Hazards and controls
Hazardous substances
Hazardous substances used in spray painting include paints, solvents, powders, acrylic lacquers, enamels, paint removers, resins, adhesives, surface preparation products, rust converters and rust removers.
Hazardous substances may be inhaled, swallowed or absorbed through the skin and eyes. Their potential health and safety risks range from short term effects such as irritant contact dermatitis, headaches and nausea to extremely serious conditions such as lung cancer, damage to the reproductive system, kidney or liver, and 'painter's syndrome' (which affects the brain).
People's exposure to hazardous substances must be prevented or reduced to as low a level as possible or at least below the workplace exposure standards for airborne contaminants (non-Queensland Government link).
You must make an assessment of the risk to your health, and the health of your workers, from the use of a hazardous substance.
MSDS and labelling
Obtain a material safety data sheet (MSDS) for every hazardous substance used. An MSDS is provided by the manufacturer/supplier and details the substance's chemical properties, health hazards and information for safe use.
Ensure that containers of hazardous materials are correctly labelled at all times.
Ways to control hazards
- You must use a spray booth when applying a hazardous substance, except when it is not practical (for example, painting a building) or when the work is minor (for example, painting over a stone chip on a car).
- Use water based paint instead of organic solvent based paint.
- Use a less hazardous process, or automate the process. For example, use high volume-low pressure (HVLP) spraying rather than conventional spraying.
- Dedicate a spray zone with barriers to restrict entry.
- Where a spray booth is not practical, use a local exhaust ventilation system to capture overspray and solvent vapour as close to the source as possible.
The system should be fitted with a particulate filtration mechanism to filter overspray and should comply with AS 1482¿Electrical equipment for explosive atmospheres - Protection by ventilation - Type of protection v (non-Queensland Government link)
- Use fans and natural fresh air (as well as local exhaust ventilation) to displace contaminated air. Systems should comply with Australian Standard 1482.
- Avoid dry sanding unless dust extraction equipment is used.
- Ensure safe spray painting operations, and keep booths clear of unnecessary equipment. Have cleanup and emergency procedures in place.
- Ensure that appropriate personal protective equipment (PPE) is available and correctly used.
More information on hazardous substances is provided in the Hazardous Chemicals Code of Practice 2003.
Two pack paint and varnish systems
Two pack paint and varnish systems are used by painters and cabinet makers to give a hard resilient finish, however chemicals used in these systems (called isocyanates) cause occupational asthma in a significant percentage of exposed people.
Isocyanates used in paint systems can cause health effects via skin contact or when breathed in during paint mixing and spraying.
Spray painting with two pack paints (even touching up or minor work) should be conducted within a spray booth fitted with effective exhaust capture and filtration systems.
Ways to control hazards
- Provide induction and training about the health hazards associated with exposure to isocyantes.
- Follow safety instructions provided in the material safety data sheet (MSDS) accompanying two pack paint and varnish systems. Implement any controls recommended in the MSDS, and ensure that workers have easy access to the relevant MSDS.
- Conduct air monitoring to measure the airborne concentration of isocyantes and help assess the effectiveness of control measures.
- Wear gloves and a full face air-supplied respirator during spraying. Also wear gloves while cleaning up.
- Ensure the mixing area is well ventilated.
- Arrange a 'designated doctor' to provide ongoing health surveillance for workers who have may have been exposed to significant risk while spraying two pack paint and varnish containing isocyantes. View our list of designated doctors.
Plant and equipment
Spray painting plant and equipment
Spray painting plant and equipment include spray guns, booths, compressors, pumps, ventilation systems, personal protective equipment (PPE) and hoses.
Spray painters use a range of plant, exposing them to risks such as electric shock, excessive noise, hazardous substances and injection bruising.
Hazards that could arise during the normal use of spray painting plant should be assessed. In addition, you should identify potential hazards when installing new plant, modifying plant, using existing plant for a different purpose or using plant in unusual circumstances.
Ways to control hazards
- Remove or replace plant that is assessed as a risk.
- Regularly carry out preventative maintenance on equipment. Always clean airless spray guns according to the manufacturer's instructions.
- Use a pneumatic sander rather than an electrical one, or a high volume low pressure (HVLP) spray gun instead of a conventional compressed air one for touch ups.
- Use a barrier to separate people from plant, and provide as much ventilation as possible.
