Welding Fume Extraction Compliance: What to Know in 2025

Updated for 2025: This guide reflects the latest HSE and COSHH requirements for welding fume extraction compliance.

Key Takeaways

• Since 2019, HSE requires all welding fume extraction systems to protect workers from mild steel fume exposure — this rule remains fully enforced in 2025.

• Employers must provide adequate local exhaust ventilation (LEV) and maintain it regularly under COSHH.

• Annual LEV testing is required for welding fume extraction compliance. With detailed maintenance records kept.

• Poor extraction can result in HSE improvement notices or fines.

• Westermans offers new and used, fully compliant fume extraction systems for all welding applications.

Contents

1. Intro – Why Welding Fume Extraction Compliance Matters

2. Understanding COSHH & HSE Requirements in 2025

3. How Inspectors Assess Welding Fume Extraction Compliance

4. 5 Practical Steps to Ensure You’re COSHH Compliant

5. What Happens If You Aren’t Compliant

6. How to Choose a Suitable Compliant Extraction System

7. Final Thoughts

Why Welding Fume Extraction Compliance Matters More Than Ever

In 2019, the Health and Safety Executive (HSE) reclassified all welding fumes — including those from mild steel — as carcinogenic. Capable of causing lung cancer and other serious health effects. Since then, COSHH regulations have made effective fume extraction a legal requirement for every employer.

Since then, COSHH regulations have required every employer to provide adequate fume extraction and LEV. This remains a key focus for inspectors across UK workshops in 2025. Inspections ensure proper risk assessment has been undertaken and check implemented control measures. As well as health surveillance processes and emergency procedures are in place if needed.

Understanding COSHH and HSE Requirements in 2025

The Control of Substances Hazardous to Health (COSHH) Regulations require employers to prevent or control exposure to substances that are hazardous to health. Including all forms of welding fume.

Since the HSE’s 2019 reclassification of mild steel fume as carcinogenic, every welding operation must have effective fume extraction and ventilation in place. Regardless of scale.

In 2025, the HSE continues to enforce this rule strictly. With inspections targeting workshops that use MIG, TIG, or arc welding on mild, stainless, or galvanised steels.

Employers should demonstrate that exposure is controlled at source. Usually through a specifically designed Local Exhaust Ventilation (LEV) system.

Under COSHH, duty holders must:

• Assess the risks from welding fumes and identify where exposure occurs.

• Provide appropriate LEV or fume extraction equipment to capture fume at source.

• Maintain and test LEV systems at least every 14 months. Keeping written records of each inspection.

• Train operators to use extraction equipment correctly and understand its importance.

• Review risk assessments regularly and update them whenever welding processes or materials change.

Failure to meet these obligations can result in improvement notices or enforcement action. Particularly where workshops rely on outdated extraction. Or have no evidence of maintenance and testing.

The HSE’s guidance document HSG258 provides detailed information on LEV system design and testing requirements. Following this guidance helps demonstrate welding fume extraction compliance. While protecting the health of anyone exposed to welding fumes in your workplace.

💡 Tip:

When planning your next LEV inspection, check that your system’s airflow and filters are performing effectively. If the unit is ageing or parts are no longer available, it may be time to consider updating your fume extraction system.

Take a look at our comprehensive Buying Guide to find the right solution for your needs.

How Inspectors Assess Welding Fume Extraction Compliance

When the HSE carries out a workplace inspection, fume extraction is one of the first things they check in any welding environment. Inspectors look for clear evidence that exposure to welding fume is controlled at source. Checking your Local Exhaust Ventilation (LEV) is effective, and that your team knows how to use it correctly.

To stay compliant and inspection-ready, it helps to understand what inspectors focus on. Plus what documentation they expect to see.

Visual Inspection and Capture Efficiency

Inspectors will start by observing how fume is being captured at the point of welding; things like visible airflow. For example, whether a portable hood or extraction arm is close enough to the weld area to capture the fume effectively.

If they can see fume escaping into the workspace or detect strong odours, it’s a clear sign your system isn’t working efficiently.

✅ Tip: Position extraction arms as close as possible to the weld without affecting access or visibility. Ideally within 150–300mm.

