Guide Spray Painting 415

WorkCover. Watching out for you. New South Wales Government

SPRAY

PAINTING

GUIDE 2001WorkCover NSW Health and Safety Guide

DisclaimerThis publication may contain occupational health and safety and workers compensation information. It may include some of your obligations under the

various legislations that WorkCover NSW administers. To ensure you comply with your legal obligations you must refer to the appropriate legislation.

Information on the latest laws can be checked by visiting the NSW legislation website (www.legislation.nsw.gov.au) or by contacting the free hotline

service on 02 9321 3333.

This publication does not represent a comprehensive statement of the law as it applies to particular problems or to individuals or as a substitute for

legal advice. You should seek independent legal advice if you need assistance on the application of the law to your situation.

© WorkCover NSW

Contents PAGe

What are the hazards associated with spray painting? How can they affect health and safety? 2

How to use this information 2

What do the symbols used in the booklet mean? 3

How to establish the special needs of your workplace 3

Common spray painting hazards tool 4

Assessing the health and safety risks of spray painting 5

Assessing the risks of using hazardous substances in spray painting: Preparation 5

Assessing the risks of using hazardous substances in spray painting: Use and Work Practices 7

Assessing the risks of using hazardous substances in spray painting: Clean Up and Maintenance 10

Putting your information into action 11

Checking that your preventative measures are adequate 13

Who needs to know about your spray painting health and safety plan? 14

the most likely questions a WorkCover inspector will ask about work involving spray painting 15

some frequently asked questions 15

sample assessment and risk control plan: Panel shop 16

spray Painting Checklist for Hazardous substances 17

1

What are the hazards associated with spray painting? How can they affect health and safety?

An employer must assess the risks associated with spray painting and consult with

employees in the process

• Spraypaintingreferstotheprocessbywhichaliquidcoatingsubstance,suchaspaint,isconverted

intoamistoraerosolinordertoapplyacoatingontoanobjectorsurface.Thisprocessiswidely

usedintheautomotive,aircraft,furniture,metalfabrication,andbuildingandconstructionindustries.

Itshazardsincludeexposuretohazardoussubstancescontainedinpaints,fire,explosion,noiseand

manualhandling.

• Healthandsafetycanbeaffectedbyexposuretosubstancesthroughinhalationofvapours,injection

ofpaintandbyskincontact.Thehealtheffectsaresignificantasbothshortandlongtermillnesses

anddiseasesmayresult.Inaddition,seriousinjuriesmayoccurfromfireandexplosionarisingfrom

thesprayingprocess.

How to use this information

What is this booklet all about?

Thisbookletaimstoassistyoutotakeactiontopreventspraypaintingrelatedinjuryorillnessinyour

workplace.Ifyoufollowtheadvicesetouthere,youwillbewellonthewaytocomplyingwithyourlegal

obligationstocontrolworkplacerisksarisingfromspraypainting.Thisguidanceshouldbereadin

conjunctionwithOHSRegulation2001.

Who is this booklet for?

Thisbookletisforemployers,managers,OHSrepresentatives,OHScommitteemembers,employees,

unionsandemployerorganisationswhoneedtoknowaboutspraypaintingwork.

When to use the information?

Ifyourworkplaceactivitiesalreadyincludespraypainting,thisguideshouldbeusedtoassessthe

adequacyofyourcurrentspraypaintinghealthandsafetypractices.Ifyouhavenotlookedatyourspray

paintinghealthandsafetypracticesinthelastsixmonths,thencheckthemnow.

Ifyouaresettingupanewbusiness,thisbookletshouldbeyourstepbystepguidetodeterminingyour

requirementsformanagingworkinvolvingspraypainting.

Theinformationinthisbookletshouldbeusedwhenconsultingwithemployeesaboutthehazardsof

spraypainting.TheOHSAct2000requiresemployerstoconsultwithemployeesandtakeintoaccount

theirviewswhenmakingdecisionsthataffecttheirhealth,safetyandwelfare.Involvingyouremployeesin

identifyinghazardsandsolvinghealthandsafetyproblemsisanessentialstepinmakingyourworkplace

safeandhealthy.

IfyouwouldlikemoredetailedinformationonspraypaintingitisrecommendedyoureadtheNational

Guidance Material for Spray PaintingpublicationproducedbytheNational Occupational Health and

Safety Commission.ThepublicationisavailablefromtheCommission'swebsitehttp://www.nohsc.gov.au

2

3

What do the symbols used in the booklet mean?

Assesstherisksinyourworkplace Legalobligationsthatyoumustfollow

Consultandcommunicatewith Questionsyou(orothers)mightaskto

employees clarifyissues

Toolsthatcanhelpyouworkoutyour Theprocessoffindingthingsthat

plan causeharm,workingouthowbiga

problemtheyareandthenfixingthem

How to establish the special needs of your workplace

OHSRegulation2001setsoutcertainminimumstandardsforspraypaintinghowevernotwo

workplacesareexactlythesame.Yourprogramtomanagespraypaintingatworkwilldepend

uponyourindustryandthespecificactivitiesyouroperationsrequire.Todeterminetheactionyoushould

take,youmustfollowthreebasicsteps:

1. Look for the hazards in your workplace–thethingsthatcancauseharm(eg.solvents,twopack

paints,epoxies,resins,ignitionsources,sprayequipment).OHSRegulation2001callsthisidentifying

thehazard.

2. Work out how serious your health and safety problems might be. Decidewhomightbeindanger

(eg.you,employees,customers),thefactorscontributingtotherisk,whatinjuriesorimpactonhealth

andsafetycouldresult(eg.allergiccontactdermatitis,occupationalasthma,MSDSdata),andhow

likelythisistooccur.ThisiswhattheOHSRegulation2001callsassessing the risk.

