION HOOD

Suction hoods are placed above the welding process. They ensure that the welding fumes and fine dust rising above the welding process are collected and removed due to thermal convection. Typically, welding fume suction hoods are equipped with curtains. They serve to screen the welding process and as an envelope for the welding fumes so that the emissions can rise unhindered and are not deflected by cross currents. The optimum design is an edge trim suction unit. Here, suction openings are placed all around the suction hood. They ensure uniform collection over the entire hood surface and protect the collection of foreign bodies and sparks. 

Suction hoods are often used in robot welding. Here, the suction hoods are placed either above the robot or directly on the robot. Even solutions with suction hoods that travel with the robot can be implemented.

Typical suction hoods have a modular design and cover a suction area of one to several square metres.

Experiences and effect

  • The operation and the degree of collection is relatively independent of the welding process if designed and executed correctly.
  • Secondary fumes can be collected with the welding fume extraction hood.
  • Welding wall extraction via a welding fume suction hood is usually installed at locally fixed welding or robot workplaces. However, moving suction hood solutions with a process path of more than 50 metres can also be implemented.
  • For welding fume extraction via suction hoods, a suction performance of 500 m³/h per square metre of suction hood is usually required for edge trim extraction or 1,500 m³/h per square metre of suction hood for area extraction.
  • Welding fume extraction with a suction hood can achieve a collection rate of up to 90% when properly designed and used.

More information on
Kappa suction hoods

WELDING FUME EXTRACTION
WITH A SUCTION CAB

Suction cabs are often used for the removal of welding fumes from production halls. Here, the welding processes are carried out in a separate enclosure. The workpieces are transported manually or by means of lifting equipment to the suction cab where the welding work is carried out. In many cases, other activities such as grinding are also carried out in the suction cab in addition to welding. Suction cabs are suitable for separating individual work processes, such as aluminium welding, normal steel welding or the welding of high-alloy steels.

Within the welding suction cabs, welding fume emissions are usually collected via the aforementioned systems, such as suction arms, welding tables and extraction walls. In addition to welding fume extraction, the cabs usually have their own air supply and extraction.

 

 

 

Experiences and effect

  • Welding suction cabs are suitable for the spatial containment of welding processes so that welding emissions do not pollute the hall.
  • Welding cabs are suitable for the logistical separation of different welding areas such as aluminium, mild steel and alloy steels.
  • Welding suction cabs can be customised and are available in any size.
  • The extraction, filter and air technology as well as the necessary air performance of the welding suction cabs are individually adapted to the respective requirements.

More information on
Kappa suction cabs

WELDING FUME EXTRACTION
WITH VENTILATION TECHNOLOGY
(ventilation, extraction, in-hall air cleaning)

Welding fume emissions not only directly pollute the workplace, but the entire hall. A complete collection of the welding fumes by the aforementioned collection methods is usually not possible. The result is fine dust and fumes that are distributed and deposited in the hall. In order to fully protect adjacent work areas in the hall from welding fume emissions, an additional ventilation solution is therefore necessary. Thus the hall is equipped with ventilation and extraction. In contrast to conventional ventilation and extraction in buildings, greater attention must be paid here to employee protection and the treatment of process heat.

In the ideal case, this is a future-proof in-hall air cleaning system. It ensures compliance with the limit values in the workplace and in the entire hall. It eliminates emissions by bringing fresh, clean air into the work area. Here it is absolutely crucial to introduce the fresh air draught-free in the floor area without mixing it with the contaminated hall air. This is the only way to ensure that the fresh air displaces the welding fume emissions together with the contaminated hall air to the hall ceiling. There, the emissions can be removed from the hall together with the excess process heat. Central filter units then ensure a high degree of filtration of the welding fume emissions, so that the excess heat carried along can be recovered with a high degree of efficiency and used to heat the fresh air.

