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Motor Vehicle Repair – Peter Woolgar
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Motor Vehicle Repair (MVR)
Industry structure Main dealers and franchises Independent/Family Self employed Mechanical Bodyshop Mobile/peripatetic
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HSE approach to MVR HSE dedicated team Working with the industry
MVR H&S Forum Industry needs simple specific information Guidance Website Example risk assessments COSHH Essentials HSG 261 INDG 356, 388
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Key hazardous substances in MVR
Where found Health risk Isocyanate based paints Bodyshops and peripatetic Asthma, Dermatitis Bodywork fillers and dusts Bodyshops Dermatitis, respiratory irritation. lead? Vehicle exhaust fumes Mechanical Eye and respiratory irritation, lung cancer? Welding fume Mechanical, bodyshops, and peripatetic Asthma, pneumonia Used engine oils Dermatitis, skin cancer Solvents, adhesives, sealants Dermatitis, acute respiratory problems Vehicle fuels Dermatitis
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Top cause of occupational asthma in UK
Isocyanates Found in MVR paints hardener in 2 pack paints used in some base coats and nearly all lacquers also in many water-based paints Top cause of occupational asthma in UK Vehicle paint sprayers 80x more likely to get asthma than average worker
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Occupational asthma Early symptoms of asthma include: recurring blocked or runny nose; recurring sore or watering eyes; chest tightness, often occurring outside working hours; persistent cough; wheezing; and breathlessness.
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Occupational asthma Continued exposure may lead to permanent and severe asthma. There is no cure. Once affected breathing in small amount of isocyanate can trigger an attack. Affected employees would have to give up their current job.
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HSE Campaign Objective: to reduce incidence of occupational asthma in MVR by 20+% Strategy: Provide information on risks and controls to individual bodyshops Main activities: half day workshops for bodyshop owners/managers and sprayers communication through trade associations, magazines etc Based on evidence of effect, activity, cause and solutions
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Campaign - Other activity
Training and inspection packs for labour inspectors Updates to HSE website 10 myths Videos Revised free guidance
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Paint contents - labels and information Beware alternative names
Key controls(1) Paint contents - labels and information Beware alternative names eg 2 pack, 2K,
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Key controls(2) Paint mixing Well ventilated (10 air changes/hour)
Proprietary system with built in extraction (if possible) Replace lids Trays for spillages
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Key controls(3) Paint Spraying - Use of spray booth/room
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Isocyanate Exposure limits
UK exposure limits for isocyanate 20 microgram/m3 (8 hours) 70 microgram/m3 (15 mins) microgram (ųg) = 10-6 gm What are exposures like during spraying?
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Spray rooms Rooms have an extraction fan, usually in a side wall. Entry of replacement air may be planned, or more usually unplanned.
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Spray booths Spray booths are designed with air blown in and sucked out through filters in a planned way. Often ‘down-draught’, with air blown in through the ceiling and out through the floor
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Spray room Spray booth Isocyanate Exposure
In the room = 1500 – 7000 ųg/m3 Sprayer = 1000 – 5000 ųg/m3 Spray booth In the booth = 500 – 1500 ųg/m3 Sprayer = <600 ųg/m3 UK exposure limits 20 ųg/m3 (8 hours) 70 ųg/m3 (15 mins)
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5 minute exposure pattern
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Purpose of spray room/booth
Stop the spread of the fine paint mist Reduce exposure of sprayer Prevent exposure to others inside and outside the workplace Control the spread of vapour (during baking)
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How do spray rooms/booths work
Negative pressure is created by air extraction – prevents spread of mist/vapour into the workplace Spray mist is diluted and displaced – reducing exposure of users Exhaust air is filtered or discharged safely – prevents, or minimises, exposure of others
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Theory of spray room
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Reality of spray room
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Effect on sprayer
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Theory of downdraught booth
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Reality of downdraught booth
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Sprayer exposure
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Effect of spray gun
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Effect on sprayer
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Sprayer behaviour Need/want to look at paint finish. Want to remove RPE. How long does it take for the air to clear of the paint mist?
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Typical clearance time
Spray booths – clearance time = 1 – 5 mins Spray rooms – clearance time = 3– 20 mins
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How to check clearance time?
Fill booth with smoke, using ‘party’ smoke machine. Measure time to clear, check annually
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Commercial vehicle spraying
Spray booths for commercial vehicles large volume need professional type smoke generator
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Show clearance time Put up sign on booth/room Not exact – round up the time.
