Welding Smoke and Fume Extraction
One problem. With more than one Solution!
Industrial Maid designs unique industrial ventilation systems for ductless welding smoke collection and fume extraction. The filter hood systems use a three stage filter package including a spark arrestance filter, a 4” pleated pre-filter and a 95% multi-pocket main bag filter. Our robotic hood system does not require storage of dust in trays or barrels and does not require compressed air for operation. The low air to cloth ratio and use of media style bags also requires a lower horsepower rating, helping save on yearly electrical operational costs. Several fume extraction hood sizes and airflow ranges from 1,000 to 8,000 CFM are available. The importance of fume extraction to the safety of workers isn't under debate any more, it's been tested and proven, so let the engineers at Industrial Maid help design the industrial ventilation system that will meet current standards set by OSHA.
At Industrial Maid we work with our customers and their mechanical contractors to find custom fume extraction hood solutions to industrial air filtration challenges.
The customer featured here needed to provide a ductless welding fume ventilation system in order to improve the air quality for their welders. As a metal fabrication shop they were dealing with an overabundance of weld smoke in their welding stations and did not have a good way to remove the weld pollutants. The most common welding ventilation systems solution would have been to enclose the work cells with walls or partitions and use an ambient fume collector, which would have severely restricted traffic flow near the workspace. An overhead crane was needed to bring in raw goods and take out finished product so an Industrial Maid robotic welding hood provided the perfect answer. A Gorbel Freestanding Work Station Crane system featuring a Model RH60-3 moves along a steel overpass with tractor drives. The ductless filter hood system can provide fume extraction for more than one welding cell and allows for the delivery crane activity with cantilevered crossbar supports on each end. Push button controls on both ends engage the tractor drives and limit switches signal the tractor drive when the hood is in place to stop the movement.
Industrial Maid knows that you need welding smoke removal that protects your workers but won't interrupt your workflow. Innovative solutions for industrial ventilation systems like this robotic welding hood and work station crane are what we do best.
The ductless welding exhaust hood featured here has a 14 & 16 gauge powder coated steel frame, 18 gauge galvanized steel hood and dust proof light kit. Other options available are HEPA afterfilter, direct drive bi-blower package, silencer, pressure gauge, side access door and curtain enclosure. This is an industrial ventilation system that can truly be designed to move your fume extraction challenges into compliance without compromising workflow.
Industrial Maid LLC introduces the new RHV fume exhaust hood – a complete packaged ductless fume hood ventilation solution for industrial air filtration. The units can be configured to cover areas from 4’ X 4’ to 16’ X 16’ or larger. A three stage fume extraction filter system includes the baffle filter, 4" pleated filter (Merv 7) and a 95% multi-pocket main bag filter (Merv 15). These filters will handle oily welding smoke and options are available to include a final HEPA filter for stainless steel fume or other applications requiring higher efficiency filtration. Our RHV fume extraction equipment incorporates a low static pressure motor blower package, requires no compressed air and no handling of dust from trays or drums. The resulting efficiency translates into an economical solution for handling welding fume collection; dollars saved as a direct result of controlling utility costs. Call 877.624.3247 to speak to an industrial ventilation systems expert where there is never a charge for getting the fume extraction help you need.
Industrial Maid introduces the new Model EB56 series packaged air filtration unit. This system is designed to handle welding fume exhaust and smoke, grinding dust, stainless steel dust and other airborne particulates. The powerful 4500 CFM, 5 HP motor with a direct drive high pressure BI composite blower makes the system quiet, efficient and easy to service. The air passes through a spark baffle for arrestance, then moves through a plenum chamber to eliminate heavy particles, then lastly passes thru a Merv 7 and Merv 14 series of filters. A HEPA final filter is also available to meet hexavalent chromium fume standards for stainless steel smoke.
