How should employers conduct a welding fume risk assessment?

A proper welding fume risk assessment starts with understanding the task — not just ticking a box. Employers should identify what type of welding is being carried out (e.g. MIG, TIG, stick), what materials are being welded, and whether coatings such as paint or galvanising are present. These details matter because different metals and coatings produce different fumes.

Next, observe how the work is actually done. Are welders leaning directly over the plume? Is local exhaust ventilation (LEV) being used correctly? Sometimes controls are installed, but not positioned effectively.

Air monitoring is often required to quantify exposure. This typically involves personal sampling — a small pump worn by the welder during the shift to measure what they are actually breathing in. The results are compared to Workplace Exposure Limits (WELs) set out in EH40 guidance.

Finally, document findings clearly and outline improvements where needed — engineering controls first, then administrative controls and PPE as a last line of defence. And importantly, review the assessment regularly, especially if processes or materials change.