Introduction
AES Ltd successfully delivered a comprehensive Local Exhaust Ventilation (LEV) solution for Citizens Theatre in Glasgow, completing the project in September 2025. The installation formed part of the theatre’s major seven-year transformation project. As part of this redevelopment, AES contributed to improvements on the backstage workshops through the design and installation of advanced dust and fume extraction systems. This wider workshop refurbishment initiative aimed to improve air quality, safety, and operational efficiency across multiple production areas.
As part of the transformative £40 million redevelopment of Glasgow’s iconic Citizens Theatre, AES Ltd played a crucial role in enhancing the venue’s health and safety infrastructure. Tasked with designing and installing a bespoke Local Exhaust Ventilation (LEV) system, AES ensured optimal air quality and compliance with COSHH regulations throughout the theatre’s workshops and technical spaces. Their solution not only supports a safer working environment for staff and performers but also complements the theatre’s broader mission of accessibility and innovation. This collaboration highlights how modern engineering can seamlessly integrate with historic preservation, securing the future of a beloved cultural landmark.
Project Overview
The scope of works included the design, supply, and commissioning of three distinct LEV systems tailored to the specific needs of:
- Metals Workshop – Portable weld fume extraction
- Paint Spraying Workshop – Dry filter spray booth with VOC filtration
- Construction Workshop – Centralised wood dust extraction system
A key feature of the project was the integration of a custom-fabricated external acoustic enclosure for the wood dust extraction system. This not only enhanced noise attenuation but also freed up valuable internal space, contributing to a more efficient and ergonomic workshop layout.
Technical Highlights
1.Wood Dust Extraction System – Construction Workshop
System Description:
AES installed a centralised C-VAC BF30/C200 wood dust extraction system designed to manage airborne wood dust generated by various woodworking machines. This system is critical for maintaining air quality and ensuring compliance with COSHH regulations in environments where both softwoods and hardwoods are processed.
Key Features:
- Extraction Points: Direct connections to machine hoods and spigots, with bespoke hoods provided where necessary.
- Filtration: Cyclone filter with polyester needlefelt tube sock primary filter (350gsm), cleaned via automatic electro-mechanical shaker.
- Fan Unit: 7.5kW medium-pressure centrifugal fan, spark-proof, mounted externally in a custom acoustic enclosure with anti-vibration mountings.
- Dust Collection: 240-litre biodegradable bag mounted on a removable trolley.
- Control System: Central control panel with auto dampers and LEV hood airflow indicators per machine.
- Airflow Capacity: Up to 2545 m³/hr (when Tenoner is in use), with diversity control to limit simultaneous machine operation.
- Discharge: Filtered air discharged externally via attenuated louvre, >3m above ground level.
- ATEX Classification: ST1 (suitable for combustible wood dust environments).
Benefits:
- Enhanced dust control across multiple machines.
- Reduced noise pollution via acoustic enclosure.
- Improved workshop space due to external plant housing.
Fully compliant with HSG258 and COSHH Group E standards.
2.Paint Spray Booth System – Paint Spraying Workshop (CT-LEV-02)
System Description:
AES provided a GEF-CS10FH dry filter paint spray booth with integrated carbon filtration to manage solvent-based aerosol spray activities. This system ensures safe handling of VOCs and paint particulates while allowing internal air recirculation.
Key Features:
- Booth Construction: Galvanised steel with deep sides and ceiling panel for partial enclosure; smooth internal panels for easy cleaning.
- Filtration Stages:
- Andrea hydrophobic pleated pre-filter
- G4 polyester paint stop secondary filter
- 112kg activated carbon VOC final filter
- Fan Unit: 4kW centrifugal fan with spark-proof impeller, mounted within an acoustic enclosure.
- Control System: Push-button DOL starter with Magnehelic differential pressure gauge for airflow monitoring.
- Airflow Capacity: 4400 m³/hr
- Discharge: Filtered air recirculated within the workshop.
- Lighting: IP65-rated LED lighting for booth illumination.
- Compliance: COSHH Group D, VOC control <0.5ppm
Benefits:
- Safe and compliant handling of solvent fumes and VOCs.
- Internal air recirculation avoids roof stack requirements.
- Acoustic enclosure reduces noise impact.
- Visual airflow indicators support ongoing performance monitoring.
3.Weld Fume Extraction System – Metals Workshop (CT-LEV-01)
System Description:
AES installed a portable W3-approved weld fume extractor to manage fumes from MIG and MMA welding processes. This mobile unit offers flexibility and high-efficiency filtration for mild steel welding operations.
Key Features:
- Extraction Arm: 3m flexible arm with capture hood and magnetic base.
- Filtration: Multi-stage including metal mesh pre-filter, nano fibre F9 main filter, and HEPA H13 final filter (>99.95% efficiency).
- Fan Unit: 2.2kW steel-cased centrifugal fan with IE3 motor.
- Control System: Manual start/stop with run/fault indicators.
- Airflow Capacity: 1050 m³/hr
- Discharge: Internal recirculation with HEPA filtration.
- Mobility: Unit can be repositioned within the workshop as needed.
- Compliance: COSHH Group E, ALARP control level
Benefits:
- High-efficiency filtration of welding fumes.
- Mobile unit allows flexible deployment across workstations.
- Internal discharge avoids external ducting.
- Visual airflow indicators ensure safe operation.
Outcome & Client Advantages
- Improved Air Quality: Effective capture and filtration of hazardous substances including wood dust, welding fumes, and VOCs.
- Noise Reduction: Acoustic enclosures significantly reduced operational noise levels.
- Space Optimization: External plant housing created more usable space within the workshop.
- Regulatory Compliance: All systems designed and installed in accordance with HSG258 and COSHH guidelines.
- User Training & Documentation: AES provided comprehensive user manuals and training to ensure safe and effective operation.
Conclusion
The successful delivery of the LEV systems at Citizens Theatre highlights AES Ltd’s commitment to engineering excellence, regulatory compliance, and client-focused solutions. By integrating advanced extraction technologies across diverse workshop environments, AES has significantly improved air quality, operational safety, and spatial efficiency.
Of particular note is the implementation of the C-VAC BF30/C200 wood dust extraction system, housed within a bespoke external acoustic enclosure. This system exemplifies AES’s capability to deliver high-performance, low-noise extraction solutions tailored to complex workshop layouts. With robust filtration, automated cleaning, and intelligent control features, the C-VAC system offers future clients a scalable and reliable solution for managing wood dust in compliance with HSG258 and COSHH standards.
AES Ltd continues to be a trusted partner for organisations seeking innovative and compliant LEV systems. Whether for wood dust, welding fumes, or VOCs, our team of BOHS-qualified engineers is ready to design and deliver systems that protect health, enhance productivity, and future-proof your workspace.
If you’re planning a new workshop, upgrading your existing extraction systems, or seeking expert guidance on LEV compliance, AES Ltd is here to help. Our C-VAC systems offer industry-leading performance, reliability, and noise control—perfectly suited for demanding environments like joinery, theatre production, and manufacturing.
📞 Contact us today to discuss your project requirements and discover how AES can deliver a tailored LEV solution that protects your workforce and enhances your workspace.
🔗 Visit www.aessolutions.co.uk or email info@aessolutions.co.uk to get started.
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