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Welding professionals across the UK are facing increasing scrutiny from the Health and Safety Executive in 2025, as inspection campaigns continue to prioritise the control of welding fume exposure. The associated risks, particularly links to lung cancer, asthma and other respiratory conditions, have prompted a shift in how inspections are conducted and safety standards enforced. Welding businesses need to be prepared for more detailed evaluations, tougher expectations and less tolerance for non-compliance.
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HSE inspectors are prioritising one key issue above all else: effective control of exposure to welding fumes. The driving force behind this increased attention is the reclassification of mild steel welding fumes as a Group 1 human carcinogen. Following new evidence from the International Agency for Research on Cancer, this new classification means there’s no known safe level of exposure. In response, the HSE has made it clear that no welding activity, regardless of duration or frequency, should take place without an appropriate fume extraction system.
During inspections, HSE officers are investigating whether businesses are applying effective controls, particularly LEV systems designed to extract harmful fumes at source. The focus is on preventing any hazardous fumes from entering the employees’ breathing zone or spreading throughout the workplace. Where LEV is in place, inspectors will assess whether it’s being properly used, maintained and tested. If the system is absent or inadequate, the HSE demands suitable respiratory protective equipment is used as an additional measure.
General ventilation, which may have been deemed acceptable in the past for short-term or light welding, is no longer considered sufficient under any circumstances.
The latest regulations require that exposure to welding fumes is controlled through engineering means wherever reasonably practicable. Fume extraction systems must be capable of capturing and filtering fumes directly at the point of generation, and they must be appropriate for the type of welding being performed. Regular maintenance and testing will be required for the systems to remain effective. In most cases, this should take place at least every 14 months. The results of the tests must be documented and made available during inspections.
Welding shops must ensure workers are issued with suitable PPE and trained in its use, as well as ensuring each person’s equipment is properly fit-tested. These requirements are integral to compliance and reflect the increased understanding of how dangerous welding fumes can be to long-term health.
A formal welding risk assessment is also essential to help identify all sources of fumes, dust and any other exposure risks. This serves as a foundation for implementing control measures and choosing the correct type of extraction system for the task.
The mandatory use of respiratory protective equipment represents one of the most significant changes to the PPE requirements. All welders, whether full-time professionals or occasional users, must now wear RPE where engineering controls do not fully contain the fume exposure. Typically, it should include tight fitting face masks or powered air purifying respirators, depending on the circumstances.
The HSE is also focusing on a wider range of PPE, such as eye and face protection, gloves and flame-retardant protective clothing. Inspectors will be assessing whether it is being worn correctly, maintained in good condition and supported by adequate training.
Thorough recordkeeping plays a critical role during inspections, with welding shops expected to demonstrate compliance through detailed documentation. Inspectors will expect to see written welding risk assessments that evaluate the potential hazards of operations and outline the measures in place to control them.
COSHH assessments should detail the nature of the welding fumes being generated and how exposure is being managed. LEV systems must be supported by a maintenance log and records of all statutory testing. Similarly, RPE programmes must include documentation of fit-testing results, maintenance checks and user training. Inspectors may also request evidence that employees have been trained to understand the risks associated with welding fumes and how to properly use control measures.
Documentation deficiencies are among the most common reasons businesses fall short during inspections. Even where physical controls such as a dust extraction system or LEV are in place, a lack of records can be treated as non-compliance under enforcement policy.
The HSE continues to identify recurring issues during welding shop inspections. One of the most prevalent is the presence of outdated, poorly designed, or inadequately maintained extraction systems that fail to capture welding fumes at source. In other cases, businesses rely solely on general ventilation or insufficient extraction methods, which do not meet current expectations. The use of modern and efficient dust extraction and LEV systems that effectively capture welding dust and fumes at source has become even more important under the updated regulations.
Another frequent issue is the improper use of RPE. This may include using the wrong type of mask, failing to carry out fit-testing, or providing RPE without any supporting training. In some cases, employees are unaware of the correct procedures for wearing or maintaining their respiratory equipment, rendering it ineffective. A lack of employee training on health risks and the correct use of safety systems is a massive red flag for HSE inspectors. Combined with missing or out-of-date documentation, these failures can result in formal enforcement action including improvement notices, prohibition of unsafe practices, or in more serious cases, prosecution.
As the standards for fume control rise, many welding and fabrication businesses are turning to companies like AirBench for practical solutions. We have been supplying dust and fume control equipment for more than 30 years. Our products are designed to meet the demands of welding and grinding environments and are built with compliance and real-world usability in mind.
The AirBench FPW range offers effective fume extraction capabilities for welding and grinding dusts and fumes, while the FN series is suited to lighter duties or applications involving non-sparking materials like aluminium. Our VertEx cross-draught booths can be configured for welding, grinding, and even coolant mist extraction. These systems integrate spark protection features and high-grade final filtration to maximise both safety and performance.
AirBench extraction systems are built to exceed the requirements of HSG258 and COSHH, ensuring they stand up to HSE inspection standards. Demonstrations are available, often at the customer’s own site, allowing businesses to see these solutions in action before making a purchasing decision.
The HSE has a range of enforcement tools at its disposal, including issuing improvement notices that compel businesses to take corrective actions within a set timeframe, and prohibition notices that halt unsafe work immediately. Where businesses fail to comply or show negligence, financial penalties and legal prosecution may follow.
In 2025, every welding activity, regardless of scale or setting, must be supported by effective engineering controls, properly managed RPE, and a clear, well-documented safety strategy. The HSE’s expectations have changed, and businesses must evolve to meet them.
AirBench Ltd are the UK’s leading manufacturer of downdraught benches and cross draught extraction systems. We have more than 10,000 extraction systems in service in the UK and overseas. Along with our range of coolant mist filters and air cleaning systems, we are actively helping businesses across many industries solve their workplace dust and fume issues.
If you'd like to try an AirBench product for FREE simply book a demo and we'll bring one to you.
If you’d like to try an AirBench product for FREE simply book a demo and we’ll bring one to you.