How to Protect from Welding Fumes Effectively and Economically

如何有效且经济地防护焊接烟雾

由 | 4 月 18, 2024 | Industrial Protection Blog

呼吸焊接烟雾的健康风险

Welding fumes are very fine particles of metal oxides, and their composition depends on the type of metal being welded. In addition to the general harm of welding fumes once trapped in the lungs, some metal fumes are particularly hazardous, such as nickel, chromium, and manganese.  Exposure to welding fumes can cause Pneumonia, Metal Fume Fever, Asthma, COPD, cancer, etc. In fact, welding fume-caused cancer is one of the top 10 occupational cancers in Australia.

然而，焊接是行业中最常见的活动之一，例如造船厂、建筑、汽车、航空航天和维护。因此，大量工人可能接触焊接烟雾，需要采取有效行动来保护他们。

为了解决这一严重的工作健康问题，澳大利亚政府对焊接烟雾实施了新的工作场所暴露标准（WES），以更好地保护工人：从之前的 5 mg/m3 到目前的 1 mg/m3。

保护选项

有两个主要选项：

  • 局部排气通风 (LEV)：尽可能安装和使用 LEV。
  • 使用有效的呼吸防护设备 (RPE)

最安全、最佳的做法是同时拥有两者。

哪种 RPE 应与焊接头盔/镜片结合使用？

由于焊接烟雾中含有细小颗粒，N95 级一次性口罩被认为是不够的。

弹性体无动力空气净化呼吸器 (NAPR) 比一次性面罩更好，因为弹性体面罩的软垫可提供更好的密封性。然而，作为负压面罩，本身对面部泄漏敏感，因此防护仍然不够可靠。此外，大多数 NAPR 面罩主体上都有笨重的过滤器，这可能会干扰头盔的镜片。 NAPR 在长时间工作时也会感到呼吸不舒服，因为过滤器会给呼吸带来额外的负担，尤其是在炎热的条件下。

针对焊接烟雾的新 WES 很可能会要求在许多 LEV 措施不切实际或不充分的焊接场所使用电动空气净化呼吸器 (PAPR)。

Lastly, welding fumes are accumulative in the lungs, and the tightened 1mg/m3 limit does not mean it is a safe limit, it is only a legal maximum upper limit to be taken as a starting point. So if welding is part of your regular work, the safest approach is to always wear the best welding mask respirator available.

考虑到上述所有因素，焊接面罩与合适的电动空气净化呼吸器 (PAPR) 相结合是焊接防护的最佳选择。这是因为：

  • 由于面罩内正压，PAPR 比负压呼吸器具有更高的防护能力。
  • 在炎热条件下呼吸更容易、更凉爽，因此在进行艰苦的焊接工作时佩戴更舒适。

Currently, a popular option consists of a Welding Helmet with an Integrated Loose-fitting Powered Air-purifying Respirator. With this option, the helmet is specially made consisting of a loose-fitting visor for respiratory and face protection, a lens for eye protection, and an air entry at the back of the helmet to receive the air produced by a PAPR that is mounted at the back of the waist and secured by a belt, with filtered air being delivered via a hose to the helmet. A popular brand of this option is a 3M Speedglas G5-01 TW Heavy-Duty Flip-Up Welding Helmet plus an Adflo PAPR unit.

但是，此选项存在一些问题： 

  • 防护等级不是同类中最高的：由于它是松配合的 PAPR，标称防护系数为 500，而紧配合的 PAPR 为 2000。
  • Expensive: at a retail price starting over $2,000.
  • 如果您已经有一个普通的焊接头盔，添加这样的 PAPR 保护意味着您必须废弃您的旧伙伴：浪费金钱，而且对环境不利。
  • 由于 PAPR 装置笨重且背面软管较长，佩戴起来很麻烦，活动性也很差。
  • 噪音很大，因为 Adflo PAPR 以恒定流量运行，这意味着持续存在烦人的噪音。

AYO WX HFM-W Welding Half-Face Mask PAPR System – The Perfect Solution for Welding Fume Protection

Invented, designed, and fine-tuned in Australia, AYO WX HFM-W is a state-of-the-art Breath-responsive PAPR that suits welding fume protection extremely well due to the following advantages over the 3M Speedglas – Adflo PAPR system:

