Installing modern and innovative exhaust fume extraction systems is essential to meet the needs of those managing or working in workshops responsible for maintenance, repairs and testing of civil and industrial vehicles. There are two key requirements:
- Speeding up and optimising the work, increasing the operational capacity and efficiency of the workshop
- Ensuring that the mechanics and other workers can carry out their duties in complete safety, without risks to their health
We take a deeper look into this topic in today's article!
What does an exhaust fume extraction system in the workshop do?
Installing modern, high-tech extraction systems helps safeguard workers’ health, guaranteeing them a safe and healthy work environment and making the workshop more efficient, with greater productivity.
Any exhaust fume extraction system must integrate into the work environment for which it is designed and in which it will be used.
The configuration of an installation with an exhaust fume extraction system depends on the number and positioning of the working areas to be served, the frequency of use and the operating conditions which will vary from one activity to another.
Below are the topics we will cover in the article. You can click on the link to go to the section which interests you.
Table of contents
- How to make your workplace healthy and safe
- Exhaust fume extraction and efficiency in the workshop: the link
- Exhaust fume extraction for cars
- Exhaust fume extraction systems for motorbikes
- Exhaust fume extraction for vans and lorries
- Designing an exhaust fume extraction system
- The added value offered by WORKY
How to make your workplace healthy and safe
The exhaust fumes produced by vehicles can cause damage to and diseases of the respiratory systems in those working in close contact with them.
As workshops are enclosed spaces where engines often have to be kept running, the risk is very high. Combustion of motor fuel produces carbon monoxide, unburned hydrocarbons and sulphur oxides which irritate the mucous membranes and, over the long term, can damage the lungs.
Filtration systems are often virtually useless when it comes to exhaust fumes, as they are composed of particles which are so fine they are almost imperceptible. The fumes must be removed before they are able to disperse in the environment, by drawing them off at the exhaust pipe.
Exhaust fume extraction systems are designed precisely with this purpose in mind: to capture the fumes and convey them outside of the workplace, thus protecting the health of the workers.
There are four types of systems used to purify the air in a workshop:
- Fixed systems, which require permanent installation and a fixed location
- Sliding systems, which also require permanent installation with multiple locations
- Stand-alone systems which are small, compact and portable, and can be moved around on wheels
- Underfloor systems, which require permanent installation and a fixed location, given that the extraction of the fumes occurs via an intake in the floor
But that’s not all: the most modern technologies meet a further requirement: increasing the productivity of the workshop. We’ll see how in the next paragraph!
Exhaust fume extraction and efficiency in the workshop: the link
Installing modern, high-tech extraction systems not only protects employees’ health, but is also able to speed up their work, optimising timeframes and reducing costs, and thus increasing profitability.
The latest machinery and technologies are functional and intuitive, allowing operatives to carry out their activities without hindrances, as well as providing the workshop with a modern image.
The important thing is that these solutions integrate perfectly with the design of the environment, the spaces, the types of vehicles worked on and the needs of customers; the layout and installation of the systems must also be designed correctly in order to adapt to the needs of the workers, without obstructing day-to-day activities.
This is why it is important to work with a partner which is able to support its customers in the workshop design phase, including the creation of custom exhaust fume extraction systems.
If you are interested in this topic, we cover it in greater depth in the section “Designing an Exhaust Fume Extraction System”.
Now let's take a look at the different types of extraction systems and their characteristics.
Exhaust fume extraction for cars
As previously mentioned, there are four types of exhaust fume extraction systems: fixed, sliding, stand-alone and underfloor.
What is a system with exhaust gas extraction composed of?
If we exclude ultra-compact portable units, there are some essential components of fixed extraction systems.
Basic elements of the system
Fixed systems include hose reels or drops at specific points of the workshop. In sliding systems, on the other hand, the hose reels, hose trolleys and innovative touchless arms – which we will talk about shortly – move along a rail, which acts as a track to allow the elements to be moved around the different working areas. Finally, in hidden underfloor systems, the hose is pulled out to be used as required; alternatively, fittings can be inserted in a floor intake when required.
Nozzles are the first component for channelling the exhaust through flexible hoses (and rigid sections of connecting pipe in centralised systems) up to the exhaust fume extraction fan. Considering the wide range of exhaust pipes found on vehicles, WORKY produces a very wide range of nozzles, specifically designed to adapt to the most common vehicle models.
Vehicles with twin exhausts integrated in the rear bumper will require a dual nozzle, which can be positioned behind vehicles to extract the exhaust fumes without touching the exhaust pipes themselves.
The most innovative systems undoubtedly include the TOUCHLESS systems, thanks to which adapters for exhausts integrated in the vehicle bumper are not required.