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Respiratory Protective Equipment
Key Controls (4) Respiratory Protective Equipment types
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Do not accept any kind of filtering device
Unsuitable RPE Do not accept any kind of filtering device Easily overloaded, cannot smell or taste isocyanate
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Key controls (5) Gun cleaning Clean in spray booth or use proprietary equipment
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Key controls (6) Health Surveillance For new employees
Annual lung function testing – spirometry Annual questionaire For new employees On starting work, 6 weeks, 12 weeks, annual If evidence that well controlled - questionaire
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Biological monitoring
Key controls (7) Biological monitoring Urine sample at end of shift Analysis for diamine metabolite Only method to check whether all controls working
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Isocyanate exposure from SMART
SMART = small/medium area repair technique Mini spray gun < 2bar Exposure time < 1 min Sprayer wears air-fed RPE Indoors – room/booth = clearance time, or 30 mins in workshop Outdoors - no exposure > 5-10m
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Key messages summary MVR Paint spraying
Isocyanate paints used in virtually every bodyshop Spraying gives invisible mist - that can be breathed in Booths/room take time to clear – know the clearance time Isocyanates cause occupational asthma - it can ruin lives Wear air fed breathing apparatus Check controls are working Have regular health surveillance
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Key hazardous substances in MVR
Where found Health risk Isocyanate based paints Bodyshops and peripatetic Asthma, Dermatitis Bodywork fillers and dusts Bodyshops Dermatitis, respiratory irritation, lead? Vehicle exhaust fumes Mechanical Eye and respiratory irritation, lung cancer? Welding fume Mechanical, bodyshops, and peripatetic Asthma, pneumonia Used engine oils Dermatitis, skin cancer Solvents, adhesives, sealants Dermatitis, acute respiratory problems Vehicle fuels Dermatitis
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Other hazardous substances in MVR
Bodywork fillers and dusts 2 pack fillers – reactive Hardeners = skin irritants, & some skin sensitisers Total dust Lead in older vehicles Use least harmful fillers Protect skin when applying Minimise grinding Local exhaust ventilation Dust mask
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Key hazardous substances in MVR
Where found Health risk Isocyanate based paints Bodyshops and peripatetic Asthma, Dermatitis Bodywork fillers and dusts Bodyshops Dermatitis, respiratory irritation. lead? Vehicle exhaust fumes Mechanical Eye and respiratory irritation, lung cancer? Welding fume Mechanical, bodyshops, and peripatetic Asthma, pneumonia Used engine oils Dermatitis, skin cancer Solvents, adhesives, sealants Dermatitis, acute respiratory problems Vehicle fuels Dermatitis
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Other hazardous substances in MVR
Vehicle exhaust fumes carbon monoxide diesel fume Local exhaust ventilation Beware pits
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Other hazardous substances in MVR
Where found Health risk Isocyanate based paints Bodyshops and peripatetic Asthma, Dermatitis Bodywork fillers and dusts Bodyshops Dermatitis, respiratory irritation. lead? Vehicle exhaust fumes Mechanical Eye and respiratory irritation, lung cancer? Welding fume Mechanical, bodyshops, and peripatetic Asthma, pneumonia Used engine oils Dermatitis, skin cancer Solvents, adhesives, sealants Dermatitis, acute respiratory problems Vehicle fuels Dermatitis
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Other hazardous substances in MVR
Welding Fume Asthma Pneumonia Local exhaust ventilation
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Welding fume control Cross Draught 150mm 75mm
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Welding - flammability risk
Hot work – flammable fuels etc Gas welding/cutting Safe storage Turn off valves after use Hose maintenance
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Key hazardous substances in MVR
Where found Health risk Isocyanate based paints Bodyshops and peripatetic Asthma, Dermatitis Bodywork fillers and dusts Bodyshops Dermatitis, respiratory irritation. lead? Vehicle exhaust fumes Mechanical Eye and respiratory irritation, lung cancer? Welding fume Mechanical, bodyshops, and peripatetic Asthma, pneumonia Used engine oils Dermatitis, skin cancer Solvents, adhesives, sealants Dermatitis, acute respiratory problems Vehicle fuels Dermatitis
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Other hazardous substances in MVR
Used engine oils Dermatitis Skin cancer Avoid contact Wear gloves Check skin
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Key hazardous substances in MVR
Where found Health risk Isocyanate based paints Bodyshops and peripatetic Asthma, Dermatitis Bodywork fillers and dusts Bodyshops Dermatitis, respiratory irritation. lead? Vehicle exhaust fumes Mechanical Eye and respiratory irritation, lung cancer? Welding fume Mechanical, bodyshops, and peripatetic Asthma, pneumonia Used engine oils Dermatitis, skin cancer Solvents, adhesives, sealants Dermatitis, acute respiratory problems Vehicle fuels Dermatitis
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Other hazardous substances in MVR
Solvents - wide range Dermatitis Avoid skin contact Wear gloves Check skin Inhalation Good ventilation Flammable
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Other hazardous substances in MVR
Adhesives/sealants Some 2 pack are skin irritant/sensitisers Dermatitis Avoid contact Use dispensers Wear gloves
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Key hazardous substances in MVR
Where found Health risk Isocyanate based paints Bodyshops and peripatetic Asthma, Dermatitis Bodywork fillers and dusts Bodyshops Dermatitis, respiratory irritation. lead? Vehicle exhaust fumes Mechanical Eye and respiratory irritation, lung cancer? Welding fume Mechanical, bodyshops, and peripatetic Asthma, pneumonia Used engine oils Dermatitis, skin cancer Solvents, adhesives, sealants Dermatitis, acute respiratory problems Vehicle fuels Dermatitis
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Other hazardous substances in MVR
Vehicle fuels – Petrol, Diesel, Biofuels Flammable Safe draining, storage Dermatitis Avoid contact Wear gloves Check skin
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General Good standard of washing facilities
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Key messages summary Skin conditions Dermatitis is common in MVR
Materials can cause problems by irritation, drying out the skin or allergy Used engine oils can cause cancer Risk of skin problems can be reduced by Avoiding contact Protect with suitable gloves Check for early signs of disease
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Information and references
Topic Pack Isocyanate spraying Inspection pack Inspection checklist
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