  • 一流的防护：作为一款紧身面罩，其标称防护系数超过 2000 (PAPR P3)，而 3M Speedglas – Adflo 宽松 PAPR 系统的防护系数为 500。
  • Fraction of the cost: $559 vs >$2,000 for the 3M Speedglas/Adflo system
  • A low-profile half mask designed specifically compatible with most common welding helmets plus a neck-peripheral mounted AYO WX PAPR P3 main unit: beneficial to many welders who currently have a common welding helmet already but now wish to use a PAPR for better respiratory protection.
  • Much improved mobility and comfort: No hose, no belt, and lighter.
  • Aimwell 的智能呼吸响应流量控制算法可确保面罩内始终保持正压，峰值流量超过 200 L/min，同时在呼气和每次吸气后期将噪音保持在最低水平。
  • 电池运行时间更长：16 小时，而 3M Adflo PAPR 为 12 小时。
  • 使用寿命：>10 年，而 3M Adflo PAPR 为 5 年。

In Summary:

Key Comparison 3M Speedglas G5-01 TW Heavy-Duty Flip-Up Welding Helmet with Adflo PAPR (Loose-fitting)

AYO WX HFM-W Welding Half-Face Mask PAPR System

(Tight-fitting or loose-fitting)
Protection Class

EN12941 TH3, MPF: 50

Nominal Protection Factor: 500

AS/NZS 1716 PAPR P3

MPF: > 100 (tight-fitting), 50 (no Fit Testing)

Nominal Protection Factor: 2000 (tight-fitting)
Wearability/Mobility

Heavy with hose and belt, troublesome to don and doff, and poor mobility

Lightweight and low-profile, no hose no belt, easy to don and doff, good mobility

 
Welding Helmet Integrated Existing non-integrated
Peak flow 170 – 200 L/min > 200 L/min (Breath responsive)
电池运行时间 12 hours 长达 16 小时
Weight 2.13kg (Helmet 1kg, PAPR 1.1kg) – not including hose) 1.26kg (Helmet 0.54kg (typical), PAPR+half-face mask 0.72kg)
Fit Testing Not required Depending on the level of protection needed
Fitting type Loose-fitting only, can not be converted to tight-fitting PAPR if needed. Tight-fitting but can attach a loose-fitting Face Seal for beard-covering.
Maintenance Difficult to maintain and clean Much easier to maintain and clean
使用寿命 5年 10年
Cost $2195 $559

Aimwell AYO WX HFM-W Welding PAPR P3 – A New Standard in Welding Fume Protection.

Quick Steps to Use AYO WX HFM-W Welding PAPR P3 with a Common Welding Helmet

  • 使用前给电池充电。
  • Fit the mask assembly over the face and tighten the strap at the back of the neck.
  • Remove the Guard Link from the Main Unit, wake it up by pressing its On/Off button, then slide the Main Unit down against the back of your head until it rests on the two supporting hooks of the head strap.
  • 将面罩推入主机的两端。
  • Adjust the height of the Hook to ensure a well-balanced support for the Main Unit and the mask.
  • Put on the Welding Helmet and you are ready to weld safely.
Shop AYO WX HFM-W Welding Half-Face Mask PAPR System Here

Aimwell AYO WX HFM Half-Face Mask PAPR System – The Dust Protection King

由 | 1 月 9, 2024 | Industrial Protection Blog

P3 Mask & Powered Respirator for Dust

When it comes to half-face respiratory protection from dust, typically there are 3 options:

1. Disposable paper mask, commonly N95 paper mask or filtering facepiece respirator (FFR).
2. Elastomeric reusable non-powered air-purifying respirator (NAPR).
3. Powered air-purifying respirator (PAPR).

Option 1 is the most common type of respirator, where the ‘Cup’ shaped mask is made of non-woven filter media and thus functions both as a barrier and as an air filter.