3. eliminate or control hazards by making changes that protect people.Forexample,alwaysusea

spraybooth,substituteahazardoussubstancewithalessdangerousone,installappropriateexhaust

ventilation,developagreedsafetyprocedures,andalwaysusepersonalprotectiveequipmenttosupport

othercontrolmeasures.TheOHSRegulation2001callsthiseliminating or controlling the risk.

Youmustfollowthesestepsforeveryhealthandsafetyissuethatrequiresattention.Forworkinvolving

spraypainting,thismethodhelpsyoutoworkoutwhatactionwillmosteffectivelysafeguardemployees.

LookingforhazardsisthefirststepandtogetyoustartedtheCommon Spray Painting Hazards Tool on

page4outlinessomeofthehazardsweknowcancauseproblems:

Common spray painting hazards tool

HAZARD tYPICAL PRoBLeMs tYPICAL sYMPtoMs/

InJURY/ILLness/DIseAse

Hazardous substances Exposuretohazardous Shorttermeffectssuchas

substances(eg.paints,solvents, nausea,skinirritationand

dusts,powders,resins)because rashes;longtermillnesseslike

ofpoorventilation,faultyequipment, occupationalasthma,lung

poorly designed spray zones cancer and sensitisation

oruseinaconfinedspace. (ineffectbecomingallergicto

thepaint).

Fire and explosion Spraypaintingmistscontaining Shock,burns,lossof

flammablesubstancesignitedby consciousness,death.

heatsourceslikesparksfrom

inappropriateelectricalequipment

orhotsurfaces.

electricity Contactwithelectricalcurrentwhen Shock,burns,lossof

undertakingwetwork. consciousness,death.

Plant Malfunctionofventilation,electric Respiratorydisease,burns,

shock. electrocution.

Manual handling Holdingaheavyspraypaintinggun Sprains,strains,fractures.

aboveshoulderheightforextended

periods;awkwardtwistingorbending

tosprayobject;movingtheitem

beingsprayed;handlinglargepaint

drums.

noise Noisefrompumps,motorsor Hearingloss,fatigue.

compressedairsprayingthepaint.

This Tool is not a comprehensive guide to spray painting hazards.Itprovidesexamplesoftypical

problemscreatedbyspraypainting,andsomeoftheinjuries,illnessesanddiseasesthatcanresult.You

mayhavehazardsotherthanthoselistedhere.

Theguidanceinthisbookletisconcentratedonhazardoussubstancesandfirerelatedhazards.

4

Assessing the health and safety risks of spray painting

Thehazardsassociatedwithspraypaintingcanbeidentifiedduringthreekeystages:

• Preparation(overallsetupofjob,paintandsurfacepreparation,mixingandpouring)

• Use(spraypaintingoperationsandworkpractices)

• Cleanup(cleaning,maintenanceandstorage)

Ineachofthesestages,thethingslikelytocausemostharmtoyouoryouremployeesarethesubstances

usedinthesprayingprocess.Mostofthepaints,solvents,dustsandpowdersusedcommonlyinspray

paintingareclassifiedashazardoussubstances.

Hazardoussubstancesmustbemanagedcarefully,followingthemanufacturer'sguidanceforuse,

includingprecautionsthatmustbetaken.Insomecasesyoumayberequiredtokeepacheckonthe

healthofemployeesworkingwithparticularhazardoussubstances.

WhilstallthehazardsmentionedintheCommonSprayPaintingHazardsToolrequireanassessmentto

workouthowseriousaproblemtheyare,managinghazardoussubstancesrequiressomeveryspecific

stepswhichareoutlinedbelow.

Assessing the risks of using hazardous substances in spray painting: Preparation

HazardoussubstancescanbeidentifiedbytheirlabelsandMaterialSafetyDataSheets(knowncommonly

asMSDS).TheMSDSwillprovideinformationaboutasubstance,including:

• astatementthatthesubstanceishazardous;

• chemicalsandphysicalpropertiesofthesubstance(suchasboilingpoint,solubilityinwater);

• itsingredients(andtheirproportions);

• shortandlongtermhealtheffects;

• howthesubstancecanenterthehumanbody(called"routesofentry"):

• byinhalation(eg.vapoursfromspraying)

• byingestion(eg.unlabelledsubstancemistakenlyconsumed)

• byskincontactorabsorption(eg.useofsolventsincleanup)

• byinjection(eg.ofpaintinhighpressurespraypainting);

• precautionsforuseandrecommendedpersonalprotectiveequipment;

• firstaidinformation;

• exposurestandardsthatsetouttheairborneconcentrationofasubstancewithinaperson'sbreathing

zone.Thesestandardsmightrelatetoacceptablelevelsforaperiodof8hoursperdayover5days,

ortoshorterperiods(eg.15minutes)forsubstancesknowntocreateimmediatedangerstohealth.

AnemployermustobtainanMSDSforahazardoussubstancebefore,oronthefirst

occasionitissupplied.TheMSDSmustbereadilyaccessibletoanyemployeeswhocould

beexposedtothesubstance.TheMSDSmustbekeptuptodate(atleast5year

intervals)bythemanufacturer.

5

TheinformationintheMSDSisvitaltosafeandhealthyspraypaintingoperations.Youmusthavean

MSDSforeachsubstanceyouuse.Manufacturersandsuppliersmustprovidethisinformationtothe

employer,whointurn,mustpassitontoallemployeeswhomaybeexposedtothesubstance.This

informationmustbekeptuptodate.

