BOHS – Online Welding Fume Control Selection Tool
The Breathe Freely Welding Fume Control Selector Tool is a free online decision-support tool developed to help managers, supervisors and employers identify appropriate welding fume control measures for common welding activities.
The tool was developed by a working group comprising experts from industry, occupational hygiene consultancies, academia and the Health and Safety Executive (HSE). It was created in response to increasing concern regarding the health effects of welding fume and supports organisations in selecting practical exposure-control solutions for different welding tasks.
Following HSE’s 2019 Safety Alert confirming that exposure to all welding fume, including mild steel welding fume, should be regarded as a carcinogenic health risk, many organisations sought practical guidance on selecting suitable controls. This tool was developed to help bridge that gap.
The tool provides guidance on:
- Local Exhaust Ventilation (LEV)
- On-torch extraction
- Extraction benches
- Mobile extraction units
- Respiratory Protective Equipment (RPE)
- Welding task-specific controls
- Indoor and outdoor welding activities
- Exposure-control decision making
Users answer four simple task-related questions and the tool generates a recommended control solution together with supporting guidance sheets. The tool is intended to complement, not replace, a suitable and sufficient risk assessment.
This resource is relevant to:
- Welders
- Welding Supervisors
- Fabrication Managers
- Occupational Hygienists
- LEV Designers
- LEV Installers
- P601 TExT Engineers
- Health & Safety Professionals
- Duty Holders
- Manufacturing Engineers
Source Document
View BOHS Online Tool here:
Source: BOHS Breathe Freely Campaign
Document Type: Online Decision Support Tool
Status: Current
Last reviewed by LEVCentral: June 2026
LEVCentral Expert Commentary
One of the most difficult challenges facing organisations following the 2019 HSE welding fume enforcement changes was determining which engineering controls were appropriate for different welding activities.
Whilst HSE made it clear that exposure to welding fume must be controlled, selecting the most appropriate solution is not always straightforward. The suitability of a control measure depends upon numerous factors including the welding process, workpiece size, location, mobility requirements and operator access.
This is where the Breathe Freely Welding Fume Control Selector Tool provides genuine value.
Rather than presenting generic guidance, the tool helps users work through a structured decision-making process and identify control options that are appropriate for the task being undertaken. The recommendations are supported by downloadable guidance sheets explaining the selected controls and any associated management requirements.
For LEV professionals, the tool demonstrates an important principle:
There is rarely a single universal solution for welding fume control
The optimum control strategy will depend upon factors such as:
- Welding process type
- Workpiece size
- Accessibility
- Mobility requirements
- Indoor versus outdoor work
- Frequency and duration of welding
- Operator working position
The tool is particularly useful for supervisors and managers who may not possess detailed occupational hygiene knowledge but are responsible for selecting appropriate controls.
It also supports a more defensible approach to decision making. By using a structured and recognised methodology developed with input from industry experts and HSE representatives, organisations can demonstrate that they have considered control options systematically rather than relying on assumptions or historical practices.
Importantly, the developers make it clear that the tool is not a substitute for a competent risk assessment. The output should be considered alongside site-specific conditions, worker competence, maintenance arrangements and overall exposure-control requirements.
Key Learning Points
Welding Fume Control Must Be Task Specific
Different welding activities require different control approaches. A solution suitable for bench welding may be ineffective for large fabrications or site work.
Engineering Controls Should Be Considered First
The tool promotes the hierarchy of control and helps users identify practical engineering solutions before relying on respiratory protection alone.
Simple Decisions Can Be Structured
The tool uses four straightforward questions to guide users towards appropriate control options.
Risk Assessment Remains Essential
The selector tool supports decision making but does not replace a suitable and sufficient COSHH risk assessment.
Further Resources
- HSE Safety Alert – Mild Steel Welding Fume
- HSE RR683 – Effective Control of Gas Shielded Arc Welding Fume
- BOHS Monitoring Exposure to Welding Fume
- HSG258 – Controlling Airborne Contaminants at Work