It is simple, light, low-profile, and can be mass-produced efficiently; however, it has the following key drawbacks:

  • The seal is prone to leak, as the facial contact is made from non-woven fiber that is not elastic with a low fit factor and cannot maintain a reliable seal with facial movement.
  • Typically, P2 grade is most practical from a flow resistance point of view due to the limited effective usable area of the mask, and P3 grade media will likely make it too restrictive to breathe comfortably.
  • The Assigned Protection Factor (APF) is only 10 for P2 FFR. For hazardous dust such as welding fumes, it is considered inadequate.
  • It is a disposable type and is not designed for reuse. Outside dust tends to accumulate around the mask seal due to negative pressure inside the mask, making it dirty to reuse the next day. Your breath will also contaminate the filter media with moisture and smell, increasing flow resistance to breathe against, and allowing bacteria to grow. Depending on how dusty and physical exertion is, it may need to be replaced in a few hours or daily.
  • You must be clean-shaven.

Option 2 improves some drawbacks of Option 1, where:

  • The elastomeric cushion improves the fit factor and seal during use.
  • The filter and the elastomeric mask are reusable, making it environmentally friendly and potentially saving costs for frequent use in dusty environments.

However, Option 2 still has the following drawbacks:

  • Although the flow resistance of the filter of a NAPR can be made lower by making the filter cartridge bigger, being a negative pressure respirator, the APF is still at 10 regardless of whether a P3 grade filter is used.
  • Being a negative pressure respirator, your lungs are still burdened by the flow resistance of the filter, making it not very suitable for high exertion work, as the flow resistance is proportional to the flow rate which is determined by the level of exertion of the work involved.
  • You must be clean-shaven to ensure the expected protection, and you are also recommended to do annual fit testing to make sure the fit factor is still adequate.

Option 3 improves most of the drawbacks of Option 2, where:

  • There is no flow resistance when the pressure inside the mask is positive, which is the case in normal and non-high exertion work where the flow rate from breathing is within the flow capacity of the PAPR.
  • Higher APF can be achieved up to 1000.
  • You may be able to keep a short and well-trimmed beard, provided you do fit testing at least once to make sure a fit factor of over 1000.

So based on the above comparison, PAPRs are the best option as far as protection is concerned.

However, not all PAPRs are equal:

    • They vary with APF levels, some are not significantly higher than a NAPR, such as a loose-fitting PAPR.
    • Other factors such as wearability, mobility, flow capability, and cost will affect whether a particular PAPR is suitable for a given work.

Here is a comparison of popular types of PAPRs on the market for dust protection:

PAPR Type Brand/Model Key Comparison
Face-mounted Tight-fitting

SHIGEMATSU

Sync11VP3

Protection level: AS/NZS 1716 PAPR P3
Peak flow:  only 138 L/min (Breath responsive)
Weight: 0.45 kg (particulate filter)
Battery Time: 11 hours
Cost: $1293
Shortcoming:

  • Low flow – not suitable for heavy work.
  • One Size only: may not be suitable for very small or very large faces.
  • Not easy to clean – The blower unit is not easily removable, and the mask can not be soaked for cleaning.
  • No Face Seal option for beard-covering.
  • Expensive
Belt-mounted Tight-fitting

Sundstrom SR700/SR900

Protection level: AS/NZS 1716 PAPR P3
Peak flow:  175 or 225 L/min
Weight: 1.24 kg (not including hoses)
Battery Time: 8 hours
Cost: $1899
Shortcoming:

  • Poor mobility – Bulky, heavy with long hose, troublesome to wear, not suitable in confined spaces.
  • Not easy to clean.
  • No Face Seal option for beard-covering.
  • Too expensive.

Back-mounted

Loose-fitting

Optrel Swiss Air System

Protection level: EN12941 TH3
Peak flow: only 130 L/min
Weight: 1.2 kg
Battery Time: 14 hours
Cost: $2122
Shortcoming:

  • P2 protection only.
  • Low flow – not suitable for heavy work.
  • Poor mobility and wearability – bulky, troublesome to wear at the back.
  • Not easy to clean.
  • Too expensive.