Employerscannotusehazardoussubstancesforcertainpurposes.Thesubstancesyou

mustnotuseinspraypaintingarelistedopposite.

Youmustestablishwhatsubstanceisbeingused,andwhetheritisprohibitedforuseinspraypainting.

• Arsenicoritscompounds

• Benzene(benzol)ifthesubstancecontainsmorethan1%byvolume

• Methanol(methylalcohol)ifthesubstancecontainsmorethan1%byvolume

• CarbonDisulphide(CarbonBisulphide)

• Tetrachloroethane

• Tetrachloromethane(CarbonTetrachloride)

Forotherhazardoussubstances,likethoseusedintwopackpaints,youmustworkouthowtheymight

affectthehealthandsafetyofemployees(andothers,suchascustomersorvisitors).Understandinghow

thesubstancecancauseharmallowsyoutobuildinwaysofpreventingexposuretothesedangers.

ThePreparationassessmentfactorsthatyoushouldtakeintoaccountinclude:

the way the substance could enter the body

Surfacepreparationcancreateduststhatcontainhazardoussubstancessuchasleadandcarbonfibres

thatcouldbeinhaledbyworkers.Pouringliquidsfromonecontainertoanothercouldalsoreleasevapours

thatcouldbeinhaled.Inhalationofvapoursandaerosols,injectionbyhighpressureequipmentandskin

contactarethemostlikelywayssubstancesusedinspraypaintingcanenterthehumanbody.TheMSDS

providesthisinformation.

the health effects of the substance

TheMSDSwillprovidethebasicinformationaboutpossibleshortandlongtermhealtheffects.Isocyanates,

commonlyfoundintwopackpaints,areskinandeyeirritants.Inhalingthemcancauserespiratory

'sensitisation'(asthmalikesymptoms).Informationfromfirstaidandincidentrecordswillhelpyoutoidentify

anyproblemsyoumighthave.Talktoemployeesaboutanyhealthproblemstheymayhaveexperienced.

other hazards related to the substance

Manyofthesubstancesusedinspraypaintingareflammableandtherisksoffireandexplosionneedto

beconsidered.Dustgeneratedbysandingorgrindingoperationsmayalsocreatehealtheffects,especially

respiratoryproblems.

the nature of the work

Exposuretohazardoussubstancesneedstobeconsideredinrelationtodifferentstagesintheprocess:

• Preparationsuchaswet/drysandingandrustconversion

• Mixingoftwopackpaints,forexample,maypresentariskofinhalationandskincontact

6

• Colourmatchinginvolvingsprayingcouldleadtoinhalationandskincontact

• Spraypaintingreleasesaerosolsandvapourswhichpresentriskstohealth

• Cleanupusingsolventscouldresultinhighlevel,shortterminhalationandskincontact

Workingouttheriskinvolvedateachstagewilldependonthepracticesyouarecurrentlyusingto

minimiseexposure.Thisisexplainedinmoredetaillaterinthebooklet.

the number of people who could be exposed

Considerhowmanyemployeesareinanareawheretheycouldbeexposedtohazardoussubstances

throughanyofthe"routesofentry"tothebody.

How often and for how long people are exposed

Forthetypicalspraypaintingjobsyoudo,workouthowoftenall,orsomeofyouremployees,areexposed

tohazards.Workoutthelengthoftimepeopleareexposedtohazardoussubstances.Theoutcomeofthis

assessmentfactorwillalsodependonwhatmeasuresarecurrentlybeingusedtopreventexposure.

Theseassessmentfactorsmustbeconsideredwhensettingupyourspraypaintinghealthandsafetyplan.

Ifyouarestillunsureaboutwhetherthesubstancesyouareusingcreaterisks,itisrecommendedthat

yougetexpertassistancetomonitortheatmospherewheresprayingisbeingdone.Thiswillgiveyoua

moredetailedbasisfordecidinghowtofixidentifiedproblems.Anoccupationalhygienistcanundertake

thisatmosphericmonitoring.

Assessing the risks of using hazardous substances in spray painting: Use and Work Practices

TheOHSRegulation2001setsoutspecificmeasuresforspraypaintinginspraybooths.

Anemployermustensurethat:

a) spraypaintingiscarriedoutinaspraybooth,and

b) nopersons(otherthanpersonsrequiredtobeinthesprayboothaspartofthesprayingprocess)areinasprayboothduringspraypainting,and

c) anypersonsinasprayboothduringspraypaintingarewearingappropriatepersonalprotectiveequipment.

Theassessmentofrisksintheplanningandpreparationstagemayonlyneedtobedoneonce.Ifyou

changetheproductsyouuseortheworkpracticesinvolved,ornewinformationbecomesavailable,then

youwouldneedtolookatitagain.

Itisthecombinationofthesubstances,thejobstheyareappliedtoandtheworkpracticesthat

determinesthesafeguardsyoumustputinplace.

Youneedtolookatwhatyouarecurrentlydoingtoprotectemployeesfromhazardoussubstances.Your

UseandWorkPracticesassessmentfactorsinclude:

the nature of the object being sprayed Thesizeandshapeoftheobject,andtheeaseofmovingit,shouldbeconsidered.Moreimportantly,the

locationoftheobjectinrelationtothepainterandotheremployeesmustbelookedat.Thedirectionof

thestreamofventilatingairiscriticalinassessingrisks.Directionofairflowcanincreaseriskwherethe

oversprayblowsbacktotheoperatororisdirectedtowardotheremployees.

