Welding Fume Monitoring

What is welding fume monitoring?

Welding fume monitoring measures the airborne concentration of fine metal oxide particles including manganese, chromium and nickel released during welding that workers may breathe in during normal operations. It quantifies real personal exposure so employers can judge whether existing controls are adequate.

IndustrialAirMonitoring.uk provides independent welding fume monitoring across fabrication, shipbuilding, automotive, construction, engineering sites throughout the UK. Our occupational hygienists deliver defensible exposure data that demonstrates compliance with the Control of Substances Hazardous to Health Regulations 2002 (COSHH) and the workplace exposure limits set out in HSE guidance note EH40.

Since February 2019 the HSE requires suitable controls for all welding fume, indoors and outdoors, regardless of duration. Monitoring demonstrates that local exhaust ventilation and RPE are keeping exposure as low as reasonably practicable.

Why welding fume monitoring matters

Under COSHH Regulation 10, employers must monitor exposure to hazardous substances where it is needed to protect health, where a workplace exposure limit could be exceeded, or where control measures need to be verified. Welding fume monitoring provides the objective evidence that satisfies this duty.

Uncontrolled exposure to welding fume is linked to lung cancer, manganism, metal fume fever and occupational asthma. Beyond the legal duty, robust monitoring protects your workforce, reduces the risk of enforcement action and civil claims, and gives insurers and clients confidence that exposure is being actively managed.

How we carry out welding fume monitoring

We measure exposure using breathing-zone personal sampling on filters analysed for total fume and individual metals by ICP, following the recognised MDHS 14/4 + metals by ICP methodology. Personal samplers are worn in the breathing zone for a representative full shift to derive an 8-hour time-weighted average, while static (background) samples help map contaminant sources across the workplace.

Samples are analysed by an accredited laboratory and the results compared with the relevant occupational exposure limit. Where short-term peaks are a concern we add 15-minute short-term exposure limit (STEL) sampling, so both the chronic and acute risk picture is captured.

Standards, limits and reporting

The current workplace exposure limit for welding fume is Manganese 0.05 mg/m3 respirable; fume controlled ALARP (EH40/2005, as amended). We assess compliance using the BS EN 689 statistical decision framework, which accounts for exposure variability rather than relying on a single result.

Your report sets out the measured concentrations, the compliance position, the adequacy of existing controls such as local exhaust ventilation, and a recommended re-monitoring interval. It is written to be understood by managers and to satisfy HSE inspectors, auditors and insurers.

Our welding fume monitoring process

Our welding fume monitoring programmes follow a structured, four-stage workflow so the results stand up to scrutiny. Request monitoring or book a site assessment to begin.

1Scoping & site survey. We review your processes, COSHH assessments and previous welding fume monitoring data, then plan a representative sampling strategy using BS EN 689 similar exposure groups.
2On-site sampling. Qualified occupational hygienists carry out calibrated breathing-zone and static measurements across a representative shift, with full chain-of-custody documentation.
3Accredited analysis. Samples are analysed using the relevant MDHS / ISO laboratory method and the results are compared against the applicable workplace exposure limit.
4Reporting & recommendations. You receive a clear exposure report with compliance status, control recommendations and a re-monitoring interval — defensible evidence for HSE, insurers and auditors.

Frequently asked questions

Is there a welding fume exposure limit?

There is no single welding fume WEL; HSE requires exposure to be controlled to as low as reasonably practicable. Component metals such as manganese (0.05 mg/m3 respirable) do have limits we measure against.

Do I need LEV for welding?

Yes — since 2019 HSE expects engineering controls (LEV) for all welding fume, with RPE where LEV alone is insufficient. Monitoring verifies they work.

What metals do you analyse?

Typically manganese, chromium, nickel and iron, plus hexavalent chromium for stainless steel welding, by ICP analysis.