Spray Painting And Powder Coating - SafeWork SA

Consulting workersWHS Act section 47Duty to consult workersA PCBU must consult, so far as is reasonably practicable, with workers who carry out workfor the business or undertaking and who are (or are likely to be) directly affected by a healthand safety matter.This duty to consult is based on the recognition that worker input and participation improvesdecision-making about health and safety matters and assists in reducing work-relatedinjuries and disease.The broad definition of a ‘worker’ under the WHS Act means a PCBU must consult, so far asis reasonably practicable, with employees, contractors and sub-contractors and theiremployees, on-hire workers, outworkers, apprentices, trainees, work experience students,volunteers and other people who are working for the PCBU and who are, or are likely to be,directly affected by a health and safety matter.Workers are entitled to take part in consultations and to be represented in consultations by ahealth and safety representative who has been elected to represent their work group.Consulting, co-operating and co-ordinating activities withother duty holdersWHS Act section 46Duty to consult with other duty holdersThe WHS Act requires a PCBU to consult, co-operate and co-ordinate activities with all otherpersons who have a work health or safety duty in relation to the same matter, so far as isreasonably practicable.There is often more than one business or undertaking involved in a housing constructionproject, who may each have responsibility for the same health and safety matters, eitherbecause they are involved in the same activities or share the same workplace.In these situations, each duty holder should exchange information to find out who is doingwhat and work together in a co-operative and co-ordinated way so risks are eliminated orminimised so far as is reasonably practicable.For example, if a PCBU engages a contractor to carry out spray painting at a workplace thenthe PCBU must work together with the contractor to coordinate management of the risksassociated with the spray painting work being carried out at that workplace.Further guidance on consultation is available in the Code of Practice: Work health and safetyconsultation, co-operation and co-ordination.Spray painting and powder coatingCode of PracticePage 8 of 57

Principal contractorsWHS Act section 309WHS management plan—duty to informThe principal contractor for a construction project has a specific duty under the WHSRegulations to document, in their WHS Management Plan for the project, the arrangementsin place for consultation, co-operation and co-ordination between the PCBUs at the site.1.4. Information, training, instructionand supervisionWHS Section 19Primary duty of careWHS Regulation 39Provision of information, training and instructionThe WHS Act requires that a PCBU ensure, so far as reasonably practicable, the provisionof any information, training, instruction or supervision that is necessary to protect all personsfrom risks to their health and safety arising from work carried out as part of the conduct ofthe business or undertaking.The PCBU must ensure that information, training or instruction provided to a worker aresuitable and adequate having regard to: the nature of the work carried out by the workerthe nature of the risks associated with the work at the time of the information, trainingand instruction, andthe control measures implemented.The PCBU must also ensure, so far as is reasonably practicable, that the information,training and instruction are provided in a way that is readily understandable to whom itis provided.Workers must be trained and have the appropriate skills to carry out a particular task safely.Training should be provided to workers by a competent person.Information, training and instruction provided to workers who carry out spray painting andpowder coating activities should also include: the proper use, wearing, storage and maintenance of personal protectiveequipment (PPE)how to work safely in hazardous environments, e.g. a confined spacefirst aid and emergency procedureshow to access safety data sheets (SDS) for hazardous chemicals, andthe nature of, and reasons for, any health monitoring if required.Training should be practical, and where relevant, include hands-on sessions, for examplecorrectly setting up a spray zone or practising emergency procedures.In addition to the PCBUs general duty to provide any supervision necessary to protect allpersons from work health and safety risks, the WHS Regulations also impose specific dutiesSpray painting and powder coatingCode of PracticePage 9 of 57

to provide supervision necessary to protect a worker from risks to health and safety incertain circumstances, for example, where the worker: uses, handles, generates or handles hazardous chemicalsoperates, tests, maintains, repairs or decommissions a storage or handling systems for ahazardous chemical, oris likely to be exposed to a hazardous chemical.The supervision must be suitable and adequate having regard to the risks associated withthe spray painting or powder coating activity and the information, training and instructionrequired under Regulation 39.Spray painting and powder coatingCode of PracticePage 10 of 57