7

the nature and effectiveness of booths used to isolate people from spray hazards

Someworkplacesusefullyautomatedspraypaintingprocesses,inwhichobjectsarefullyenclosedina

boothandemployeesareseparatedfromhazardoussubstances.Automotivespraying,forexample,

requiresafullyenclosedbooth.Inmostcasesacombinationofboothsandpersonalprotectiveequipment

willberequired.Thelikelihoodofexposureisgreatestwheretheenclosuredoesnoteffectivelyisolatethe

painter,orotheremployees.

Onabuildingsitespraypaintingmaynotbepracticableinabooth.Measurestoprotectemployeesand

othersintheareamustbetakentodealwiththepotentialforexposure.

Theadequacyandsuitabilityofanenclosureorsprayboothisatechnicalmatter.Specificguidanceset

outintheStandardsAustraliadocumentAS/NZS 4114.1 Spray Painting Booths Part 1Design,

Construction and Testing shouldbeconsidered.

IfitisnotpracticabletocarryoutspraypaintinginaboothOHSRegulation2001setsout

specificmeasuresandseparationdistancestoisolatespraypaintingfromobstructionsto

ventilation,peopleandprocesses.Thesemeasuresrequirethespraypaintingprocesstobe

isolatedfromanysourcesofignitionandthatpersonsworkingonotherprocessescannot

inhalesubstancesfromspraypainting.Anypersonscarryingoutspraypaintinginthese

circumstancesmustwearappropriatepersonalprotectiveequipment.

Wherespraypaintingisundertakenoutsideabooth,azonemustbedesignedtoisolatetheactivityfrom

otherpeopleandfrompotentialsourcesofignition.Thiszonecanbebothaphysicalbarriertorestrict

accessoratimeperiodoverwhichconcentrationsofhazardoussubstanceswillbreakdowntoan

acceptablelevel.

Theseconsiderationswilldependontheassessmentdoneinthepreparationstage.

the type of ventilation used to minimise exposure to hazardous substances

Effectiveventilationcanreducetheriskofinhalationofsubstancesandreducecontactwithskinandeyes.

Ithastheadditionalbenefitofreducingfireandexplosionhazards.

Adowndraftsprayboothisconsideredthemosteffectiveformofventilationandproduceslowerlevelsof

overspray.Filteredairentersthroughtheceilingoftheboothandexitsthroughthefloor.Fullyenclosed,

standardwetwallorfiltertypeboothsarealsohighlyeffectiveandcommonlyused.

Localexhaustventilationdrawscontaminantsintoahoodandcapturestheoversprayandvapourasclose

tothesourceofsprayingaspossible.Aswithspraybooths,thedesignandconstructionoflocalexhaust

ventilationrequiresexpertadviceandAustralianStandardsAS/NZS 2381.1 Electrical equipment for

explosive atmospheres – Selection, installation and maintenance – General requirements and AS 1482

Electrical Equipment for explosive atmospheres – Protection by ventilation–shouldbeconsulted.

Dilutionventilationisthedisplacementofcontaminatedairbyfreshair,andmaybeachievedby

mechanicalsupplyfansorbynaturalaircurrents.Again,thedesignofsuchventilationrequiresreference

toadvicesuchasthatprovidedinAS/NZS2381.1andAS1482toensurethatthemosteffective

extractionofvapoursandaerosolsismaintained.

8

OHSRegulation2001setsoutspecificmeasuresforelectrostaticspraypainting.

Equipmentmusthaveautomaticpowerdisconnectionandwarningdevicesthatactivateif

anyconveyorcarryingarticlesthroughthehighvoltageelectricfieldstops.Handheld

equipmentmustheeffectivelyearthedalongwiththearticlesbeingpainted,metalwork

ofaboothandanymetalarticlesinsideorwithin2metresofthebooth.Asignbearing

thewordsDANGER–HIGHVOLTAGEmustbeclearlyattachedtoequipmentusedin

electrostaticspraypaintingandanexhaustsystemmustbeinoperationwhilstany

electrostaticspraypaintingisundertaken.

the type of spray painting undertaken

Therearevarioustechniqueswhichmaybeusedinspraypainting.Thesetechniqueswillvaryaccording

tothejobandthetypeofcoatingused.Eachhascharacteristicsthatmustbeunderstoodtoundertake

worksafely.

Conventional compressed air (low pressure)spraypaintingcreatesproblemswithextensiveoverspray,

whilst airless (high pressure)spraypaintingreducesoversprayandrequireslesssolventinthepaint.

Electrostaticspraypaintingreducesreboundandoverspray;however,theignitionofvapoursbyan

electricaldischargeisahazardinvolvedwiththisprocess.Earthingandisolationofelectricalequipment,

andmeasurestopreventelectrostaticbuild-upsareessential.

Mostoftheguidanceinthisbookletisdirectedtowards“wet”ratherthan“dry”spraypaintingprocesses

butthespecifichazardsofadryprocesssuchaspowdercoatingshouldbenoted.Powdercoatingswhilst

freeofsolventsstillneedtobecheckedforhazardoussubstancepropertiesandtheriskcontrolmeasures

outlinedabovegenerallyapply(ie.useofbooths,sprayzones,personalprotection).Triglycidylisocyanurate

(TGIC)powdercoatings,forexample,shouldonlybeusedinaboothcompliantwithAustralianStandard

AS 3754 1990 – Safe Application of Powder Coatings by Electrostatic Spraying.Theminimisationof

powderdustintheworkingareathroughouttheprocess,fromfillinghopperstocleanupstage,canbe

achievedbyapplyingthecontrolsoutlinedinthefollowingpages.

spray painting work practices

Usingthecorrectequipmentandtechniqueswillreduceemployeeexposuretohazardoussubstances.