Around-neck

Tight-fitting

CleanSpace Works

Protection level: AS/NZS 1716 PAPR P3
Peak flow: 200 L/min (Breath responsive)
Weight: 0.54 kg
Battery Time: 8 hours
Cost: $990
Shortcoming:

  • The battery is not replaceable – when the battery is dead, the system dies.
  • Head movement restrictions due to the rigid and bulky neck module.
  • Uncomfortable at the neck when raising the head.
  • No Face Seal option for beard-covering.
  • Expensive

Around-neck

Tight-fitting and loose-fitting configurable

Aimwell AYO WX HFM Half-Face Mask PAPR System

Protection level: AS/NZS 1716 PAPR P3, MPF: >100
Peak flow: > 200 L/min (Breath responsive)
Weight: 0.70kg
Battery Time: 16 hours
Battery replaceable
Cost: $559
Best overall performance among all:

  • Best-in-class protection PAPR P3.
  • Great mobility – good head movement and comfort, no nuisance long hose and belt.
  • Very long battery life with replaceable battery.
  • Very easy to clean – tap water flush-washable.
  • Face Seal option for beard-covering.
  • The most value-for-money Half-face Mask PAPR in the world.

From the table above, Aimwell AYO WX HFM Half-Face Mask PAPR System is a clear winner among common half-face mask PAPRs on the market in terms of overall performance for dust protection.

You may wonder why Aimwell AYO WX HFM PAPR System comes only at a fraction of the cost of most PAPRs while achieving the best overall performance on the market.

You can better appreciate it with our mission as a company: to make you breathe safer and better. We mean it by striving to innovate the technology, the design, and the manufacturing process to make the product work better and cost less.

In the case of Aimwell AYO WX HFM PAPR, firstly the technology used is unique and among the most advanced in the world, then we went a step further to make the overall product cost less by optimizing the design for a low-cost manufacturing process, and we went even further to make the running cost very low by providing an unconventional pleated pre-filter not seen in other respirators.

As a result, the running cost of Aimwell AYO WX HFM PAPR is so low, that within 12 months, its total cost after purchase will be less than that for a common NAPR.

In summary, Aimwell AYO WX HFM Half-Face mask PAPR System has the following properties:

  • Best-in-class protection and lowest-in-class cost.
  • Great wearability and mobility – can be worn just like a common NAPR.
  • Comfortable to breathe – once you have used Aimwell AYO WX HFM PAPR, you will not want to go back to NAPR.
  • Easy to clean and maintain – flush wash compatible.
  • Less demanding on clean-shaven with a Loose-Fitting Face Seal as an Add-on option.
  • Cheaper than using a NAPR.

So if you are looking for the best half-face respirator for dust protection, look no further than Aimwell AYO WX HFM PAPR.

Aimwell AYO WX HFM PAPR is ideal for protecting the following: Asbestos, silica dust, metalliferous dust, powder coating dust, coal dust, and sawdust.

Upgrade from NAPR to Aimwell AYO WX HFM Half-Face Mask PAPR System now for better protection, better comfort, and cost savings.

Shop AYO WX Half Face Mask PAPR Systems here

Case Study – Running Cost Comparison Between a NAPR and an AYO WX HFM PAPR

Case Study – Running Cost Comparison Between a NAPR and an AYO WX HFM PAPR

由 | 12 月 6, 2023 | Industrial Protection Blog, Industrial PAPR Case Study

从性能角度来看，具有弹性面罩的自吸式空气净化呼吸器（NAPR）可以实现比N95一次性纸口罩更好的密封，从而实现更好的防护。 此外，它的滤芯通常不会受到呼气影响，并且可以设计实现更高的容尘量，因此可以使用更长时间。

自吸式呼吸器的另一个特点是它可重复使用，从长远来看更节省成本，而且更环保。 因此，自吸式呼吸器的市场份额不断上升也就不足为奇了。

然而， 对于电动空气净化呼吸器 (PAPR)，, especially tight-fitting PAPRs, apart from being elastomeric, they offer better protection by design, as the pressure inside the breathing zone is positive, and they are also more comfortable to breathe.

研究表明，2022 年 自吸式呼吸器 市场规模超过 95 亿美元，而 PAPR 市场规模为 24 亿美元。 假设平均 自吸式呼吸器为 每套50 美元，平均 PAPR 为 1000 美元（大致正确），这表明其比率为 79:1，这意味着对于 79 个 自吸式呼吸器用户，只有一个 PAPR 用户。 因此PAPR还有更大的增长空间。

In fact, the industry trend is heading for more workers to move up from NAPRs toward PAPRs for better protection. For example, in Australia, the exposure limit for welding fumes is reduced from 5mg/m3 to 1mg/m3, and this almost certainly will demand the use of PAPRs in many welding sites.