As leading fume hood manufacturers, Industrial Maid is proud to announce the addition of our Model FW35-4 "side draft" filter wall unit for use in industrial manufacturing plants to contain welding smoke & fumes, grinding dusts, vapors and other air borne contaminants. This unit is mounted on a steel pallet with fork lift slips, offers three stages of filtration – 1) 2" polyester pre-filter or 2" spark baffle filter – 2) 4" pleated filter & 3) 45% to 95% multi pocket bag filter. The system has a cabinet manufactured from high density polyethylene plastic – making it lighter, quieter, non-corrosive and environmentally friendly versus a steel cabinet industrial ventilation system. The unit runs on low horsepower ratings, uses low air to cloth ratios and requires no compressed air or control boards for operation. The maintenance is fast and simple – access thru the front or an option is available for rear access doors - no tools required. The units offer business and industry a "lower cost of ownership" as compared to existing technologies for fume extraction.
Industrial Maid has designed a unique Model EB80-1 environmental control booth to help contain fugitive dust in the industrial workplace. The system incorporates a three stage media style filtration system, powered by a totally enclosed motor and belt drive blower package. Three standard sizes are available - 6' width, 10' width and 20' width. The booth housing is modular in design with acoustical sound control. The air filtration module has fork lift slips and an airflow range from 4,500 to 15,000 CFM. As with other IM LLC equipment, the outer cabinet shell is manufactured using a recycled polyethylene plastic, making it lighter, quieter, less expensive and more environmentally friendly than a typical industrial ventilation system with carbon steel cabinets. The booth systems do not require use of compressed air and have a lower energy consumption rate as compared to similar cartridge style units.
At Industrial Maid we are very proud of our "workhorse" the T-Series. The use of a T-style air cleaner configuration offers key advantages for "free hanging" air filtration applications:
- Dual Intake - Twice the normal intake area of a straight-through air cleaner (more intake helps create a better airflow pattern)
- Dual Filters - Nearly twice the filter media of a straight-through air cleaner (longer filter life and filter service intervals)
- Air Angles - Clean air throw is 90° from the intakes allowing for better air patterns (more intake helps create a better airflow pattern)
Industrial Maid's T-Series includes our most popular AZTECH Model T-3000 modular ambient industrial air cleaning units with cabinets fabricated from recycled polyethylene plastic. The attractive black matte finish will not dent, scratch or corrode and meets all NFPA fire codes. The Industry will notice that the product is lighter, dampens blower noise, is less expensive and more environmentally conscious than comparable equipment manufactured with carbon steel cabinets. These unique industrial ventilation systems are completely modular, so additional cabinets can be added for more sq. ft of filter media and will accommodate air flow rates of 3,000 to 7,500 cfm.
Portable welding fume extractor and dust collector Models PFC8 and PFC12 are in demand for source capture of welding fumes, grinding dust, etc. A flexible, flame-proof Z-Max fume extraction arm captures fumes and dust at a distance of 30-50 cm (12-20") from the source and within an area of 0.5m (20") diameter. The welding fume arms are available in 6” or 8” diameter and 7’, 10’ or 14’ lengths and feature a yellow hood with optimized airflow, ring handle and built-in damper.
Utilizing leading edge technologies such as our unique “Filter Hammer” sonic cleaning system ensure your mobile fume collector will perform at its best and give you a long cartridge filter service life. A simple push button cleaning system (requires compressed air connection) and sealed dust tray make cleaning select systems a breeze. Our portable fume collectors provide ample airflow for even the heaviest welding and grinding applications.
Industrial Maid portable fume extractors can also be fitted with an activated carbon filters which remove gases, or a 99.97% Hepa for removal of Hexavalent Chromium and other pollutants. Also available is an optional 24" x 24" downdraft bench in lieu of arm. Other portable fume extraction features include, easy access service door, tool-less filter change out and removable dust tray.