Goodworkpracticesinclude:

• Adjustingthesprayingdistancetoreduceoverspray

• Adjustingsprayingpressuretoreduceoverspray

• Selectingappropriatespraynozzlestominimiseoverspray

• Selectingthebestspraymethodforthejob

Use of personal protective equipment (PPe)

EvidenceaboutcommonpracticesinspraypaintingindicatesthatpoorlychosenPPE,andthe

inappropriateuseofPPE,arefactorscontributingtogreaterexposuretohazardoussubstances.

PPEisanessentialpartofreducingrisksandmustbeusedasanadditionalmeasuretobooths.Over

relianceonPPEmaybeariskfactorthatshouldbeassessedwhendevelopingreliablewaysoflimiting

exposuretohazardoussubstances.

ThePPEusedshouldfollowtherecommendationsontheMSDS,andbeproperlyfittedandmaintained.

ConsultationwiththePPEsuppliercanalsoassistinmatchingequipmenttothespraypaintingprocessto

beused.EmployeesmustbeconsultedonthechoiceofPPEandtrainedinitscorrectuse.

9

Assessing the risks of using hazardous substances in spray painting: Clean Up and Maintenance

Therisksassociatedwithspraypaintingdonotceasewhenasprayjobiscompleted.Itisalsoimportant

tolookatpotentialproblemsinvolvedinthecleanupandmaintenancestages.

YourCleanupandMaintenancestageassessmentshouldconsiderthefollowingfactors:

Labelling of unused or surplus liquid

Whenasubstancelikepaintorthinnerispouredfromonecontainertoanotherandisnotused

immediately,thecontainermustbelabelled.Thelabelmustincludetheproductnameandthe‘riskand

safetyphrases’outlinedintheMSDS(ie.standardinformationlike‘flammable’and'keepawayfrom

sourcesofignition–nosmoking’).

Wherethereissurplusproductnotusedimmediately,itmustbereturnedtoalabelledcontainer

designatedforthatsubstance.

storage of spray painting supplies

Onlytheminimumquantityofsuppliesshouldbekeptinreadinessnearthesprayzone.Allotherproduct

shouldbestoredinaseparateroomorstoragecabinet.Flammablesubstancesmustbekeptintightly

closed,clearlylabelledcontainers.FurtheradviceonstoragerequirementscanbefoundinAS 1940 The

Storage and Handling of Flammable and Combustible Liquids.

Cleaning and maintenance of spray booths and associated equipment

Spraygunsandassociatedplantmustberegularlycleanedandcheckedinaccordancewith

manufacturer'sinstructions.Hosesandlinesconveyingflammableliquidsalsoneedtoberegularly

maintained.Employeesmustbeprotectedinthecleanupprocesstominimisecontactwithsubstances.

Ifnotregularlycleanedandmaintained,sprayboothswillgraduallybecomeineffectiveinproviding

protection.Inadditionthebuildupofdriedoversprayonsurfacescontributestoanincreasedfirehazard.

AS/NZS 4114.2 Spray Painting Booths: Selection, Installation and Maintenanceprovidesguidanceon

recommendedmaintenancepractices.

Ventilationsystemsmustalsobecleanedandmaintainedandfiltersandhosesregularlychecked.

Personal clean up practices

Theuseofsolventstocleanthehandsorbodyislikelytoleadtoabsorptionthroughtheskin:water

basedcleansersaremoreappropriate.Cleaningragssaturatedwithpaintorsolventandleftinopenbins

createbothaninhalationriskandafirerisk.Theuseofliddedwetbinsisrecommended.

Thenumberoffactorsyouneedtoconsiderhighlightstherangeofproblemsspraypaintingpresents,and

themanywaysinwhichpeoplecanbeexposedtohazards,oftenresultinginharmfulhealtheffects.

10

Putting your information into action

HavingworkedouthowseriousyourOHSproblemsareyoumustnowtakeactiontofixthese

problems.Themorethoroughyourassessmenthasbeenthemoreoptionsyouwillhaveforeliminatingor

controllingrisks.This is because the problems are closely related to each other: this must be kept in

mind when you try to fix any one of them.

Forexample,usingpoorlyadjustedsprayequipmentwillresultinmoreoverspray,andpotentialexposure

fortheemployee.Inturn,thiswillleadtoabuildupofpaintonsurfacesandincreasedriskoffire.In

addition,inefficientsprayingwillraisecostsandencouragepeopletocutcornerstomeetmargins.This

viciouscyclecanposeaseriousthreattothehealthofemployees.

Thefollowingoptionsforfixingproblemsaredrawnfromtheassessmentfactorssetoutinthethreestages

andinclude:

Follow the recommendations on the MsDs

TheMSDSoutlinesthebasicplantoreducerisksassociatedwithhazardoussubstancesusedinspray

painting.UsetheMSDSforeachsubstanceasthestartingpoint,andfinetuneyourplansoitaddresses

thecircumstanceswhichapplyinyourownworkplace.

Keep records of the hazardous substances you use, and of how you have assessed the problems they present in your workplace

Youarerequiredtodothisbylaw.Inanycaseitisanessentialpartofyourriskcontrolplan,asit

providesareadyreferenceastohowthingsshouldbemanaged.

Minimise the use of the most hazardous substances

Youmayhaveanumberofoptionsforminimisingtheuseofhazardoussubstances:

• Trytoreplacesolventbasedcleanserswithwaterbasedcleansers.

• Usewaterbasedpaintswherepossible,minimisingtheuseofpolyurethaneandacryliclacquersand

2packpaints.

• WhereyouneedtouseahighlyhazardoussubstancelikeIsocyantes(foundinhardeners),adopt

spraytechniqueswhichminimisethelevelofoversprayandrebound.

