SPRAY PAINTING

Presented by:

John Zivanovic
Principal Inspector
Manufacturing Team
Workplace Services
 SCOPE OF PRESENTATION

This presentation refers to the specific

hazards associated with the substances
being used in the activity of spray painting
and the design and construction of spray
booths and designated spray zones which
form the basis of sound risk control
measures and OHS management.
 CONTENTS
z What is spray painting
z General hazards in spray painting
z National OHS strategy
z Hazardous substances
z Legal requirements
z References
z Work areas for spray painting
z Control strategies
z Maintaining standards
z Monitoring
z Record keeping
 WHAT IS SPRAY PAINTING

“Spray Painting” means a process in which-

z Molten or powdered metal; or

z A form of paint, enamel, varnish, shellac or

liquid containing nitrocellulose, or a mixture of
these materials; or

z A flammable, injurious or toxic substance,

Is applied to an object by spraying.

SPRAY PAINTING APPLICATIONS

Hand held or Automatically operated:

z Air pressure

z Airless

z Electrostatic
 GENERAL HAZARDS IN SPRAY
PAINTING

z Substances
z Plant
z Fire / explosion
z Electricity
z Noise
z Manual tasks
z Confined spaces
z Thermal conditions
z General work environment
 NATIONAL OHS STRATEGY

Workplace Services endorses the National

priority action plans 2002 – 2005

These are to:

z Reduce high incidence / severity risks

z Improve the capacity of business operators and workers to

manage OHS effectively

z Prevent occupational disease more effectively

z Eliminate hazards at the design stage, and

z Strengthen the capacity of government to influence OHS

outcomes.
 NATIONAL OHS STRATEGY

For government to influence OHS outcomes,

government will demonstrate a leadership
role, through:

z Promoting

z Legislating, and

z Enforcing

OHS requirements via a wide range of mechanisms.

 LEGAL REQUIREMENTS

Primarily focus on OHS legislation for:

z General Hazardous Substances

(Division 4.1 – OHSW Regulations 1995)

z Spray Painting
(Division 5.8 – OHSW Regulations 1995)
 REFERENCES
Reference material adopted:

OHSW Act 1986

OHSW Regulations 1995
AS/NZS 1715: Selection, use and maintenance of respiratory
protection devices
AS/NZS 1716: Respiratory protective devices
AS/NZS 3000: SAA Wiring rules
AS/NZS 2430: Classification of hazardous areas
AS/NZS 2430.3.9: Examples of area classification –
Miscellaneous
AS/NZS 4114.1: Spray painting booths, designated spray
painting areas and paint mixing rooms – Installation and
maintenance
AS/NZS 4114.2: Spray painting booths, designated spray
painting areas and paint mixing rooms – Design, construction
and testing
National (NOHSC) guidance material for spray painting 1995
 HAZARDOUS SUBSTANCES

Potentially all workers engaged in or nearby

the activity of spray painting and where
exposure to hazardous substances is not
adequately controlled, may suffer serious
health effects and or injury.
 HAZARDOUS SUBSTANCES

Sound OHS management of general

hazardous substance will include:

z Hazardous substance register

z Material safety data sheets
z Correct labelling
z Induction and training
z Risk assessments
z Risk control
z Atmospheric monitoring
z Health surveillance, and
z Record keeping
 HAZARDOUS SUBSTANCES

Material safety data sheets:

z Identification
z Physical aspects (flammability/explosion limits)
z Other properties
z Ingredients
z Health effects
z First aid
z Precautions (exposure levels)
z Safe handling / storage
 HAZARDOUS SUBSTANCES

Spray painting processes involving

hazardous substances include:

z Preparation

z Spray painting, and

z Storage, clean up and disposal.

Additionally, some other forms of work processes also

generate substances that can be harmful.
 HAZARDOUS SUBSTANCES

Key areas of risk, are the potential:

z Health effects

z Flammability / explosion hazards, and

z Handling & storage of substances .

 HAZARDOUS SUBSTANCES

Risks to health, should consider the type

and duration of exposure:

z Hazardous substance

z Routes of entry

z Acute (short term) exposure

z Chronic (long term) exposure.

