Case Study: Protecting Welders From Toxic Lead Fume at Central Milled Lead Ltd

Central Milled Lead Ltd, a leading UK manufacturer of bespoke lead fabrications and British Standard Rolled Lead Sheet, needed a way to protect its welding team from a serious and invisible hazard: lead weld fume. Here's how Workplace Safety Management designed and installed a Local Exhaust Ventilation (LEV) solution that captures fume at the source and keeps workers breathing clean air.

Project Summary

Client: Central Milled Lead Ltd

Industry: Bespoke lead fabrication; manufacturer and supplier of British Standard Rolled Lead Sheet

Challenge: Protecting welders from inhaling toxic weld fume particles

Solution: Installation of a 2-point LEV extraction system

Result: Fume captured at source, keeping it out of workers' breathing zones

The Challenge: An Invisible Threat on the Welding Floor

Welding bespoke lead parts generates lead weld fume, a highly toxic, fine particulate that's largely invisible to the naked eye. Without proper controls, welders can inhale it directly, putting their long-term health at risk. The HSE's guidance on health risks from welding confirms these are serious, well-documented occupational hazards.

Key Health Risks of Lead Welding Exposure

• Lead poisoning (acute and chronic): Inhaling lead oxide fumes or dust can cause high blood pressure, fertility problems, headaches, and extreme fatigue.

• Respiratory issues: Welding fumes irritate the throat and airways and can cause metal fume fever and pneumonia.

• Cancer risk: Long-term exposure to fumes containing lead is linked to a higher risk of lung, kidney, and stomach cancers.

• Neurological damage: Continued exposure can cause brain damage, poor attention span, irritability, and memory issues.

• Reproductive health: Lead exposure can affect fertility in both men and women.

Given these risks, Central Milled Lead needed an engineering control that would remove fume before workers had a chance to breathe it in.

The Solution: A 2-Point LEV Extraction System

Workplace Safety Management installed a double extraction arm system using two ceiling-mounted Plymovent EA articulated extraction arms, paired with a Plymovent extraction fan from the FUA range. Airflow gauges were fitted to each extraction arm to give operators a clear visual indication that the system is working correctly.

By positioning extraction hoods right at the source of the welding process, the system removes fume before it can spread into the wider workshop, protecting each operator's breathing zone.

Key Features and Benefits

Superior Health Protection

• Reduced inhalation risk: The LEV system captures lead fumes and fine particles directly at the point they're generated, stopping them from spreading through the workshop.

• Prevention of occupational disease: Filtering toxic lead oxides helps prevent long-term effects like chronic poisoning, reproductive health issues, and lung disease.

• Cleaner working environment: Cleaner air means less toxic dust settling on surfaces, equipment, and clothing.

Legal Compliance

• COSHH compliance: The system helps Central Milled Lead meet the UK's Control of Substances Hazardous to Health (COSHH) regulations, which require employers to control exposure to hazardous substances.

• HSE alignment: The Health and Safety Executive expects suitable engineering controls like LEV for indoor welding, helping to prevent fines and prosecution.

• Built for mandatory testing: The system is designed to support the regular testing and thorough examination required at least every 14 months, which WSM can carry out as part of an ongoing LEV testing and service contract.

Operational Advantages

• Higher staff productivity: Workers feel safer and more comfortable in a clean environment, leading to fewer disruptions and better output.

• Improved employee retention: Providing proper safety equipment demonstrates a duty of care, boosting morale and reducing staff turnover.

• Energy efficiency: Because the system targets fume at the source rather than ventilating the whole workshop, it's more energy-efficient than general whole-room ventilation.

Asset Protection

• Reduced equipment damage: Removing metal fumes and dust reduces contaminant buildup on machinery and electronics, cutting down on breakdowns and maintenance costs.

The Result

By installing a targeted 2-point LEV system, Workplace Safety Management gave Central Milled Lead Ltd a solution that captures fume at the source, protects welders' breathing zones, and supports ongoing COSHH compliance, all while improving productivity and protecting equipment on the shop floor. Explore our full range of fume extraction and industrial ventilation services to see how we can help your site too.

Need an LEV system for your welding or fabrication workshop? Get in touch with Workplace Safety Management to discuss a solution tailored to your site, or learn more about our team.