On-tool extraction is the most effective way to stop dust at source, but small missteps can halve performance. These are the pitfalls that repeatedly drive exposure up—and how to fix them quickly on site.

Poor shroud contact and wrong interfaces

Leaking shrouds, missing brushes, and generic adapters leave gaps where dust escapes. Fit the manufacturer’s shroud, check the skirt contacts the surface, and use the correct cuff to match hose diameter. If the hose kinks at the tool, step up one size or shorten the run.

Wrong filter class for the risk

Using general-purpose (L/M-Class) filtration for fine or carcinogenic dusts undercontrols exposure. For respirable crystalline silica, some hardwoods, and other fine fractions, use high-efficiency filtration and ensure the final stage meets H14 for critical work. Pair with effective prefilters to extend service life.

Chasing free-air numbers

Specifying by free-airflow leads to disappointment. What matters is airflow under load with hose, shroud, and filter installed. Keep hoses short, minimise bends, and maintain seals. If you must extend, upsize the hose to protect volume.

Letting filters blind

Waiting until suction collapses wastes time and increases exposure. Empty before the bin is full, knock out or change prefilters on schedule, and check for bypass around the gasket. A cyclone or pre-separator reduces dust reaching the main filter and holds airflow steadier.

Ignoring task sequencing

Two operators sharing one extractor at the same time starve both tools. Sequence high-dust tasks or allocate an additional unit to the riskiest operation. For background control between operations, run an air scrubber to catch what escapes.

No verification

Relying on feel is not enough. Use a simple particulate meter to confirm the area clears quickly after stops. Under COSHH, controls must be maintained and effective; spot checks help you prove it.

Practical takeaways

• Seal the shroud and match hose diameter to prevent leaks and kinks.
• Select filtration appropriate to the hazard; use H14 for fine/carcinogenic dusts.
• Optimise for airflow under load, not free-air specs; shorten and smooth hose runs.
• Service prefilters and bins before they choke; consider a pre-separator.
• Sequence tasks and verify effectiveness with a PM meter.

Small adjustments compound: tighter seals, correct filtration, and timely maintenance keep exposure down and productivity up.