Evidence of Regular Maintenance and LEV Testing

LEV systems must be thoroughly examined and tested at least every 14 months. Or more frequently if exposure risks are high, in accordance with COSHH Regulation 9. Inspectors will expect to see:

• A recent LEV test report (within the last 14 months)

• Records of filter replacements or air-flow checks

• Clear labelling on the extractor unit showing test date and next due test

If these records aren’t available, you could face an improvement notice. Even if your equipment appears to be working! If your equipment needs an LEV test, we can arrange an engineer to do this on site for you – find out more.

Operator Awareness and Training

HSE inspectors often speak directly to welders and supervisors to check whether they understand how and why the extraction system is used. They may ask questions like:

• “How do you know the extractor is working properly?”

• “When was it last tested?”

• “What should you do if the airflow seems weak?”

Operators should be confident in their answers and know how to spot early warning signs such as reduced suction or blocked filters.

Suitable Extraction for Each Welding Process

Different welding methods create different types of fumes. So inspectors will also assess whether your extraction setup matches your process. For example:

• MIG welding generates a large visible fume plume that needs high capture velocity.

• TIG welding creates lower amounts of fume, but still requires local capture.

• Plasma cutting may need extra filtration like spark arrestors. Or extraction at multiple points.

An extraction system that’s effective for one process may not provide enough protection for another!

💡 Tip:

Keep your LEV inspection reports and maintenance logbook near the extraction unit or welding bay. HSE inspectors often ask to see them on site, and being able to produce them quickly shows good control and competence.

5 Practical Steps to Stay COSHH-Compliant

Meeting your obligations under COSHH doesn’t have to be difficult, but it does need consistency. Following these five steps will help you with fume extraction compliance and protect your workforce. While avoiding costly downtime or enforcement action.

1. Assess Your Current Extraction Setup.

   Start by reviewing every welding station and identifying where fumes are generated. Check that each workstation has effective local extraction, and that it’s positioned close enough to capture fume at source. If systems are old, under-performing, or no longer supported by the manufacturer, it may be time for an upgrade or refurbishment.

   Tip: Use a simple airflow indicator or smoke test to confirm capture efficiency during daily checks.

2. Carry Out Regular LEV Testing and Maintenance

   Under COSHH Regulation 9, all Local Exhaust Ventilation (LEV) systems must be tested at least every 14 months by a competent person. Routine checks like filter cleaning, airflow readings, and duct inspections should be done regularly in-house.

   Keep a logbook that records:

   • The date of each test or maintenance activity

   • Airflow measurements or test certificate numbers

   • Any corrective actions taken

   This evidence is often requested during HSE inspections and helps demonstrate good control.

3. Train Operators to Use Extraction Effectively

   Even the best extraction system can fail if operators don’t use it properly. Training should cover operation instruction, like how to position extraction arms or hoods. As well as troubleshooting like recognising reduced suction, and report faults quickly. Short refresher sessions every few months keep best practice front-of-mind. Especially in busy fabrication environments!

4. Keep Accurate Documentation and Records

   Inspectors will expect to see written evidence that you’re maintaining and testing your LEV correctly. Keep copies of:

   • Risk assessments

   • COSHH assessments for welding processes

   • Maintenance logs and LEV certificates

   Store them near the extraction unit and in digital format if possible. Good record-keeping shows control, competence, and a proactive safety culture. Easily demonstrating welding fume extraction compliance.

5. Plan for Replacement or Upgrades

   Like welding, extraction technology moves fast. Worn or inefficient systems can struggle to meet modern standards. Plan ahead for equipment replacement — don’t wait for a breakdown or inspection failure.

   Opting for a refurbished fume extraction system from a trusted supplier can be a cost-effective way to upgrade. All our used fume extraction units are tested and serviced. With on-site LEV testing available, you can meet COSHH and HSE requirements without the price tag of new equipment.

💡 Quick Checklist:

• LEV tested within last 14 months

• Operators trained and confident

• Maintenance log up to date

• Records stored on site

• Extraction arms capturing fume effectively

HSE Penalties and Risks of Non-Compliance

Failing to comply with COSHH and HSE welding fume regulations can have serious consequences. Both for your business and for the health of your team! The HSE has made it clear that there is no safe level of exposure to welding fume. With enforcement around extraction control remaining one of its top inspection priorities in 2025. Failure to demonstrate welding fume extraction compliance can result in the following:

Health and Safety Risks

When extraction systems are missing, under-performing, or poorly maintained, welding fumes accumulate quickly. Prolonged exposure is linked to:

• Lung cancer and occupational asthma

• Metal fume fever (flu-like symptoms from zinc oxide exposure)

• Chronic bronchitis and reduced lung function

• Headaches, fatigue, and long-term respiratory irritation

These issues don’t just affect welders, anyone working nearby can be exposed if the workspace isn’t properly ventilated. Protecting air quality is essential to the wellbeing of your entire team.