Neurological complications and disorders of the central nervous system have been definitively linked to exposure to welding fumes and smoke. There is no question that exposure to welding fumes can cause serious health problems. When inhaled, these fumes can enter the lungs, bloodstream, brain nerve cells, spinal cord and other organs resulting in both short and long term health issues. Studies show when placed right next to the area where the welding is taking place, local exhaust ventilation (LEV) reduces exposure to welding smoke and fumes. Contrary to common practice, attempts to reduce exposure by setting up fans or opening up windows and doors has been proven to be an ineffective way to protect workers. Research data tell us that welders that work in enclosed areas without LEV are subject to much higher levels of exposure to dangerous welding fumes. The information gleaned from exhaustive studies regarding the dangers of exposure to Hexavalent Chromium or Cr(VI) has led OSHA to set new strict standards and guidelines. It is important to note that the deadline for implementing engineering controls as part of an industrial ventilation system is May 31, 2010. 1910.1026 Chromium (VI).
In the "hot work" of the welding process Cr(VI) some materials such as stainless steel, the chromium is not originally hexavalent but is converted by the high temperatures involved. In order to protect their workforce, all employers should ensure that proper industrial ventilation systems are incorporated into welding work areas. These systems, which include ventilation hoods, ducted overhead units, portables, ambient air cleaners or backdraft units, filter walls and booths efficiently source capture toxic fumes and gases and remove them so that they never enter the welder's breathing space.
Because of the May 31, 2010 deadline OSHA has established which tightens the standards on Hexavalent Chromium exposure in the workplace, much attention has justifiably been directed at the dangers of welding stainless steel. But there are many other reasons for making sure all weld operations have the proper fume extraction systems in place for weld smoke and fumes:
Welding as a process most commonly applies high heat to a welding rod that serves as a metal filler for fusing other pieces of metal. Many of these welding rods contain a high amount of manganese because it strengthens the metals being joined. The action of heating and melting metals produces a gas, so when welders breathe in the smoke and fumes released in many welding processes, they are taking manganese toxins into their lungs which then very quickly travel to their bloodstream. Fume extraction must be the highest priority.
One of the most documented ill-effects of toxic environmental exposure is Manganese poisoning - and welders test at a higher than normal average of manganese exposure. Frequent exposure to high levels of manganese over long work periods can result in a disease known as manganism, also known as "Welder's Disease". Another common label is Parkinson’s Syndrome because the symptoms mimic Parkinson’s Disease. A crippling and incurable disease, it depresses the central nervous system's natural ability to produce dopamine, a neurotransmitter in charge of regulating movement, emotion, motivation and the feeling of pleasure. The outward manifestations of Parkinson’s Syndrome include shakiness or tremors especially in upper body areas, decreased facial expressions, slowed or stiffer movements, swallowing problems, and slurred or slowed speech. Welders exposed to the manganese fumes from welding rods are likely to develop side effects and symptoms of Parkinson’s 15 years earlier than the average individual who is not.
Unfortunately, manganese is not the only hazard of welding fume exhaust and the often related process of torch-cutting. Go to lhsfna.org to see a list of the other common toxins listed by OSHA that are released during these operations.
Solution: Choosing the right system to insure Employee safety. Industrial Maid can help.
Finding the best welding ventilation system to capture and remove welding smoke and fumes is important but it doesn't have to be complicated. At Industrial Maid we have engineers with years of experience when it comes to putting together all of the factors you need to consider when implementing an air filtration system. We have included a few application pictures here to demonstrate that there are many options when designing a fume extraction plan.
At Industrial Maid we use the newest technology to design and manufacture air filtration equipment that will address the problems all business face including space, air flow, costs, efficiency and challenges that are specific to the type of material being welded. Another important consideration is the type of filters that best suit the fume extraction system you choose. Give us a call at TF: 1-877-624-3247 or send us an email: firstname.lastname@example.org. We carry a full line of pleat, bag, and HEPA filters so be sure to ask our staff which would be best for handling welding fume exhaust.