Spray Painting and Coating

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Course Outline – Spray Painting and Coating

1. Why Take Spray Painting and Coating Training?

2. Methods of Application
3. Approved Locations
4. Spray Areas
5. Spray Booths
6. Spray Rooms
7. Housekeeping
8. Fire Prevention
9. Handling Flammable and Combustible Liquids
10. Equipment
11. Maintenance
12. Health Hazards
13. Summary
Why take spray painting and coating training?

Spray painting and coating safety is important!

• Spray painting and coating are widely performed in a variety of

industries.

• Many hazards are associated with spray finishing.

• These may include health hazards and fire or explosion hazards.

• This presentation is to help you become knowledgeable about

many of the hazards and the precautions which should be taken to
avoid injury and illness resulting from spray painting and coating.
 Methods of Application

• Many different spraying methods are used to apply paints and

coatings.

• The most common methods are:

► Compressed air
► Airless (high pressure)
► Electrostatic
Methods of Application

Compressed air application:

• Sometimes called conventional

spray painting, this method uses
compressed air to force the paint
through a nozzle into a fine spray.

• This method usually requires more

solvent than other methods,
making a significant fire hazard.
Methods of Application

Airless application:

• Paint is forced through a small opening under very high pressure

causing a spray.

• Smaller amounts of solvent are used.

• The high pressure creates a hazard of injecting paint through the skin.
Methods of Application

Electrostatic application:

• Paint particles are negatively

charged when passing through
a paint gun.

• The paint is attracted to the

object being painted which is
positively charged and
grounded.

• Sparking hazards are of

particular concern.
Approved Locations

• There are three locations which provide safe conditions for spraying
flammable and combustible paints and coatings:
1. Spray areas
2. Spray booths
3. Spray rooms

• The concern is with fire and explosion, as well as controlling airborne

exposure to paint ingredients.

National standards:

• The National Fire Protection Association (NFPA) has established

standards for the design and construction of spray booths/rooms as well
as set provisions for spray areas.

• OSHA has adopted NFPA Standards.

Approved Locations

Ventilation:

• Adequate ventilation is necessary to control fire, explosion, and health

hazards when spraying.

• Health hazards may occur from exposure to excessive amounts of

paint chemicals.
Spray Areas

Spray areas:

• A spray area is any area where

flammable and combustible materials
are sprayed.

• Usually this refers to a designated

area outside of a spray booth or room.

• Spray painting indoors but outside of

a booth or room is not considered
acceptable.

• A booth or room is required for

production spray finishing
Spray Areas

Design and construction:

• Ignition sources: Designated spray areas need to be located where there

is no risk of vapors igniting.

• Examples of ignition sources include:

► Non-explosion proof electrical equipment (lighting and outlets)

► Welding or open flames
► Grinding (sparks)

• Only special explosion proof wiring and fixtures approved for hazardous
locations are considered safe where flammable and combustible gases
are present.

► This type of electrical equipment will not ignite vapor-air mixtures.

Spray Areas

Design and construction (continued):

• Hot surfaces
► It is important that hot surfaces are not
located in spraying areas where deposits
of combustible residues accumulate.
► An example of a hot surface is a steam
pipe.

• Minimum distance
► Ignition sources must be controlled within
20 feet of a spray location.

• Sprinklers
► Sprinklers or other automatic
extinguishing equipment are necessary
for spray operations, as well as ducting
systems.
Spray Booths

Spray booths:

• A spray booth is an enclosure with an open face which is mechanically

ventilated.

• A booth may use baffles, dry filters, or a water washing (waterfall)

system to remove paint overspray before it enters the exhaust duct.
Spray Booths

Design and construction:

• There are numerous design and construction requirements for spray

booths.

• Requirements have been established for the purpose of fire and staff
protection.

• Construction:

► Booths must be constructed of fireproof material:

• 18 gauge steel
• Concrete
• Masonry

► The exhaust duct must also be constructed of non-combustible

materials.

► Combustible floor surfaces are allowed (but not advised) so long as

they are covered with non-combustible material such as steel plates.
 Spray Booths

Proper ventilation for spray booths:

• Spray booths with dry filters need to have a flow rate across the open face of
the booth of 100 feet per minute (fpm).
► For electrostatic spray operations a minimum of 60 fpm is required.

• Air intake openings to spray rooms or rooms containing booths need to be

adequate to allow sufficient exhaust ventilation.
Spray Booths

Proper ventilation for spray booths (continued):

• Make-up air: Air exhausted from spraying operations can not be re-
circulated.
► Make-up air needs to be supplied in the same direction as it is being
exhausted, and should not be greater than twice the air exhaust
velocity.

• Gauge or alarm: For conventional dry filter type booths or rooms, an

audible alarm, visible gauge, or similar device must be installed.
► This is to indicate that the filters are not clogged up and that there is
adequate air velocity.