However, most PAPRs are much more expensive than NAPRs, and they are also bulky, heavy, and troublesome to use and maintain, and these are the key inhibitors of their adoption. Therefore, it is easy to comprehend that there are more users of NAPRs than PAPRs.

To allow widespread workers to be able to take advantage of the improved protection from PAPR technology, Aimwell invented, designed, and optimized AYO WX HFM Half-Face Mask PAPR System, and we believe it can not only significantly enhance respiratory protection, but can also cost less within 12 months of use compared with typical NAPRs when doing daily dusty work, such as stonework.

以下是我们的案例比较：

自吸式呼吸器参考对象：带有 2135 P2/P3 颗粒过滤器的 3M 6200。

Comparing PAPR: AYO WX HFM Half-Face Mask PAPR System with pleated pre-filter and PAPR P3 HEPA filter.

参考应用：石材
预计更换过滤器时间：

  • 3M 2135 P2/P3 过滤器：每 5 天一次
  • AYO WX 打褶预过滤器：每2 天一次。
  • AYO WX主滤芯：每 20 天一次。

Result:

分析：:

  • At initial purchase, the 3M 6200/2135 system costs $70 versus $559 of AYO WX HFM PAPR.
  • 由于2135颗粒过滤器的设计，没有可以廉价更换的预过滤器。 因此，每5个工作日就需要更换整对过滤器。
  • In contrary, AYO WX HFM PAPR has a unique low-cost pleated pre-filter that can capture larger particles with reasonable dust-loading capacity and protect the HEPA filter. As a result, the HEPA filter can last longer while the pleated prefilter can be changed often at a very low cost.
  • At 12 months of use, the total cost of use for AYO WX HFM PAPR is $1,163 versus $1,245 for the 3M 6200/2135 system.

其它考虑因素

  • The above comparison is based on the RRP for one AYO WX HFM Half-face Mask PAPR System. For large organizations with higher order quantity, the unit price will be lower than the RRP, thus the ‘breakeven’ time will be shorter accordingly.
  • Being a PAPR, AYO WX HFM PAPR is more comfortable to breathe, especially for long working hours.
  • Being a PAPR, AYO WX HFM can tolerate some facial leaks, but being a NAPR, the protection of 3M 6200/2135 is highly sensitive to facial leaks.
  • A non-clean-shaven person shall not use a NAPR. However, a person with a short beard may use AYO WX HFM PAPR and still achieve good protection even better than most loose-fitting PAPRs.
  • With patented technology, AYO WX HFM PAPR achieves a great wearability similar to common NAPRs. This is dramatically different from most common PAPRs which are bulky and heavy, with poor mobility.

For daily work in highly dusty environments, AYO WX HFM Half-Face Mask PAPR System can not only provide better and more reliable protection than a typical NAPR but also costs less after using for 1 year, in addition to being more comfortable to breathe, making AYO WX HFM PAPR a perfect upgrade from common NAPRs for many industrial respiratory protection applications.

How to Protect from Silica Dust Effectively

如何有效防护二氧化硅粉尘

由 | 10 月 17, 2023 | Industrial Protection Blog

吸入二氧化硅粉尘的健康风险

二氧化硅是一种天然物质，存在于大多数岩石、沙子、粘土以及砖和混凝土等产品中。产生的一些粉尘被称为可吸入结晶二氧化硅 (RCS)。这种粉尘细小得看不见，可以深入肺部，在症状出现之前就可能造成永久性肺部损伤。大量接触 RCS 会导致矽肺，这是不可逆的，即使停止接触后也可能继续恶化。接触该物质还可能导致其他严重疾病，例如慢性阻塞性肺病 (COPD) 和肺癌。

