Cutting with any known thermal technologies such as plasma, laser, or oxy-fuel, can produce toxic fumes and gases that pollute the air we breathe. Fabrication shops tend to have both dry contaminants, from cutting, grinding and welding such as airborne dust, smoke and fumes, and some sticky contaminants, from oil mist and other lubrication needs.

There are conductive materials that can be cut using above mentioned arc processes where a considered approach is required. A number of materials and coatings contain elements that are classed as “Heavy Metals” and other toxic constituents, examples of these are: zinc (galvanized steel), lead, cadmium, chromium, beryllium etc. Such materials should not be cut without a comprehensive safety review.

Health Risks

It is not surprising that long-term exposure to all of these toxic air contaminants make no good to our health. Some elements in polluted air have been proven to be cancer-causing. Except of this, other health issues can appear, for example a reduction of cognitive function, lower work productivity, weakening of the immune system etc. Operators and co-workers in close proximity are at risk, where possible the work should be done in a controlled environment.

Faced with these scientific facts and the legal regulations in force in different countries, many companies cannot underestimate the risks and are forced to continuously consider how to improve their working environment to prevent health risks. This process involves monitoring work processes, safety mechanisms and employee exposure.

Be Aware of and Follow All Safety Regulations in Your Country

Safety is the number one priority in metal cutting. There are many safety regulations regarding the prevention of health risks, which may differ from country to country. For many fabricators, especially small to medium sized companies, it can be difficult to keep up with all the changing regulations, so it is very common and recommended to cooperate with external experts and professionals in this area of legislation.

There are several regulations that set the basic requirements for working safely with metals in the European Union. These regulations are mandatory for all EU members, although each EU country can adopt even stricter rules.  Here are some of them:

• ● The Workplaces Directive (89/654/EEC), which deals with minimum health and safety requirements in workplaces, such as lighting, ventilation, temperature, noise, vibration, signage and emergency exits.
  
  
• ● The Chemical Agents Directive (98/24/EC) protects workers’ health from risks associated with occupational exposure to chemical agents, including metals. It outlines employers’ obligations for risk assessment, exposure prevention and limitation, measurement and monitoring, information, training, and health surveillance.
  
  
• ● The Physical Agents Directive (2004/40/EC) sets minimum requirements to protect workers from risks related to electromagnetic fields, such as induction heating or metal welding. It includes exposure limits, risk prevention measures, and mandates for information, training, and worker consultation.

Find All Sources of Air Pollution in Your Workplace

It is obvious that contaminants will come from the torches and the base metal you are cutting. Once you have identified all the hazards in your workplace, you can explore the options to find the best solution to meet your needs.

It is worth inviting and consulting also with the operators, because it makes no sense to invest huge sums in equipment that won’t be used.  The right system should match your working processes and the workers should be comfortable using it.

“What is the best solution for you?
Explore options and consult not only with expert but also with your operators.”

Smaller shops have different needs than large manufacturers. The solutions can range from simple natural ventilation, such as opening a garage door at the start of a shift, to sophisticated industrial air filtration systems for heavy industrial production.

It is important to choose the right technology, the right size, and the optimal cost-effectiveness. You need to find something that works for you, your budget, operational flow, and employee needs. There are some very effective options that focus on safety that don’t cost a fortune to install.

Start with answering some basic questions and consider as many factors as possible:

• ● What material are you working with?
  
• ● What is your frequency of cutting as well as the length of cuts?
  
• ● Is it continuous or intermittent?
  
• ● Do you want to recirculate the air inside the building or vent it outside?

There are different ways how to handle smoke and dust generated by light plasma cutting application and robot welding. A good solution can also be the EXTRACTION systems combined with suitable cutting table. Such systems have filter cartridges placed in the upper section of the extraction systems. This allows easy access for maintenance and cleaning of the dust collection box. The cleaned air is blown back into the workshop – no heat loss.

The latest trends incline to the on-torch fume extraction capturing a contaminant directly at the source. They are also becoming popular thanks to improved ergonomics and performance. Another important tool or approach for bigger fabricators is automation like cobots, and how they can be integrated into the working process.

Unlock a world of possibilities at www.ex-track.com. Dive in now to explore our exciting range of related products!

Text:               Thermacut, k.s.
Photo:            Archive of Thermacut, k.s.

Source of information:
Link referring to the web article from Canadian Fabrication & Welding
6 steps to limit air contaminants in the job shop (canadianmetalworking.com)