2. The risk management processA risk assessment is not mandatory for spray painting and powder coating under the WHSRegulations. However, in many circumstances it will be the best way to determine themeasures that should be implemented to control risks. It will help to: identify which workers are at risk of exposuredetermine what sources and processes are causing that riskidentify if and what kind of control measures should be implemented, andcheck the effectiveness of existing control measures.Risk management is a systematic process to eliminate or minimise the potential for harm topeople.2.1. Identifying the hazardsThe first step in the risk management process is to identify all hazards associated with spraypainting and powder coating. This involves finding things and situations which couldpotentially cause harm to people. Hazards generally arise from the following aspects of workand their interaction: physical work environmentequipment, materials and substances usedwork tasks and how they are performed, andwork design and managementHazards may be identified by looking at the workplace and how work is carried out. It is alsouseful to talk to workers, manufacturers, suppliers and health and safety specialists andreview relevant information, records and incident reports. Potential hazards may also beidentified through: inspecting the materials and equipment that will be used during the spray painting orpowder coating process, andreading product labels, SDS and manufacturer’s instruction manuals.Table 1 lists the common hazards associated with spray painting or powder coating.Spray painting and powder coatingCode of PracticePage 11 of 57

Table 1 Examples of common hazards associated with spray painting and powder coatingHazardPotential harmHazardouschemicals Plant (machineryand equipment)Examplesdermatitis, respiratory illnessesand cancerssome hazardous chemicals arealso fire and explosion riskspaints, solvents, adhesives, resins,rust removers, rust converters,lacquers and degreasers injection injuries, being caught bymoving parts of machinery cancause fractures, bruises,lacerations, dislocations,permanent injuries or deathSpray booths, sanding, grindingequipment, airless spray equipment,compressed airHazardous manualtasks overexertion, sustained awkwardpostures or repetitive movementcan cause muscular strainrepetitive spraying action, lifting andpushing objects into placeFire and explosion serious burns and deathexposure to projectiles anddamage to propertyflammable paints and solvents incontact with an ignition source combustible dusts usedpowder coatingWorking at height falling objects, falls, slips andtrips can cause fractures, bruises,lacerations, dislocations,concussion, permanent injuriesor deathspray painting at height or of trucks,ships, aeroplanes or bridgesElectricity or staticelectricity exposure to electricity can causeshock, burns or death fromelectric shockelectricity and static electricity arealso sources of ignition forcombustible dusts and hazardousatmospheresusing electrical equipment, wiring ofand within equipment andelectrostatic charges Noise exposure to loud noise can causepermanent damage to hearingnoise from pumps, compressors andspray boothsConfined spaces exposure to hazardouschemicals, unsafe oxygen levels,potential for fire, explosionand engulfmentspraying inside the cavity of ships,aircraft or tanksHeat or highhumidity exposure to heat or high humiditycan cause burns, heat stroke andfatiguewearing impervious PPE, workingoutdoors or in a poorly ventilatedworkplaceSpray painting and powder coatingCode of PracticePage 12 of 57

2.2. Assessing the risksAssessing the risks of a hazard involves understanding the nature of the harm that could becaused by the hazard, how serious the harm could be and the likelihood of it happening.A risk assessment can help you determine: how severe a risk iswhether any existing control measures are effectivewhat action you should take to control the risk, andhow urgently the action needs to be taken.Hazards have the potential to cause different types and severities of harm, ranging fromminor discomfort to a serious injury or death. For example, exposure to chemicals used inspray painting or powder coating activities can adversely affect a worker’s health in waysranging from minor illness such as headaches, to major illness such as asthma and cancer.Many liquid and powder paints contain flammable substances. Spray painting vapours andmists and powder paints used in powder coating can spread rapidly, particularly in anenclosed space, and create a potentially explosive atmosphere. If the aerosol, mist, vapouror powder paint is ignited, for example by static electricity, open flame, a lit cigarette orspark, it could result in an explosion that could destroy the building and kill or injure anyonenearby.Many hazards and their associated risks are well known and have well established andaccepted control measures. In these situations, the second step to formally assess the risk isnot required. If after identifying a hazard you already know the risk and how to control iteffectively, you can implement the controls without undertaking a risk assessment.A risk assessment may be appropriate to reuse in situations where all the hazards, tasks,things or circumstances are the same and no worker or other person will be exposed togreater, additional or different risks.In some circumstances, a risk assessment will assist to: identify which workers are at risk of exposuredetermine what sources and processes are causing the riskidentify if and what kind of control measures should be implemented, andcheck the effectiveness of existing control measures.The nature and severity of risks will depend on various factors, including the: properties of the paints and other substances being usedsurface coating of the items being painted or coated (e.g. whether they contain lead orother toxic materials)equipment being usedconditions under which the spray painting or powder coating is carried out (e.g. confinedor restricted spaces), andskills, competence and experience of the worker.The following questions may help to assess the risk: How often, and for how long, will exposure to the hazard occur?In the event of exposure to the hazard, will the outcome be severe, moderate or mild?How do workers interact with the hazard (e.g. being exposed to hazardous chemicals bybreathing it in or skin contact)?Is there evidence of exposure (e.g. dust or fumes visible in the air, chemical odours,spills, splashes)?What are the conditions under which spray painting is carried out (e.g. in a spray boothor in a partially or enclosed space)?Spray painting and powder coatingCode of PracticePage 13 of 57

