The metal-mechanic sector represents 8% of the total EU business. Welding is the most important joining technique in this sector; there are about 730,000 full time and 5.5 million welding related jobs in Europe.
The main drawback is that welding has a great impact on health for it is physically high demanding leading to a high percentage of sick leave (yearly about 160 working hours per welder).These high sick leave costs are extremely threatening to the financial position of SMEs, endangering their competitiveness.

ECONWELD - Economically welding in a healthy way was a European funded project, comprising 19 partners from 7 European countries.

Strategic Objectives:

1. Reduction of welding costs and improvement of production for European SMEs
The project will come up with solutions and guidelines for (flexible) mechanization of welding. The benefits and possibilities of alternative high speed and/or high deposition welding processes will be demonstrated.

2. Reduction of sick leave of welders and improvement of production
Reducing sick leave will pay off 80 hours, meaning 10 working days per welder per year. An improved productivity is expected throught the development of new solutions to improve the work conditions (ergonomics and work flow).

3. Reduction of exposure to welding fumes for GMAW welding and for other processes.
ECONWELD will come up with solutions to reduce welding fumes at the source, also focussing better ergonomics and fume extraction capabilities.

Outcomes:

• An innovative welding torch with the ability to capture over 80% of the welding fumes emitted during the process;
• A remote-controlled, extensible hydraulic support arm, enabling the welder to perform his work in difficult to reach areas;
• An innovative ventilation concept for welding helmets, allowing increased air flux efficiency and reduced discomfort to the welder;
• Two softwares, VIRTWELD and COSTCOMP. The first for support in decision-making process covering welding fumes and ergonomics.
  The 2nd one providing cost estimation and cost comparison between welding processes

2nd Steering and Technical Committees Meeting, May 2006, Genova, Italy