• Lookatalternativewaysofapplyingpaintforsomejobs.

separate people from the hazard by establishing a spray zone

Asprayzoneisaspecificareaforspraypaintingthatlimitsentrybyuseofphysicalbarriersortimedelays.

(Thesizeofthesprayzoneandthetimedelaywilldependonthenatureofthesubstancesbeingused.)

Thesprayzonecanbewithinanenclosureorbooth,ormaybeappliedinanopenairsituation.Ineither

circumstance,thezoneshouldbedesignatedwithwarningsigns.(eg.'SPRAYZONE:UNAUTHORISED

PEOPLEKEEPOUT.NOSMOKING,NAKEDFLAMESOROTHERSOURCESOFIGNITION')

Barrierstorestrictentryofunprotectedpersonstothezoneshouldbeconstructedandignitionsources

(eg.litcigarettes,abrasivegrinding)mustberemoved.

Thesprayzoneshouldbeclearofsubstancesnotimmediatelyneeded,andwastesshouldberemoved

fromtheareatominimisefirerisks.Asprayzonecanonlyprovidelimitedprotectiontopaintersandother

peopleandshouldonlybeanoptionwhereasprayboothisnotpracticable.

11

Install suitable ventilation to reduce exposure to substances

Ventilationisaprimarymeansofreducingthelevelofvapoursandaerosolsintheatmosphereinwhich

spraypaintingworkisdone.Italsoreducestheriskoffireorexplosion.Wherepracticableaspraybooth

shouldbeusedasthisisthemosteffectivewayofreducinghazards.Thetypesofventilationinorderof

theireffectivenessare:

• Downdraftspraybooth

• Anopenspraybooth

• Localexhaustventilation(exhaustfanextraction)

• Dilutionventilation(usesfansornaturalaircurrentstodisplacecontaminatedair)

Eventhoughdowndraftsprayboothsarethemosteffective,othermeasureslikePPEwillstillberequired.

Forthelesseffectivedilutionventilationsystem,therearepracticesthatshouldbefollowedtoachievea

minimumlevelofsafety.Theyinclude:

• ensuringtheoperatorisalwaysbetweentheairinletsupplyandthesourceofvapours;

• ensuringtheexhaustoutletsareasclosetothespraypaintingaspossible;

• settingupthesystemtoensuretheairflowsthroughthesprayzoneanddoesnotre-entertheworkarea.

Theserecommendationsalsoapplytopreparationandcleanuptasksandareas.

Minimise electrical safety risks and ignition sources

Allequipmentlocatedwithinthespraypaintingzoneshouldbecheckedtoensureitissafeandsuitable

foruseinsuchanarea.Normaldomesticelectricalequipment,motors,powertools,heatersetcmay

becomedangerousasignitionsources.

Somespraypaintingprocesses,likeelectrostaticpaintingandairlessspraypainting,canproducestatic

electricity:allequipmentandcontainersandthepersonusingthemshouldbeearthed.

Use practices that minimise the exposure of the spray painter

Whateverothermeasuresareused(booths,PPE)additionalprotectioncanbegainedbyadoptingwork

practicesthatfurtherminimiseexposure.Thepaintershouldavoidbeingpositionedbetweentheobject

beingsprayed,andtheexhaust.Thiscanbeachievedby:

• using'inline'spraybooths,toensureoperatorsdonotspraytowardseachotherorotherpersons;

• rotatingobjectsonturntablesorhookstoavoidsprayingagainsttheairflow;

• keepingspraybelowshoulderheightwhenusingdowndraftbooths.

Use clean up and storage practices that minimise exposure and fire risks

Useofwaterbasedcleansers,soakingcleaningragsin"wetbins",andensuringsurplusorunusedproduct

iscorrectlylabelledandsealedareamongthestandardpracticesthatshouldbeadopted.Makesure

suitablewashupfacilitiesareavailable.

Storageofsubstancesshouldalsotakeintoaccounttheirotherproperties(asflammablesorcombustibles).

Useofseparatestorageareasandstoragecabinetswillberequiredtomeetlegalobligationsinregardto

DangerousGoods.Wastepaint,solventsandcleanupmaterialsmustbesafelydisposedof.

12

Use and maintain Personal Protective equipment in addition to other measures

TheMSDSwillstatewhatPPEisappropriate:itsrecommendationsshouldbefollowedwherepracticable.

RecommendedPPEmightinclude:Airsuppliedrespirators,Halffaceparticulaterespirators,Eye

protection,Suitableglovesandoveralls,Hearingprotection.Thisequipmentshouldbeusedinconjunction

withotherriskcontrolmeasures.

EmployeesneedtobeinvolvedintheselectionandfittingofPPEandtrainedinitscorrectuse.PPEmust

besuitablystoredawayfromsourcesofcontaminationandregularlyinspectedforsignsofwearandtear.

Filtersshouldberegularlycheckedandreplacedwhennecessary.AS/NZS 1716 Respiratory protective

devices, and AS/NZS 1715 Selection, use and maintenance of respiratory protective devicesprovide

specificguidanceontheseissues.

Be prepared for emergencies

Leaks,spillsoruncontrolledreleaseofhazardoussubstancesmayoccurdespiteyourbestefforts,and

emergencyplansmustbedevelopedforsuchaneventuality.CorrectlabellingandavailabilityofMSDSwill

makeanysituationeasiertodealwithandprovidethebasisforproceduresthatstaffcanbetrainedin.

Fireprotectionmeasuresmustbeinplaceandfirstaidandemergencyplansmustbeincludedaspartof

yourplan.

Checking that your preventive measures are adequate

Youmayalreadyhavetakenstepstomanageyourspraypaintingrisks.Itisimportantthatyouknow

whetherornotyouractionscontinuetoprovideeffectivesafeguardsforyouremployees–before the

healthandsafetyofanypersonisputatrisk.

