Spray painting

Spray painting is used in a variety of industries and by a variety of workers. It is used to

paint motor vehicles, buildings (inside and outside), structures, furniture, white goods,
boats, ships, aircraft and machinery.

Spray painting is associated with a number of health and safety concerns, so employers
and self employed people who conduct this activity must manage the risks in their
workplaces.

In order to understand the workplace health and safety requirements for spray painting,
and your obligations under the law you must consider and understand relevant legislation
and codes of practice.

What law applies

Legal obligations, legislation, guides

Hazardous substances
Hazardous substances used in spray painting, MSDS, labelling, two pack paint and
varnish systems

Plant and equipment

How to use spray painting plant and equipment safely, spray painting booths, spray
painting motor vehicles

Flammable hazards
Types of flammable substances used in spray paining, preventing fire and explosion, heat
stress, electrical safety

Other hazards
Confined spaces, noise, workplace environment, manual tasks

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What law applies
In order to understand the workplace health and safety requirements for spray painting,
and your obligations under the law you must consider and understand relevant
legislation and codes of practice.

General health and safety obligations

To understand your obligations and safety requirements you must be familiar with the:
Workplace Health and Safety Act 1995 which imposes obligations on people at
workplaces to ensure workplace health and safety. The Workplace Health and Safety
Act 1995 also helps you to meet your workplace health and safety obligations through:

• The Workplace Health and Safety Regulation 2008 which describes what must
be done to prevent or control certain hazards which cause injury, illness or death
• codes of practice, which are designed to give practical advice about ways to
manage exposure to common risks. In particular, the Risk Management Code of
Practice 2007 should be read in conjunction with information on PPE.

Every Queensland employer must have workers’ compensation insurance. Most

employers insure with WorkCover Queensland, while a small number of large
organisations have their own insurance. This insurance coverage ensures that
employees injured at work receive financial support.

What you must do

It is a requirement of the Workplace Health and Safety Act 1995 that risks must be
assessed and control measures then implemented and reviewed to prevent or minimise
exposure to the risks.

If the Workplace Health and Safety Regulation 2008 describes how to prevent or
minimise a risk at your workplace you must do what the regulation says. If there is a
code of practice that describes how to prevent or minimise a risk at your workplace you
must do what the code says or adopt and follow another way that gives the same level
of protection against the risk.

If there is no regulation or code of practice about a risk at your workplace you must
choose an appropriate way to manage exposure to the risk. People must, where there is
no regulation or code of practice about a risk, take reasonable precautions and exercise
proper diligence against the risk.

See the Risk Management Code of Practice 2007 for further information.

Specific regulations for spray painting

Part 16 of the Workplace Health and Safety Regulation 2008 applies to the use of
hazardous substances in spray painting operations.

The Spray Painting Guide for Employers and Operators provides practical advice to all
industries where spray painting occurs about how to manage typical risks to health and
safety from spray painting.
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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 National exposure standards for atmospheric
contaminants in the occupational environment.

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
• Use fans and natural fresh air (as well as local exhaust ventilation) to displace
contaminated air. Systems should comply with Australian Standard AS 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 Substances

Advisory Standard 2003 (now known as a Code of Practice).
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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. A list of designated doctors is available from
Workplace Health and Safety Queensland.

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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 Australian Standard AS/NZS
4114.1 Spray painting booths, designated spray painting areas and paint mixing rooms -
Design, construction and testing 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.
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 • 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.

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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.
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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.

There is more information available on the electrical safety website.

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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 Noise Advisory Standard 2004
(now known as a Code of Practice).

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
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 • 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 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 Advisory Standard 2000
(now known as a Code of Practice).

© The State of Queensland (Department of Employment and Industrial Relations) 2008.

The State of Queensland makes no statements, representations, or warranties about the accuracy or completeness of, and you should
not rely on, any information contained in this document.

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