WELDING FUME REDUCTION
WITH VENTILATION TECHNOLOGY

KAPPA A.I.R.TM
IN-HALL AIR CLEANING SYSTEM

WELDING FUME REDUCTION
WITH VENTILATION TECHNOLOGY

KAPPA A.I.R.TM
IN-HALL AIR CLEANING SYSTEM

WELDING FUME REDUCTION
WITH CLEANROOM TECHNOLOGY

 

KAPPA A.I.R.TM
IN-HALL AIR CLEANINGSYSTEM

WELDING FUME REDUCTION
WITH VENTILATION TECHNOLOGY

 

KAPPA A.I.R.TM
IN-HALL AIR CLEANING SYSTEM

WELDING FUME REDUCTION
WITH VENTILATION TECHNOLOGY

 

KAPPA A.I.R.TM
IN-HALL AIR CLEANING SYSTEM

Experiences and effect

  • A modern in-hall air cleaning system in the welding hall displaces welding fume emissions from the work area
  • A modern in-hall air cleaning system in the welding hall removes welding fume emissions from the hall and thus prevents emissions from being transferred to neighbouring areas of the hall.
  • A modern in-hall air cleaning system takes care of emission collection as well as ventilation and extraction throughout the hall.
  • A modern in-hall air cleaning system enables the recovery of excess process heat as well as the heating and also cooling of the entire hall.
  • The extraction, filter and ventilation technology and the air performance required for this are individually adapted to the respective requirements.

Mohr information to
Kappa A.I.R.TM in-hall air cleaning system

Personal
protective equipment

Personal protective equipment consists of protective devices worn by the individual - similar to other work protection such as hearing protection, protective goggles or work clothing. This includes, for example, ventilated welding helmets. They have a ventilating filter device, usually placed at the back. Filtered air is fed directly into the welding helmet via a ventilation hose.

The task of personal protective equipment is not to collect and filter welding fume emissions, but to protect the welder from them. The protective effect is therefore limited to the welder and to the duration of use of the ventilated welding helmet.

The welding fumes are distributed unhindered in the working area and in the hall if no other protective measures are used. If the personal protective equipment is taken off, there is no longer any protection against diffuse emissions. This applies to all employees in the hall.

Personal
PROTECTIVE EQUIPMENT

Personal
protective equipment

Experiences and effect

  • Ventilated welding helmets are usually used in addition to other protective measures to protect welders as comprehensively as possible.
  • Ventilated welding helmets are particularly useful when adequate or desired protection cannot be achieved by alternative solutions. This is the case, for example, when welding in boilers.
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Filter technology – highly effective
and energy-efficient filtration of welding fumes

The filter technology and exhaust air cleaning is essential for optimum operation and efficiency of the overall system. It determines whether and under what conditions the purified air can be returned to the work area and the hall. The regional and national guidelines for air recirculation must be observed. A maximum permissible pollutant concentration of 1/3 of the permissible maximum workplace concentration (MAK value) often applies. Substances for which a technical guideline concentration (TRK value) exists are generally prohibited from use for circulation. Exceptions to the ban on air circulation require special protective measures. With welding fume filters, we can distinguish between local devices and central systems.

 

For welding fume filters, we can distinguish between mobile filters and central filters:

  • Mobile filters or wall filters with integrated suction arms: These are placed locally on the welding process and serve one or two welding workstations.
  • Central filter systems: These are centrally located and serve several welding workstations or the entire in-hall air cleaning

KAPPA MYKRON®
THE WELDING FUME FILTER

Central welding fume filters

Central welding fume filters are stationary filter units. They cover several welding workstations and are designed for continuous operation. Today, filtering separators that work according to the surface filtration principle are used almost exclusively for the filtration of welding fumes. Here, the fumes and fine dust emissions are retained on the filter surface without penetrating the filter material. The surface of the filter elements is continuously cleaned. To do so, the emissions are trussed off the surface by means of compressed air and collected in a dust collection container.

Due to the extreme fineness - the majority of welding fume particles are smaller than 1 micrometre - the cleaning effect of such welding fume filters is low. The fineness of the particles and the process heat mean that welding fumes are airborne dusts. They do not fall to the ground, but remain in the air. This leads to the welding fumes occupying more and more of the filter surface. The result is a higher air resistance and a falling suction performance of the filters.

 

Kappa Mykron® welding fume filter

Kappa has therefore developed the so-called Sequence Dedusting®. This is a cleaning technology that ensures that the individual filter areas are cleaned sequentially. This creates a downward flow in the filter, which captures the suspended dust and transports it to the dust collection container. This results in a consistently high suction performance and a constantly low air resistance. The result is 30% improved filter performance and a reduction in energy consumption of up to 35% . The Kappa Sequence Dedusting® cleaning technology is used in the Kappa Mykron® fine dust filter and energy-saving filter. It therefore represents one of the most modern and future-proof welding fume filter systems.