• Buildinaperiodicreviewofyourprocedures,involvingthepeoplewhohaveaccountabilitiesfor

healthandsafety.Ensurethatspraypaintingequipment(includingbooths,exhaustventilation,spray

gunsandcompressors)isregularlyinspectedandmaintained.

• Ifyouchangethetypeandformulationofpaintensuremeasuresareappropriate.

• Ifworkpracticesaremodified,ornewworkpracticesintroduced,reviewyourpreventivemeasures

againsttheassessmentfactorstoensuretheyarestilladequate.

• Ifaspraypaintingincident(injury,illnessor'nearmiss')occurs,reviewtheproceduresyouhadin

placeatthetime,andmakechangestopreventarecurrence.

• Ifnewinformationisobtainedaboutapreviouslyunidentifiedhazard,reviewyourpreventative

measures.

special note on atmospheric monitoring and health surveillance

Asnotedearlieratmosphericmonitoringmayberequiredtoassesswhetheryouaremeetingexposure

standardsforthehazardoussubstancesyouareusing.Itcanalsobeusedasawayofcheckingwhether

yourcontrolsareworkingtoreducerisks.Anoccupationalhygienistcanundertakethismonitoringand

recommendanychangesyouneedtomake.

Healthsurveillanceinvolvesperiodichealthchecksofanyemployeeswhoareexposedtohazardous

substances.Typesofhealthsurveillanceincludebiologicalmonitoring(eg.determiningthepresenceof

substancesinblood,urineorexpiredair),medicaltestssuchaslungfunctiontestsandmedical

examinations.

13

Healthsurveillanceisrequiredwhereyourassessmentshowsemployeesareexposedtoarisktohealth

fromoneofthehazardoussubstances,listedasascheduledsubstanceunderOHSRegulation2001.

Isocyanatesregularlyfoundintwopackspraypaintarescheduledsubstances.Healthsurveillancemay

alsoberequiredwherethereisareasonablelikelihoodofanadversehealtheffectoccurringunderthe

particularconditionsofwork.

YoushouldcheckChapter6HazardousSubstancesoftheOHSRegulation2001toestablishwhathealth

surveillanceyouneedtodo.

Who needs to know about your spray painting health and safety plan?

employers/Managers

Employersandmanagersmustknowtheeffectsofexposuretohazardoussubstances,therisksoffireand

explosionandotherhazardsassociatedwithspraypainting.Managersandsupervisorswillbeaccountable

formakingsurethatpreventivemeasuresareimplemented,understoodbyemployees,andmonitored.

Keepingofrecordsofassessments,trainingandanymonitoringorhealthsurveillanceisanessentialpart

oftheplan.

Inmanysmallerworkplaces,employersandmanagerswillthemselvesbedirectlyexposedtothese

hazards–sotheymustprotectthehealthandsafetyofboththeiremployeesandthemselves.

employees

Employeesmustknowandbeconsultedontheharmfuleffectsthatmayresultfromspraypainting,and

themeasuresinplacefortheirprotection.Theymustalsorecognisethephysical'warningsigns'iftheir

healthisaffectedbyworkinvolvingspraypainting.

ProvisionofMSDSisrequiredbylaw,andisthebestfirststepinadvisingemployeesofhazardsand

recommendedsafeguards.YoumustconsidertheneedsofemployeeswhosefirstlanguageisnotEnglish,

andmakesuretheyunderstandboththerisksandthechosencontrols.

Contractors, suppliers, customers and visitors

Allpeoplewhoundertakeworkforyou,orentertheworkplaceasavisitor,mustbemadeawareofyour

expectationsinregardtotheirsafety.Ifcontractors,suppliers,customersorvisitorsmayatsometimebe

exposedtospraypaintinghazards,youmustalsotakestepstoensuretheirsafety.

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the most likely questions a WorkCover inspector will ask about work involving spray painting

Q. Whathazardoussubstancesareusedinthespraypaintingprocessandwhereistheregisterlisting

them?

Q. HaveMSDSbeenmadeavailabletoemployeesandaretheyuptodate?

Q. Whatassessmentofspraypaintingriskshasbeenundertakenandhaveyoukeptrecordsofthem?

Q. Hasanyatmosphericmonitoringbeenundertaken?

Q. Whatsortofboothisusedforspraypainting?

Q. Ifasprayboothisused,whenwasitlastsubjecttoinspectionandmaintenance?

Q. Hasanyhealthsurveillancebeenundertakenwherescheduledhazardoussubstances(eg.isocyanates,

leadbasedpaint)areused?

Q. Istheelectricalplantassociatedwithspraypainting,wellmaintainedandisolatedtoreduceignition

sources?

Q. Howaresubstancesusedinspraypaintinglabelled,wherearetheystoredandhowaretheydisposed

of?

Q. WhatPersonalProtectiveEquipment(gloves,respirators,eyeprotection)isusedandhowisitstored

andmaintained?Whenwerefiltersandgloveslastchanged?

Q. Whattraininghasbeenprovidedtoemployees?

some frequently asked questions

How do I deal with some of my employees who will not use the PPe that is provided, saying it is uncomfortable to wear and interferes with the job?

EmployeesneedtobeinvolvedintheselectionandfittingofPPEandmustbemadeawareofthe

recommendationsontheMSDS.Employeeshaveobligationstofollowsafetyprocedures,andthesemust

beenforced.EffectiveventilationandisolationpracticesmayreducethelevelofPPEwhichisneeded.

How do I know if the spray booth I use is effective in removing vapours and aerosols from the area where the spray painter is working?