What are the skills, competence and experience of the operator?Further guidance on the risk management process and the hierarchy of control measures isavailable in the Code of Practice: How to manage work health and safety risks.Assessing the risks of hazardous chemicalsAs a PCBU, once you have listed all the hazardous chemicals used in each stage of thespray painting or powder coating activity, you should review the information on the labelsand safety data sheets (SDS) to determine the nature and severity of the harm. Dependingon the chemical, the severity of the harm could range from minor to major, for example fromminor skin irritation to chronic lung disease or cancer.Using information found in the label and SDS, spray painting and powder coating chemicals,mixtures or materials can be put into three hazard categories as provided in Table 2 below.Many chemicals that are used in spray painting, including two-part polyurethane paints,contain isocyanates and toluene (an ingredient in many oil-based paints), and in powdercoating, triglycidyl isocyanurate, hydrofluoric acid and chromic acid are known hazardouschemicals. These chemicals are known to present significant health risks and should beassessed as high risk.Table 2 Hazard categories of spray painting or powder coating chemicals, mixture and materialsRiskExamplesHigh riskA chemical should be considered as high risk if it is: Medium riskA chemical should be considered medium risk if it is: Low riskcarcinogenicmutagenic, genotoxic or has reproductive hazardsaffects the central nervous system (including affecting hearing dueto ototoxic effects 1).a skin or respiratory sensitiser or if it is corrosive or has acuteirritant effectsa chemical which causes severe effects after a single, repeated orprolonged exposure, ora flammable liquid, vapour or aerosol.an contain organic solvent that are not already assessed as highriska flammable liquid, ora combustible dust.A chemical should be considered low risk if it does not meet the aboveconsiderations.The level of risk depends not only on the toxicity or flammability of the hazardous chemicalbut also on the nature of exposure. This may include frequency of use, quantities used,effectiveness of existing controls (such as exhaust or ventilation systems) and the processesinvolved at the workplace. For example, some spray painting processes may be moreThat is, they may cause hearing loss or exacerbate the effects of noise. Evaluating the use of these chemicals should becarried out in conjunction with the Code of Practice: Managing Noise and Preventing Hearing Loss at Work.1Spray painting and powder coatingCode of PracticePage 14 of 57

suitable than others when attempting to minimise the exposure of a hazardous chemical orthe risk of fire (see Table 3).Further guidance on managing risks associated with hazardous chemicals is available in theCode of Practice: Managing risks of hazardous chemicals in the workplace.Table 3 Characteristics of spray painting and powder coating activitiesProcessCharacteristicsConventional compressed air(low pressure) spray painting extensive overspray of potentially hazardous chemicalsbounce of potentially hazardous chemicals in cavities andat corners (rebound)Airless (high pressure)spray painting risk of injection injury and static electricity that could causea sparkless overspray, bounce and aerosol than conventional airsprayingrelatively high viscosity paints can be used (less solvent isneeded in the paint)higher capacity (flow rate) and faster applicationAir assisted airless spraypainting risk of injection injuryless aerosol and overspray than conventional air sprayingHot spraying increase of potential for fire or explosionuses very little thinnerreduced oversprayPressure pots risk from over pressurisation (pressure should be releasedbefore opening to refill)potential for vessels damage and incorrectly fitted hosesand couplingsawkward hazardous manual tasksmore solvents used

Powder coating is a process by which electrostatically charged powder is applied onto an earthed object. Spray painting and powder coating are carried out in a variety of industries. For example, items that are commonly spray painted include motor vehicles, buildings, furn