• When baffles or a water-wash system is used, air flow velocities at the

booth opening must meet the requirements of the table on the following
slide.
 Spray Booths

Operating conditions for objects Crossdraft fpm Design

completely inside booth

Electrostatic and automatic airless

operation contained in booth without 50 large booth (range 50-75)
Negligible
operator 100 small booth (range 75-125)

100 large booth (range 75-125)

Air-operated guns, manual or automatic Up to 50
150 small booth (range 125-175)

150 large booth (range 125-175)

Air-operated guns, manual or automatic Up to 100
200 small booth (range 150-250)
Spray Rooms

Spray rooms:

• A spray room is a fully enclosed room with mechanical exhaust.

• It is usually used for the spray painting of large objects such as

automobiles.
Spray Rooms

Design and construction:

• In general, the design and
construction requirements for spray
rooms is the same as for spray
booths:
► Rooms must be constructed of
substantial non-combustible
material having a fire resistive
classification.

► Other booth requirements

mentioned need to be followed,
e.g., electrical, grounding,
lighting, sprinklers, etc.

Proper ventilation for spray rooms:

• Ventilation in spray rooms must be
adequate to allow a minimum of 30
air changes per hour.
Housekeeping

An excellent housekeeping program is

important:
• Residue build-up can increase fire risks.

• There is the possibility of spontaneous

combustion, especially if residues of
different types of coatings build-up on top
of each other.

• It is necessary to keep deposits of paint

and coating residues from accumulating in
spray areas, booths, and rooms with
regular cleaning.

• If different combinations of coatings are

used which may react and contribute to
spontaneous combustion, then cleaning
must be conducted between coats.
 Housekeeping

• Interiors of spray booths and rooms must be cleaned

(non-sparking tools must be used for this purpose):
► Exhaust ducts
► Exhaust fan blades
► Sprinkler system heads

Residues and wastes:

• Residue scrapings, used rags, waste paper, and other
debris which may contain flammable or combustible
liquids and paint residue need to be removed and
placed in specific containers.

• Containers must be made of metal, have self- closing

metal and sealed lids, and be properly labeled.

• They must be emptied at least once a day.

Fire Prevention

Meeting construction requirements alone will not

eliminate potential fire hazards from spray
painting.

Regular maintenance at spray painting

operations is important in preventing fire.

Smoking:
• Smoking is not permitted in areas where
flammable and combustible liquids are kept
and at spraying operations.

• “NO SMOKING” signs need to be posted at

all spraying areas and paint and solvent
storage areas.
Fire Prevention

Other ignition sources:

• No open flame or spark producing
equipment are allowed at spraying
operations.

• Hot surfaces are not allowed where

combustible residues may accumulate (an
example of this is a space heater).

Sprinklers:

• If a fire breaks out in a booth, chances are

that the fire will be controlled if the booth
has sprinklers.

• Sprinklers must be installed both upstream

and downstream from the filters.

• The exhaust duct also needs to have

sprinklers.
Fire Prevention

Bonding and grounding:

• When flammable liquids are

transferred from one container to
another, this can result in static
sparks igniting vapors.

• To prevent this, an electrical

connection or bonding wire must
connect the two (metal)
containers.

• The two containers can also be

connected to electrical grounds
to prevent sparks.

• Dispensing containers such as

drums always need to be
grounded.
Fire Prevention

Bonding and grounding (continued):

• Containers more than one quart need to be grounded and bonded.

• Piping systems for flammable liquids need to be permanently grounded.

• Be sure that grounding systems are continuous to earth.

Handling Flammable and Combustible Liquids

Certain safe work practices need to be followed to address fire hazards when
handling flammable and combustible solvents.

Storage:

• The quantity of flammable and combustible liquids kept in the vicinity of a

spray operation needs to be kept to a minimum (this normally refers to the
amount used in one day or work shift).

• Storage of large quantities of flammable and combustible liquids at a spray

operation would increase the intensity of the fire if one broke out, possibly
causing the fire to spread and cause more damage.

• No more than 120 gallons of flammable and combustible liquids (660

gallons in portable tanks) can be stored in an area of a building except in
an approved storage room.
Handling Flammable and Combustible Liquids

Storage (continued):

• For extremely flammable liquids with a

boiling point below 100o F e.g., Ethyl
Ether, only 25 gallons in containers can be
stored in a location outside of an approved
storage room.

• An approved storage room must have

special fire-resistant construction,
explosion-proof wiring and lighting and
meet other requirements.
Handling Flammable and Combustible Liquids

Approved containers:

• Only certain containers or piping systems should be

used to bring flammable or combustible liquids into a
spray room or booth.

• Original closed containers or approved safety cans

are considered acceptable (piping systems are also
sometimes used).

Transferring liquids:
• The transfer of flammable or combustible liquids in a
building must be through a closed piping system,
from safety cans, with a device drawing liquid through
the top of a container, e.g., a pump, or with a self-
closing valve.

• For containers over 60 gallons, only approved pumps

are allowed.
Equipment

Electrical equipment:

• Electrical equipment in spray booths and areas

immediately adjacent to booth openings must
be approved explosion-proof types.

• This includes such incidental equipment as

electrical space heaters, portable sanders, and
radios.

• For electrostatic spraying, most electrical

equipment such as transformers, power packs,
and control apparatus need to be located
outside the booth.