More information on
Kappa Mykron® welding fumes filter 

Combine actions

Welding fumes are - as described above - not homogeneous emissions, but a heterogeneous mixture of fumes, dusts, gases, and vapours that are generated during welding and emitted into the ambient air. This is something to consider when we talk about welding fume filters. They represent filter systems for the filtration of fumes and fine dust. Gaseous emissions are not filtered. This is another reason why modern in-hall air cleaning systems with fresh air supply to the work area are the right choice. They ensure optimum air exchange and thus clean fresh air at the welding workplaces.

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Customer testimonials

Liebherr-Werk Telfs GmbH

"Thanks to our new in-hall air cleaning system, the air quality in the welding shop is now very good. Despite the low outside temperatures in winter, we hardly had to heat up. Before, we lost the waste heat via the roof, now we can use it."

Johann Struc, head of work organization

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Wasserbauer GmbH

"Wasserbauer is a company where the closeness to nature already results from the product. That's why we are happy to integrate another building block into our production with our air concept, which not only counteracts the rising energy prices, but also makes a contribution to the environmental protection."

Franz Wasserbauer, Managing Director

 

 

 

 

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Lemken GmbH & Co. KG

"The air quality in the steel construction is very good. This is also confirmed by our employees. Last winter we hardly had to heat up because we were able to cover our heat requirements from heat recovery."

Thomas Heenen, safety officer

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Primatech Metallverarbeitung GmbH

"With the new extension to our production hall, we are already gearing up our company to meet the requirements of the future. Just as we rely on the most advanced technology for our machinery, we also do so consistently for structural measures, such as the air concept. A welding technician told me some days ago during an inspection, that this is the clean and bright working-environment, which makes the difference at welding. In this place he would like to work."

Johann Kasper, Managing Director

 

 

 

 

 

 

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FAQs

Filter towers are filter units that freely draw in hall air, filter it and release it back into the hall. Authorities assess filter towers very differently. Thus, filter towers are not classified by the authorities as a ventilation measure. Since they freely draw in the hall air, they are also not an air filtration system. Therefore, for regulatory purposes, filter towers do not constitute a permissible protective measure. However, it may very well be accepted by the competent authority in individual cases in the course of an individual assessment.

Do you have questions about the effect of individual protective measures? We are happy to assist you.

The current manganese limit value (A-dust) is very low, especially in Germany. This often leads to the permissible workplace limits being exceeded. Individual measures are often not sufficient here. In these cases, a mix of measures consisting of organisational and technical protective measures must be defined.

We are happy to support you in this and develop a solution concept together with you that is tailored to your needs.

Welding fumes are often a fire hazard. Also because partially oiled or coated components are welded. This leads to a combustible mixture in the extraction system. If sparks also get into the extraction system during welding, a fire can develop. It often starts as a flash fire in the pipework and spreads to the filter. Therefore, the possibility of a fire hazard must be taken into account as early as the system planning stage and, based on this, a fire protection concept with appropriate protective measures must be implemented. They range from organisational measures to technical measures such as the installation of pre-separators or fire extinguishing systems.

We are happy to support you in this and develop a solution concept together with you that is tailored to your needs.

As a rule, the welding fumes are not explosive and can therefore be removed with traditional extraction technology. In certain cases, welding fumes can still be explosive. An investigation of the safety parameters for the respective application is therefore strongly recommended.

We are happy to support you in this and develop a solution concept together with you that is tailored to your needs.

Recirculated air-operation means that air that has already been filtered is returned to the work area. In order to avoid additional hazards for the employees, legislators regulate the possibilities for air recirculation. The corresponding standards vary from country to country. In general, the possibility of recirculated air-operation depends on the separation efficiency. In many cases, air recirculation is permitted if the purified air falls below 1/3 of the permissible workplace limit value. The situation is different for air recirculation when handling carcinogenic substances.

We are happy to support you in this and develop a solution concept together with you that is tailored to your needs.

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