HSE Enforcement and Penalties

If inspectors find that welding fume isn’t being adequately controlled, they can issue:

• Improvement notices. Requiring you to make changes within a set period.

• Prohibition notices. Stopping welding work immediately until compliance is achieved.

• Fines or prosecution. For serious or repeat offences.

Even where penalties aren’t issued, failure to demonstrate good control can lead to unwanted disruption. Plus reputation damage, and extra costs during follow-up inspections.

Protecting Your Business

The simplest way to ensure welding fume extraction compliance is to make sure your extraction systems are effective and well-maintained. Regular LEV testing is essential. If your equipment is outdated or too costly to repair, we offer a range of new and used solutions for various demands and applications.

Every unit supplied is fully inspected and serviced before delivery, with warranty package as standard. Complete with an LEV test, you can protect your team and maintain a safer, cleaner workshop. As well as ensuring welding fume extraction compliance.

How to Choose a COSHH-Compliant Welding Fume Extraction System

Choosing the right fume extraction system is essential for maintaining a safe, compliant, and efficient workshop.

The ideal setup will depend on your welding process, materials, and workspace layout. Above all, it must meet COSHH requirements for capturing fumes at source.

Here’s what to consider when reviewing or upgrading your extraction in 2025:

1. Match the System to Your Welding Process

   Each welding method produces a different type and volume of fume:
   – MIG and MMA welding generate dense fumes that need high-velocity local capture.
   – TIG welding creates less visible fume but still needs effective point extraction.
    – Plasma cutting and gouging often benefit from a combination of extraction hoods and filtration units.

   Use a combination of welding processes? Choose a versatile system with adjustable extraction arms or modular ducting that can serve multiple bays.

2. Prioritise Local Exhaust Ventilation (LEV) Design

   A well-designed LEV system removes fumes before they reach the welder’s breathing zone. Look for:

   • Correct hood design and capture area

   • Adequate airflow and filtration performance (tested in line with HSG258)

   • Accessible ductwork and filters for easy maintenance

   • Systems designed for continuous duty if you operate long production shifts

   Good LEV design is the foundation of COSHH compliance.

3. Check Documentation and Certification

   During an HSE inspection, you’ll need to show that your fume extraction has been tested and maintained correctly. Make sure your system is supplied with:

   • A performance test certificate or LEV report

   • Full technical specifications and operating manuals

   • Records of service or filter replacement

   These documents demonstrate compliance and provide traceability.

4. Choose Between New or Used Systems

   We offer both new and used fume extraction solutions to meet different budgets and requirements.

   • New systems deliver the latest filtration and airflow technology. Ideal for heavy-duty or high-spec workshops.

   • Used systems are fully serviced, tested, and can be COSHH tested on site. A cost-effective way to stay compliant while extending equipment lifespan.

   Whichever you choose, every system comes with expert advice and after-sales support from our technical team.

💡 Next Step:

If you’re unsure which type of extraction best suits your workshop, explore our Fume Extraction Buying Guide. Or browse our full range of New and Used Fume Extractors — tested, compliant, and ready to install.

Final Thoughts

Welding fume extraction compliance isn’t just about ticking regulatory boxes. It’s about creating a safer, healthier, and more productive workshop for everyone who works in it.

With the HSE continuing to focus on fume control and LEV performance in 2025, maintaining effective extraction is one of the simplest and most valuable investments a welding business can make.

Whether you’re upgrading an ageing system, setting up a new workshop, or expanding your welding capacity. We can help you find the right balance of performance, compliance, and cost-efficiency.

We have been supplying new and used fume extractors for decades. Each one serviced and tested, backed by our 5 star rated after-sales support. Helping you stay protected and productive for years to come!

💡 Next step: Explore our Fume Extraction Range. Or get in touch to speak with our technical team about the right extraction solution for your workshop.

This article has been reviewed by Westermans’ technical team, who have decades of experience supplying and servicing industrial fume extraction systems in compliance with COSHH and HSE standards.