Therearespecificstandards(availablefromStandardsAustralia)describingtheairflowratewhichshould

beachieved,andyoucanhavethistested.Also,youcanhaveatmosphericmonitoringconductedthatwill

tellyouwhetheremployeeexposuretothesubstanceyouareusingiswithintherequiredlimits.

If I am using two pack paints do I have to use a full face air supplied respirator and have the health of employees checked?

Yes.Twopackpaintscontainisocyanatesandarelistedashazardoussubstancesthatrequirehealth

surveillance.Unlessyoucandemonstratethatthereareminimalrisksyouwillneedtoarrangehealthchecks

asrequiredbytheregulation.MSDSforthesesubstancesstatethatfullfaceairsuppliedrespirators

shouldbeused.Thisprotectionshouldbeusedincombinationwithasuitablyventilatedenclosure.

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sample assessment and risk control plan: Panel shop

eMPLoYee eXPosURe to HoW seRIoUs Is tHe PotentIAL eXPosURe AnD WHAt

HAZARDoUs sUBstAnCes sHoULD Be Done to ReDUCe It

DURInG sPRAY PAIntInG

RIsK AssessMent FACtoRs summary Assessment:Potentialforexposuretosubstancesby

type of hazardous substance inhalationisextremelyhigh,andpotentialforskincontactishigh.

used:Identifiedonlabelas Thelengthofexposureinthesprayingtaskplusexposurein

containinghexamethylene preparationandcleanupstagesindicatesmoreeffectivewaysof

diisocyanate. preventingexposurearerequired.CurrentPPEisnotadequate.

Routes of entry to body: Recommended Actions:

inhalation,injectionandskin • EnsureMSDSisdistributedtoemployeesaffected

contact. • PutcopyofMSDSwithlistofsubstancesusedinworkplace

• Ensuresprayboothandairfiltersareclean

Health effects of substance: • Ensureventilationinareaaroundboothextractscontaminatedair

MSDSstatesrespiratory • Ensuresprayequipmentisadjustedformostefficientsprayingof

irritationandsensitisation, paint

skinsensitisation. • UsefullfaceairsuppliedrespiratorsasrecommendedonMSDS.

Briefandtrainemployeesontheiruse

nature of the work:sprayingof • Ensuresuitableglovesandbodyprotectionareprovided

carbodypanels. • Ensurehearingprotectionisprovidedifnoiselevelsarehigh

• Rotateemployeestominimiseexposureandensuretheytake

number of people who could be shortbreaks

exposed:3employeesworkingin • Checkadequacyofemergencyproceduresandfirstaidfacilities

andaroundbooth. • Regularlychecktheeffectivenessofyourcontrolsandassess

situationifyouintroducenewproducts,equipmentorpractices

How often and how long each

exposed: Typicallyeachwould special Measures:

spend4hourssprayingeachday. • Previouspracticesindicatehealthsurveillanceisrequiredand

medicalchecksshouldbearranged

nature of object being sprayed: • Previouspracticesindicatetheneedforatmosphericmonitoring

Passengermotorvehicles. tocheckexposurelevels

enclosure used: Downdraftspray

booth.

type of spray painting: Airless

(highpressure).

PPe currently used:Halfface

respirator,latexgloves.

Note:Thisworkedexampledealsonlywithspraypaintingworkand

doesnotincludepreparationandcleanupstages.Eachofthese

stagesshouldbeassessedalongwiththeotherhazardssuchas

fire,explosion,noiseandmanualhandling.

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spray Painting Checklist for Hazardous substances

1. Identify your hazards

Know:

Whathazardoussubstancesareused?

WhattheMSDSsaysaboutthesubstance,includinghowitgetsintothebody,whateffectsithas,

andhowitshouldbecontrolled?

Howmanyofyouremployees,contractors,visitors,suppliersorcustomerscouldbeexposedto

substancesusedinspraypainting,andforhowlong?

Whetherhealthsurveillanceislikelytoberequired?

Whatyouremployeescantellyouaboutthehazardsinvolved?

2. Work out how serious your problem might be

Lookat:

Thenatureoftheobjectbeingsprayedandthepositioningoftheobjectinrelationtothespray

painter.

Thefrequencyanddurationoftask.

Theeffectivenessofcurrentmeasurestoisolatepeoplefromsprayhazards.

Thetypesofventilationusedtoreduceexposuretohazardoussubstances.

Themethodofspraypaintingusedandworkpracticesadoptedbyemployees.

ThesuitabilityandeffectivenessofdifferenttypesofPPE.

3. take preventive action

Haveyoutakenstepstoeliminateorcontrolexposuretohazardoussubstancesandmadesure

everyoneknowsthepracticeswhichmustbefollowed?

Doesyourplanuseseveralmeasures(booths,restrictedareas,timedelays)toreduceexposure,as

wellasrelyingonPPE?

Haveyoumadefirstaidandemergencyarrangements?Dopeopleunderstandthem?

4. Checking that your preventive measures are adequate

WhenwerethesprayboothandPPElastinspectedandcheckedforeffectiveness?

HaveanyemployeesreportedsymptomsthatarelistedontheMSDS?

Haveyouprovidedrefreshertrainingtoemployeesinyouroperationalandemergencyprocedures?

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Catalogue No. WC00415 WorkCover Publications Hotline 1300 799 003

WorkCover NSW 92-100 Donnison Street Gosford NSW 2250Locked Bag 2906 Lisarow NSW 2252 WorkCover Assistance Service 13 10 50Website www.workcover.nsw.gov.au

ISBN 1 9876995 78 5 ©Copyright WorkCover NSW 0508