 HAZARDOUS SUBSTANCES

Some examples are:

z Paints
z Solvents
z Dusts
z Powders
z Lacquers
z Paint removers
z Resins
z Adhesives
z Surface preparation products
z Rust converters & removers
z Various metal products
 HAZARDOUS SUBSTANCES

Routes of entry include:

z Inhalation (toxic vapours & mists)

z Indigestion (swallowing the substance)

z Absorption ( contact through the skin & eyes)

 HAZARDOUS SUBSTANCES

Acute effects can include:

z Irritant contact dermatitis

z Burns to the skin & eyes

z Vomiting and diarrhoea

z Irritation to the lungs, throat & eyes, and

z Headaches, dizziness, nausea and fatigue.

 HAZARDOUS SUBSTANCES

Chronic effects can include:

z Occupational asthma

z Allergic contact dermatitis

z Lung cancer

z Painter’s syndrome – organic solvents

z Reproductive system damage, and

z Kidney and or liver damage.

 HAZARDOUS SUBSTANCES

Risks from flammable substances, can

include:

z Fire, and or

z Explosion - (atmospheric conditions resulting from any

source of ignition), and

z Safe handling & storage.

 WORK AREAS FOR SPRAY
PAINTING

Spray painting must be carried out in a booth

unless-

(a) The painting consists of minor spotting or touching up

operations; or

(b) The painting in carried out on any plant or item that is fixed
or too large to move into a booth.

This may occur within a “designated spray painting zone”

 WORK AREAS FOR SPRAY
PAINTING

Spray painting that consists of minor

spotting or touching up operations,
comprises of:

z An area not larger than an A4 size sheet of paper, and

z Spraying does not exceed the total time of 5 minutes

within any given 60 minute period, and

z Does not constitute production work.

 WORK AREAS FOR SPRAY
PAINTING

The painting is carried out on any plant or

item that is fixed or too large to move into
a booth, comprises of:

z Bridge

z Ship, and

z Does not constitute production work

 CONTROL STRATEGIES
Controlling risks from hazardous
substances:

z Eliminate

z Substitute

z Isolate

z Engineering

z Administrative

z Personal protective equipment, and

z Monitor & review

 CONTROL STRATEGIES

Controlling risks from hazardous

substances:

z Spray booths
(with a spray area within a booth)

z Spray zones
(where spray booths are not required)
 CONTROL STRATEGIES
(SPRAY BOOTHS)

Spray booths:

z Various types of spray booths

z Design / Construction requirements

z Ventilation / extraction standards

 CONTROL STRATEGIES
(SPRAY BOOTHS)

Spray booths must be one of the following

types, (or a combination of two or more of
them):

z Room or Cabinet Booth

z Tunnel / Production Booth

z Canopy / Open Face Booth , or

z Any other form of booth which, in the opinion of the Director,

gives adequate protection and which is approved, in writing,
by the Director.
 CONTROL STRATEGIES
(SPRAY BOOTHS)

Spray booth design and construction

principles:

z Structure – (supporting structure)

z Interior surfaces – (walls, ceiling, floor & glazing)

z Access and egress – (doors)

z Electrical equipment / wiring

 CONTROL STRATEGIES
(SPRAY BOOTHS)

Structure and interior surfaces:

The internal walls and ceilings of a spray

painting booth must be constructed entirely of,
or be entirely lined internally with, sheet steel
or some other substantial incombustible
material, and must be free from any
obstructions.
 CONTROL STRATEGIES
(SPRAY BOOTHS)

Walls & Ceilings:

z Capable of passing impact test requirements as

detailed in (AS 2380.1)

z Withstand desired operating temperatures

z Impervious to materials being used

z Smooth to prevent the build-up of paint and easy to

clean, and

z Supporting structure to be located on the outside of the

booths internal lining to eliminate internal obstructions.
 CONTROL STRATEGIES
(SPRAY BOOTHS)

Internal floor surfaces:

The floor of a booth and the floor area to a distance of at

least 1 metre beyond its entrance must be of
impervious, incombustible material.

z Concrete slab

z Steel trowel finish

z Easily maintained
 CONTROL STRATEGIES
(SPRAY BOOTHS)

Means of safe access and egress:

Any exit door fitted to a booth must be fitted so as to open

outwards from the booth, and

Every exit door from a booth must be kept clear and free
from obstructions at all times.

z Egress: one or more – six metres from any point,

unless for large booths; e.g. spraying aircraft etc.

z Roller door: is permitted only when used as a

secondary means of access and meets “equipotential
bonding requirements”
 CONTROL STRATEGIES
(SPRAY BOOTHS)

Electrical installations:

The electrical equipment and wiring fitted to or in a booth

must comply with the relevant specifications of AS 3000
SAA Wiring Rules.

z AS/NZS 2430: - Classification of hazardous areas

z AS/NZS 2430.3.9: - Examples of area classification –

Miscellaneous

z AS 2381.1 - General Requirements (Electrical

equipment for explosive atmospheres – Selection,
installation and maintenance, as required by AS 2381)
 Control Strategies
(Spray Booths)

Ventilation systems:

z Ventilation methods

z Plant & equipment

z Exhaust ducts

z Ventilation flow
 CONTROL STRATEGIES
(Spray Booths)

Method of ventilation:

A spray painting booth must be fitted with a

suction exhaust ventilation system that is
capable of maintaining air changes at the rate
that keeps the concentration of contaminants
in the booth at the lowest practical level (as
measured in the breathing zone of the
operator).
 CONTROL STRATEGIES
(Spray Booths)

Method of ventilation:

The method of ventilation used in a spray

painting booth must be one (or more) of the
following-

z Induced or Syphon type of ventilation, for which the

fans and motors are entirely outside the booth and duct.
 CONTROL STRATEGIES
(Spray Booths)

Exhaust ventilation must provide a level of

air velocity at the operators breathing zone
at any one point within the booths spray
area.

z Not less than 0.50 lm/sec – side draught booth

z Not less than 0.25 lm/sec – down draft booth

z Not less than 0.40 lm/sec – electrostatic processes

 CONTROL STRATEGIES
(Spray Booths)

Method of ventilation:

z Directly driven fans within a duct, where the motor

driving the fan is an explosion proof type and is
shielded against vapours and dust; or

z Fans within a duct which are belt driven by an external

motor, where the belt and pulley within the duct or
spray painting booth are completely enclosed and the
enclosure electrically earthed; or
 CONTROL STRATEGIES
(Spray Booths)

Method of ventilation:

z Any other method of ventilation which is similarly

effective and is approved, in writing, by the Director,
and

z Unless otherwise approved by an Inspector, if more

than one fan is used, the control must be connected to
each fan so that one fan cannot be operated without
operating all the fans.
 CONTROL STRATEGIES
(Spray Booths)

Method of ventilation:

z A booth must be fitted with one or more

ventilation exhaust ducts that have air tight
joints and sufficient capacity to discharge all
spray laden or contaminated air from the
booth.
 CONTROL STRATEGIES
(Spray Booths)

Exhaust duct requirements:

z Ducts to be fabricated in sheet steel

z Ducts to be galvanized as preferred finish

z Appropriate to ensure sufficient discharge

z Clear of flammable material below roof line

z Lobster back bends to have cleaning holes

z External duct / outlet to comply with EPA requirements

 CONTROL STRATEGIES
(Spray Booths)

Method of ventilation:

z The exterior termination of all exhaust ducts

that are open to the outside atmosphere must
be protected from the detrimental effects of
weather and fire hazards, and must not be
such as to cause a nuisance or fire hazard.
 CONTROL STRATEGIES
(Spray Booths)

Filtering & exhaust stack systems:

Dry type
z Treated perforated cardboard or paper
z Fibre glass wool pads

Wet type
z Pump type (water wall / scrubbers)
z Non pump type

Exhaust stacks (distance requirements)

 CONTROL STRATEGIES
(Spray Booths)