- Ensure that purchasing specifications for new equipment cover all safety features.
- Clearly display equipment information regarding emergency stops/guards.
- When preparing rosters, consider workload and fatigue factors.
More information on plant and equipment can be found in the Plant Code of Practice 2005.
Spray painting booths
Spray painting hazardous substances must be conducted in booths, except where it is not practical to do so or where the work is of a minor nature.
Booths must be designed and built to comply with AS/NZS 4114.1 Spray painting booths, designated spray painting areas and paint mixing rooms - Design, construction and testing (non-Queensland Government link) and fitted with filtration and ventilation systems. Booths must be regularly checked and maintained.
A spray booth should have effective exhaust capture and filtration systems and must be able to maintain an average air flow rate (measured when the booth is empty) of:
- 0.3 metres/second (m/s) for full down draught booths
- 0.4 m/s for electrostatic spray painting booths
- 0.5 m/s for any other booth.
Ways to control hazards
- Ensure spray booths, including filters, are regularly inspected by a competent person.
- Carry out regular and appropriate maintenance of spray booths.
- Operate the spray booth according to manufacturer's instructions.
- Use spray booths only for spray painting.
- Ensure that necessary personal protective equipment (PPE) is used.
- Keep PPE well maintained.
Motor vehicles
If possible, remove LP gas cylinders or fuel tanks from vehicles before placing them in a spray booth/bake oven. Where this is not practical, bake ovens should be operated at a temperature where it is not possible for fuel vapour or gas to be released to the bake oven atmosphere.
Ovens should be constructed so there is no ignition source within the oven air circulation zone.
Any recirculated hot air should include enough fresh air to remove the potential build up of explosive gas.
Flammable hazards
Fire and explosion
Many paints contain flammable substances, and spray painting is hazardous if painting mist comes into contact with a source of ignition.
Possible sources of ignition include lit cigarettes, abrasive grinding wheels and other equipment that produces sparks, combustion motors, welding torches, hot surfaces, electrical short circuits and portable electrical equipment like mobile phones.
A catalytic reaction can also create a fire or explosion (for example, when two-pack epoxy paints are mixed and this creates heat). Fires may also be started by incorrectly stored flammable materials, paint and solvent soaked rags, or a build up of paint residue in work areas or on equipment.
Ovens used for baking automotive coatings must have no ignition sources within the oven air circulation zone. Recirculation of hot air should include a percentage of fresh air to avoid the build up of potentially explosive gases.
Ways to control hazards
- Establish a spray zone with warning signs that restrict access. Provide fire extinguishers and train staff in their use.
- Provide as much ventilation as possible to the work area.
- Mix and pour in a clearly designated room that is naturally ventilated with no ignition sources.
- Before pouring flammable liquids from one container to another, set both containers down on an earthed surface, then bring the containers into contact while pouring. Keep them in contact while pouring (it is best to connect them with alligator clips).
- When using containers with air lines, replace the plugs as soon as the air lines are disconnected.
- Leave empty drums or cans in a safe place with the lids off.
- Store and handle flammable combustible liquids correctly. For instance, store paints in containers with lids and store solvents in covered containers with taps.
- Remove LP gas cylinders or fuel tanks from vehicles before placing them in a spray booth/bake oven. Where this is not practical, operate the spray booth/bake oven at the lowest possible temperature and below the levels where it is possible for fuel vapour to be released to the atmosphere.
Heat
Heat stress occurs when a person's body cannot lose heat fast enough. The person may suffer irritability, discomfort, dehydration, heat rash, cramps, heat exhaustion or heat stroke.
Heat stress while spray painting may be caused by many factors other than the air temperature in the work area. People most at risk are those who are dressed inappropriately, unfit, overweight, dehydrated, suffering from heart, circulatory or skin disorders, unused to the workplace heat levels or taking medication that can change a body's temperature regulation.
Ways to control hazards
- Limit the time that spray painters have to wear personal protective equipment (PPE) such as helmets and protective suits. Wear cotton garments underneath PPE.
- Rotate jobs so a spray painter does not have to work for long periods in hot conditions.
- Take frequent short breaks and drink cool water regularly.
- Shade an outdoor work area from the sun or reschedule work to occur in a cooler time of the day.
Electrical
Electrocution and burns are the main health risks associated with using electricity in spray painting.