• The electrostatic gun itself can be located in the

booth.
Equipment

Exhaust fan:

• To prevent ignition of vapors, electric

motors driving exhaust fans must be
outside booths or ducts.
• The fan belt must also be placed
outside of the duct unless the belt is
enclosed.
• The fan rotating element needs to be
non-sparking.

Deflector:

• A 2 1/2 inch deflector or curtain is

needed at the upper edge for booths
with front openings greater than 9
square feet.
Maintenance

Grounding maintenance:

• All metal parts of a spray booth including pipes and ducts need to be
grounded.
► If an airless system is used, then the spray gun and metal objects
must also be grounded.

• Electrostatic spraying requires special care.

► The gun, the object being painted, and all conductive equipment
need to be grounded.

• Hooks holding objects need to be cleaned to bare metal to ensure

grounding.

• When a hand-held gun is used, the gun must be held twice the sparking
distance or at least 12 inches from the piece and all other conductive
equipment.
Maintenance

Interior surfaces:

• Interior surfaces need to be smooth to prevent pockets of paint and coating

residues.
Maintenance

Lighting:

• Regular fixed lighting can be used to

light a booth so long as the lights are
separated from the booth by non-
combustible panels.

• An example of a non- combustible

transparent panel is sealed glass which
is protected against breakage.

• Portable lamps are not permitted.

• Explosion-proof lights are acceptable.

 Health Hazards

Health hazards:

• Many types of painting and coating materials

with different potential health effects are applied
in industry including solvents, Hexavalent
chromium, lead, and other toxic chemicals.

• It is not possible to describe fully in this

presentation the health hazards from all the
spray finishing materials. Refer to the Hazard
Communication Plan and applicable Safety Data
Sheets.

• Therefore this section will concentrate on health

hazards of some of the most common hazardous
materials.

• A thorough hazard assessment of all materials

and establishment of proper controls before
materials are handled is necessary.
Health Hazards

Organic solvents:

• Beside being fire hazards, organic solvents are known to affect the
central nervous system, liver and blood forming tissue.

• Solvents act as depressants and anesthetics on the system.

• Due to the large number and types of solvents, specific effects vary
widely depending on the actual solvent.
► Some solvents are irritants to mucous membranes, some affect the
liver and kidneys, and others affect the blood system.

• Review the Safety Data Sheets and follow controls listed!

Health Hazards

Organic solvents (continued):

• Solvents dissolve the natural fats and oils in the skin.

• Excessive skin contact will cause dermatitis, and inflammation of the

skin.

• Solvents should not be used to clean the hands or other body parts.
Health Hazards

Isocyanates:

• Isocyanates are hardeners found in polyurethane paints and some

lacquers.

• Sometimes they are added separately to paints.

• Inhalation of isocyanates may cause an asthma-like attack characterized by

difficulty in breathing and a constricted feeling.

• Some people develop sensitization, so that asthma symptoms appear even

at extremely low concentrations.

• Irritation to the skin and eyes can also result from contact with isocyanates.

• When respirators are used as protection against overexposure to

isocyanates, only supplied air types are allowed.

• Use of air purifying respirators is not acceptable due to poor warning

properties (odor).
Health Hazards

Epoxies:

• Epoxies are mild to strong skin irritants and some are allergic skin
sensitizers.

• This does not apply to fully cured epoxies but applies to the uncured resins
and curing agents.

• Some curing agents, particularly certain amines may cause burns and eye
damage upon contact.
Health Hazards

Lead:

• Although becoming less common, lead

is still found in some paints (other
hazardous metal ingredients may exist
as well, such as, chromium, copper, etc.
in paints).

• When inhaled, lead is absorbed through

the lungs and upper respiratory tract.

• If such things as food or cigarettes are

handled with lead contaminated hands,
the lead may result in ingestion.

• Chronic overexposure to lead may result

in severe damage to the nervous,
kidney, reproductive, and blood forming
systems of the body.
Health Hazards

Chromium (chromates):

• Exposure to certain chromates

used in paint pigments poses a
cancer risk.

• Other toxic metals found in

certain paints include antimony,
copper, cadmium, strontium, and
mercury, etc.

• Review the Safety Data Sheets

(SDSs) and specific OSHA
standards before handling and
establish proper controls and
monitoring evaluations.
Health Hazards

Deflocculants:

• Deflocculants are sometimes used in

water wash booth systems to
minimize foaming.

• They can be corrosive and present

an eye and skin hazard.

• Suitable eye and skin protection

needs to be specified, such as
chemical goggles, and should be
worn if there is a chance of
splashing.

• An eyewash/safety shower is needed

in the vicinity.
Summary

• Be knowledgeable of the health and fire risks.

• Establish proper handling controls and hazard communication training

before handling materials through your hazard assessment process.

• Identify loss sources and needed controls.

• Train and ensure all workers exposed are aware of the hazards and
needed controls.

• Observe and communicate.

• Analyze continual improvement.

 ATALIAN. For a better performance

For more information, please contact:

safety.us@atalianworld.com

ATALIAN Global Services

417 Fifth Avenue, New York, NY 10016
www.atalian.us