Method of ventilation:

z The ventilation of a workroom in which a spray painting

booth is erected must permit the free flow of the outer
air to ensure further that the spray painting occurs
between the source of air and the exhaust fan.
 CONTROL STRATEGIES
(Spray Zones)

Defined:

“A designated spray zone is where a

spray booth is not used, with
restrictions on entry and that all
hazards / risks associated with the
spraying of hazardous substances have
been controlled”
 CONTROL STRATEGIES
(Spray Zones)

Spray zones are used where a booth is not

“legally” required:

z A spray zone has restrictions on entry to the spray

area.

z It isolates other persons from the spray painting activity,

and

z Determines the size of the zone and time frames for re-
entry to the spray zone is allowed.
 CONTROL STRATEGIES
(Spray Zones)

When introducing a spray zone,

consideration must be given to the:

z Nature of substances being sprayed

z Type of process being used (HVLP)

z Work environment

z Location of other people

z Hygiene
 CONTROL STRATEGIES
(Spray Zones)

The controls for spray zones generating

hazardous substance, include but are not
limited to:

z Designating the spray zone

z Removal of any hazardous substance
z Physical barriers & signage
z Restriction to entry
z Isolation of ignition sources
z Temporary screening & tunnelling
z Use of local mechanical exhaust ventilation
z Dilution ventilation
 CONTROL STRATEGIES
(Spray Zones)

Ignition sources:

While any spray painting is being carried out

outside a spray painting booth, a person must
not, within 6 metres of the immediate vicinity
in which spray painting is being carried out,
light or introduce any source of ignition, or
start or set in motion the engine of any plant.
 CONTROL STRATEGIES
(Safe Working Procedures)

Administrative controls:

An article to be spray painted within a booth

must be placed in a position where the person
using the spray gun always has the spray
between himself or herself and the exhaust
fan or appliance.
 CONTROL STRATEGIES
(Safe Working Procedures)

Administrative controls:

Turntables or other mechanical appliances of

impervious incombustible material must be
provided, where necessary, to ensure
compliance with; (previous ppt requirements).
 CONTROL STRATEGIES
(Personal Protective Equipment)

Personal protective equipment program:

z Selection
z Fit
z Use
z Maintenance
z Storage
z Training
z Supervision
z monitoring
 CONTROL STRATEGIES
(Personal Protective Equipment)

Respiratory protective devices:

If isocyanates are used in spray painting, a person

employed in the performance of the work must be
provided with, and use, a suitable respiratory protective
device that complies with the specifications of AS 1715
selection, use and maintenance of respiratory
protective devices and AS 1716 Respiratory protective
devices and that is, if the work is being carried out in a
spray painting booth, air supplied, or of a type
otherwise approved by the Director.
 CONTROL STRATEGIES
(Personal Protective Equipment)

PPE should be:

z Used in conjunction with other control measures

z Suitable, clean, functional, and

z fitted correctly, and

Workers must be informed and instructed to identify PPE

deficiencies / malfunctions and encouraged to report
the same.
 MAINTAINING STANDARDS
(General Provisions)

A spray painting booth and designated spray

zone must be cleaned on a regular basis to
ensure that any over-spray or residue from
painting is removed.
 MAINTAINING STANDARDS
(Specific Requirements)

It is essential that a detailed inspection

should be performed after any
maintenance work has been carried out, as
to ensure that maintenance work does not
reduce the level of safety established. This
shall include the:

z Equipment

z Installation, and

z Environment.
 MONITORING
(General Provisions)

Control measures should be:

z Regularly monitored and reviewed to make sure they

stay effective and do not create new risks

z Reviewed if work-related ill health or injury is evident

and or reported, and

z Reviewed to identify any new hazards if there is a

change to the substances being used and or
subsequent processes.
 RECORDS

Records must be retained in a suitable form

of all assessment reports that either
indicate or not indicate the need for:

z Maintenance

z Atmospheric monitoring

z Health surveillance, and

z Instruction & training.

When a business is to cease operating, where necessary,

all such records must be provided to the Director.