Great care should be taken to prevent static discharge (for example, caused by touching two metal cans together during decanting) and during electrostatic spray painting.
Don't operate electrical equipment that is damaged or not designed to give explosion protection.
Ways to control hazards
- Ensure that the electrostatic spraying system is operated only by trained spray painters.
- Carry out electrostatic spraying in a spray zone free of electrical equipment. The floor of the zone should be made of an electrically-conducting material which is earthed. The exhaust system must provide air movement of at least 0.4 metres/second at the spray position.
- Remove drums of paint or cleaning solvent from the spray zone.
- Earth equipment and metal surfaces within 3 metres of the charged head of the spray gun used in electrostatic spraying.
- Remove metal items (for example, watches), material with silk or synthetic fibres, and insulating gloves (except those with the palms cut out) before entering the spray zone.
- Wear antistatic or conductive footwear to stop the build up of electrostatic charge. Avoid old footwear or footwear with paint, oil or wax stained soles.
- When cleaning the spray gun, check that the high voltage supply is switched off.
Further information
View the Electrical Safety website for more information.
Other hazards
Confined spaces
Spray painters sometimes have to work fully or partly in confined spaces with poor ventilation or restricted entry and exit points. The main hazards presented by this type of work environment are lack of oxygen, toxic or flammable fumes, engulfment and mechanical equipment.
Associated health risks include burns, electrocution, suffocation and asphyxiation, poisoning, crush injuries, brain damage and death.
Ways to control hazards
- If possible, remove the object to be painted from the confined space.
- Use mechanical ventilation systems and non-sparking tools (if there is a flammable atmosphere). If an air-supplied respiratory device is needed, protect the breathing line at all times.
- Allow only people wearing correct personal protective equipment (PPE) to enter the space.
Noise
Sources of noise in spray painting workplaces include plant and equipment, ventilation systems, workshop operation and vehicles. Sanders, air compressors, angle grinders, spray booth operations and processes involving compressed air all generate noise.
Employers must prevent workers being exposed to excessive noise.
Ways to control hazards
- Use nozzles that reduce compressed air noise and other equipment with noise reduction features.
More information on ways to control noise is provided in the Managing Noise and Preventing Hearing Loss at Work Code of Practice 2011
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Workplace environment
Good housekeeping in a workplace is essential for the health and safety of workers. You are less likely to slip or fall on clean dry floors, or suffer eye strain and headaches in a working environment with adequate lighting.
Assess the risk of workplace environment factors such as cleanliness, temperature, lighting, storage and the availability and location of amenities.
Ways to control hazards
- Keep the workshop clean and tidy, and regularly clean residue from walls, floors and work surfaces.
- Clean up sanding or grinding dusts with damp rags, wet vacuum cleaners or other wet-cleaning equipment.
- Clean spilt water, oil or chemicals straight away.
- Locate washing, changing and meal areas away from hazards. Keep these areas clean.
- Remove rubbish, boxes and potential hazards from walkways.
- Provide a comfortable workplace temperature.
Manual tasks
Manual tasks involve carrying, lifting, lowering, pushing, pulling, gripping or restraining something. These tasks require repeated and sometimes strenuous use of the same parts of the body, often resulting in wear and tear of muscles, joints, ligaments, tendons and discs.
Here are some examples:
- Shoulder and neck problems may be caused by holding a spray gun above shoulder height for a long period.
- Polishing a car may strain hands or wrists.
- Back problems may result from pushing or pulling a heavy compressor.
Ways to control hazards
- Place all frequently used items within easy reach, and store heavy items between thigh and shoulder level.
- Use stable, adjustable work platforms that raise workers.
- Use devices that reduce the amount of manual activity involved in a task (for example, mobile winches or cranes, trolleys, pallet jacks, manual or electric forklifts, and height adjustable stools).
- Rotate workers or alternate tasks between repetitive and non-repetitive work. Take regular 'micro' rest breaks of a few seconds when doing repetitive work.
- Consider workload and fatigue factors when preparing rosters and organise the flow of materials at the worksite to avoid double handling.
- Train people in heavy lifting and other manual tasks and provide personal protective equipment (PPE) such as kneepads (for kneeling work), gloves (especially when using vibrating tools) and safety boots.
- Keep all walkways and work areas clear, especially when moving heavy loads. Use team lifting for heavy loads.
For more information on manual tasks, read the Manual Tasks Code of Practice 2010.
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