Touchless extraction arms are an effective element for serving different work areas in a flexible and efficient manner. As they do not come into contact with the vehicle exhaust pipes, they can adapt to any type without the need for specific nozzles.
You can see them in action in this video:
These systems offer significant time savings, seeing as continuous nozzle changes are not required, in addition to cost savings, as it is not necessary to purchase specific adapters.
But that’s not all: the touchless arms make work in the workshop more efficient, as they are designed to slide easily and not clutter up the ground thanks to their rail mounting and ability to fold up when not in use.
In order to ensure the effectiveness and efficiency of the extraction system, it is necessary to select the appropriate size of exhaust fan.
Workshop exhaust fans are essential to capture the gases created and expel them outside the workplace. They are available in different power levels, and the choice must be assessed on the basis of the specific requirements. The most modern systems are designed to allow remote control of the extraction units via microswitches, RF remote controls and control panels, significantly optimising the work of the operatives.
Take a look at the range of exhaust fans and accessories offered by WORKY.
Connection and exhaust pipes
Rigid pipework is used to connect the intake point to the exhaust fume extraction unit and then carry the fumes outside.
An efficient exhaust fume extraction system must collect all harmful gases before they leave the exhaust pipe, so that they are not able to escape. The lines must be both flexible and tough.
As mentioned, all these elements are available in numerous variants, depending on the requirements they must meet. WORKY has always been specialised in the design and production of complete systems with exhaust fume extraction systems, and offers a huge array of different solutions to meet any and all requirements.
Unlike the other three systems, stand-alone systems are portable extraction units which do not require permanent installation, declarations of atmospheric emissions or installation of a roofline outlet. In order to be able to operate and carry the fumes outdoors, they must be completed with a 10-metre outlet hose.
As they are highly portable, these stand-alone extraction systems are ideal for small workshops, private garages or plant rooms.
Exhaust fume extraction systems for motorbikes
The exhaust pipes of motorbikes, scooters and all two-wheeled motor vehicles have different characteristics to those found on cars. Modern workshops often have dedicated exhaust gas extraction systems for larger vehicles, but in many cases the mechanics try to adapt the existing system to work on the exhaust pipes of two-wheeled vehicles as well.
However, specific professional systems for motorbikes and similar vehicles are now available, which meet the needs of the different types of exhaust (for example, coupled exhausts, underbody exhausts, exhausts under the tail fairing, multiple exhausts and oversized exhausts due to the presence of catalytic converters), but which also adapt to the space available in the workshop, considering that repairs on two-wheeled vehicles are performed both on the ground and on stands or lifts.
The ideal solution is a nozzle with four powerful magnets and support bar with self-supporting floor plate. This solution also allows the support rod to be positioned on the workbench or stand when there is not sufficient space for the entire plate.
An additional magnet then connects the rod to the rubber nozzle so that the adapter can be easily and precisely positioned at the exhaust outlet point.
Exhaust fume extraction for vans and lorries
Heavy vehicles produce greater amounts of fumes and require suitably sized extraction systems. Specifically:
- The size of the hose is key, and this must also resist high temperatures and potential crushing
- The hose reel must be tough and functional
- The nozzle, as well as being durable and of high quality, should be equipped with a manual shutter in order to allow regulation of the extraction so that the power level can be adapted to meet requirements, preventing waste
Often, repair shops working on these types of vehicles prefer to use sliding systems or portable systems, depending on how frequently they are needed and on the size of the workshop.
Designing an exhaust fume extraction system
The choice of an exhaust fume extraction system for workshops or testing/service centres is not as easy as it might seem: it is important to evaluate the size of the equipment, the needs of the mechanics, the dimensions of the workplace, the frequency of use and the type of customers.
This is why it is so important to have a partner able to analyse the premises, by carrying out a site inspection to identify any obstructions and specific requirements, and to understand what custom solutions may be required, providing guidance and recommendations in the selection process.
The ideal supplier should also be able to create 3D plans of the system, also interfacing with architects and engineers where required, to ensure that the system is perfectly integrated in the building.
The added value offered by WORKY
WORKY believes in the value of a job done well, with attention to detail. It has always seen its maximum level of fulfilment in the creation of solutions for the Automotive sector, designing systems which are able to visibly improve the quality of work for any workshop.
Due precisely to the high quality of products we offer and our customer-centric focus, today WORKY boasts approvals and partnerships with the major vehicle manufacturers, producing systems which meet their standards of excellence.
We are constantly working to make company processes more efficient and innovative, developing customised products tailor made to meet the needs and requirements of each of our customers.
Our highly qualified after-sales personnel have extensive experience not only in dealing with unexpected problems during the works, but also of the phase preceding the installation.
Thanks to the extensive network of WORKY resellers present in over 80 countries, we can provide support for all customer requirements: arrange a free consultancy session now!