矽肺

RCS 引起的肺组织疤痕会导致肺功能丧失，通常会持续数年。在疾病的早期阶段，通常没有任何症状。但可能会出现呼吸短促，最终影响短距离行走的能力。

慢性阻塞性肺疾病（COPD）

慢性阻塞性肺病是一种长期疾病，会在几年内逐渐发展。肺部受到永久性损伤，导致呼吸困难。

高风险职业

这些包括采石场、板岩厂、铸造厂、陶器、石材加工、建筑（切割或破碎石头、混凝土或砖石）以及使用硅粉制造商品的工业。

在澳大利亚的一些地区，四分之一的石材工人因硅尘而患有矽肺病。

保护选项

  • 工程控制：尽可能使用自动切割设备。
  • 水抑制：尽可能使用带有喷水附件的工具。
  • 局部排气通风：尽可能使用专为局部除尘而设计的工具。
  • 使用有效的呼吸防护设备 (RPE)

应使用哪种 RPE？

RCS 粉尘深入肺部后会积聚。因此，当切割石材成为您年复一年的日常工作时，就没有所谓安全限量了。最安全的方法是除了工程控制、水抑制、局部排气通风外，还需要日常佩戴防护等级最高的RPE。

电动送风空气净化呼吸器 (PAPR) 与纸质口罩和空气净化呼吸器 (APR) 相比，是防护二氧化硅粉尘的最佳选择。 这是因为：

  • 纸质口罩的面部密封不可靠，尽管口罩最初可能看起来很密封：但密封性可能会随着面部运动和出汗而降低，尤其是在进行艰苦的体力工作时。当您专注于工作时，您不太可能会注意面罩佩戴的状况以确保不会泄漏，这样您就容易受到有害灰尘的侵害。
  • Most APRs have better seals thanks to the elastomeric mask cushion. However, inevitably, leaks will still be present although less than in paper masks. Due to negative pressure inside the mask, dust can be sucked in through the small gaps. Besides, being non-powered means your lungs need to work harder to overcome the resistance of the filter. For physically demanding jobs, frequent breaks and rest are often needed.
  • PAPRs can provide more reliable protection: the pressure inside the mask is positive, meaning the air tends to be pushed out from inside the mask preventing outside dust from getting in. In addition, the blower in the PAPR does the hard work to suck the air through the filter without your extra effort to breathe, making your tough job easier, especially in hot conditions.

Why Aimwell AYO WX Around-neck Series PAPRs are Ideal RPEs for Stone Workers?

由于成本高、重量重、体积大、气管的不便、腰带带来的麻烦，以及使用和购买时的困难，PAPR 虽然 能提供很好的保护但石材工人确很少使用。

现在不同了，AYO WX 可以消除所有这些障碍。

Invented, designed, and fine-tuned in Australia, AYO WX HFM Half-Face Mask PAPR System is a state-of-the-art PAPR that stands out from the rest in that:

  • 具有最高的防护等级：PAPR P3
  • It has a very high fit factor: demonstrated by superb results from PortaCount Fit Testing.
  • The around-neck structure eliminates hassles associated with hoses and belts, while being compatible with common PPEs, such as hard hats, goggles, earmuffs, etc.
  • 重量轻、尺寸小：适合体力工作。
  • It is very comfortable to breathe: thanks to the breath-responsive airflow control.
  • 电池续航能力长：每次充满电可使用 8 – 16 小时。
  • 使用寿命长：可更换电池。
  • 操作便捷，清洁简单，维护方便
  • 可用水冲洗，适合高粉尘场合应用。
  • 运行成本低：采用低成本的打褶式预过滤器，无需频繁更换成本较高的 HEPA高效 过滤器。
  • 价格非常实惠— 是市场上大多数 PAPR 价格的 的几分之一。

In short, Aimwell AYO WX Around-neck series PAPRs are the only PAPRs to date that are finally within reach by most stone workers.

Quick Steps to Use AYO WX HFM Half-Face Mask PAPR System

  • 使用前给电池充电。
  • 首先将面罩组件戴在脸上，然后拉紧颈后的带子。
  • Remove the Guard Link from the Main Unit, wake it up by pressing its On/Off button, then slide the Main Unit down against the back of your head until it rests on the two supporting hooks of the head strap.
  • 将面罩推入主机的两端。
  • 将头带的带扣拉到橡胶颈垫上。
  • 然后呼吸，然后出发！
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