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Motor Vehicle Repair – Peter Woolgar
Motor Vehicle Repair (MVR)
• Industry structure– Main dealers and franchises– Independent/Family– Self employed
• Industry structure– Mechanical– Bodyshop– Mobile/peripatetic
HSE approach to MVR
• HSE dedicated team• Working with the industry
– MVR H&S Forum– Industry needs simple specific information
• Guidance– Website http://www.hse.gov.uk/mvr/index.htm– Example risk assessments– COSHH Essentials– HSG 261– INDG 356, 388
Key hazardous substances in MVR
Hazardous substance 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 Mechanical Dermatitis, skin cancer
Solvents, adhesives, sealants
Mechanical, bodyshops, and peripatetic
Dermatitis, acute respiratory problems
Vehicle fuels Mechanical Dermatitis
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
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.
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.
HSE Campaign 2004 - 08
• 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
Campaign - Other activity
• Training and inspection packs for labour inspectors
• Updates to HSE website • 10 myths• Videos• Revised free guidance
Key controls(1)
• Paint contents - labels and information• Beware alternative names
– eg 2 pack, 2K,
Key controls(2)
• Paint mixing– Well ventilated (10 air
changes/hour)– Proprietary system with
built in extraction (if possible)
– Replace lids– Trays for spillages
Key controls(3)
Paint Spraying - Use of spray booth/room
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?
Spray rooms
• Rooms have an extraction fan, usually in a side wall. Entry of replacement air may be planned, or more usually unplanned.
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
Isocyanate Exposure
• Spray roomo In the room = 1500 – 7000 ųg/m3o Sprayer = 1000 – 5000 ųg/m3• Spray bootho In the booth = 500 – 1500 ųg/m3o Sprayer = <600 ųg/m3
UK exposure limits – 20 ųg/m3 (8 hours)– 70 ųg/m3 (15 mins)
5 minute exposure pattern
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)
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
Theory of spray room
Reality of spray room
Effect on sprayer
Theory of downdraught booth
Reality of downdraught booth
Sprayer exposure
Effect of spray gun
Effect on sprayer
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?
Typical clearance time
• Spray booths – clearance time = 1 – 5 mins• Spray rooms – clearance time = 3– 20 mins
How to check clearance time?
• Fill booth with smoke, using ‘party’ smoke machine.
• Measure time to clear, check annually
Commercial vehicle spraying
• Spray booths for commercial vehicles– large volume– need professional type
smoke generator
Show clearance time
• Put up sign on booth/room
• Not exact – round up the time.
Key Controls (4)
• Respiratory Protective Equipment– types
Unsuitable RPE
• Do not accept any kind of filtering device– Easily overloaded, cannot smell or
taste isocyanate
Key controls (5)
• Gun cleaning• Clean in spray booth or
use proprietary equipment
Key controls (6)
• Health Surveillance– Annual lung function testing –
spirometry– Annual questionaire
• For new employees– On starting work, 6 weeks, 12
weeks, annual
If evidence that well controlled - questionaire
Key controls (7)
• Biological monitoring– Urine sample at end of shift– Analysis for diamine
metabolite
• Only method to check whether all controls working
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
Key messages summary
MVR Paint spraying1. Isocyanate paints used in virtually every bodyshop2. Spraying gives invisible mist - that can be breathed in3. Booths/room take time to clear – know the clearance
time4. Isocyanates cause occupational asthma - it can ruin lives5. Wear air fed breathing apparatus6. Check controls are working 7. Have regular health surveillance
Key hazardous substances in MVR
Hazardous substance 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 Mechanical Dermatitis, skin cancer
Solvents, adhesives, sealants
Mechanical, bodyshops, and peripatetic
Dermatitis, acute respiratory problems
Vehicle fuels Mechanical Dermatitis
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
Key hazardous substances in MVR
Hazardous substance 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 Mechanical Dermatitis, skin cancer
Solvents, adhesives, sealants
Mechanical, bodyshops, and peripatetic
Dermatitis, acute respiratory problems
Vehicle fuels Mechanical Dermatitis
Other hazardous substances in MVR
• Vehicle exhaust fumes – carbon monoxide– diesel fume
• Local exhaust ventilation
• Beware pits
Other hazardous substances in MVR
Hazardous substance 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 Mechanical Dermatitis, skin cancer
Solvents, adhesives, sealants
Mechanical, bodyshops, and peripatetic
Dermatitis, acute respiratory problems
Vehicle fuels Mechanical Dermatitis
Other hazardous substances in MVR
Welding • Fume
– Asthma– Pneumonia
• Local exhaust ventilation
Welding fume control
75mm150mm
Cross Draught
Welding - flammability risk
• Hot work – flammable fuels etc
• Gas welding/cutting– Safe storage– Turn off valves after
use– Hose maintenance
Key hazardous substances in MVR
Hazardous substance 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 Mechanical Dermatitis, skin cancer
Solvents, adhesives, sealants
Mechanical, bodyshops, and peripatetic
Dermatitis, acute respiratory problems
Vehicle fuels Mechanical Dermatitis
Other hazardous substances in MVR
Used engine oils• Dermatitis• Skin cancer
– Avoid contact– Wear gloves– Check skin
Key hazardous substances in MVR
Hazardous substance 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 Mechanical Dermatitis, skin cancer
Solvents, adhesives, sealants
Mechanical, bodyshops, and peripatetic
Dermatitis, acute respiratory problems
Vehicle fuels Mechanical Dermatitis
Other hazardous substances in MVR
Solvents - wide range• Dermatitis
– Avoid skin contact – Wear gloves– Check skin
• Inhalation – Good ventilation
• Flammable
Other hazardous substances in MVR
Adhesives/sealants• Some 2 pack are skin irritant/sensitisers• Dermatitis
– Avoid contact– Use dispensers– Wear gloves
Key hazardous substances in MVR
Hazardous substance 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 Mechanical Dermatitis, skin cancer
Solvents, adhesives, sealants
Mechanical, bodyshops, and peripatetic
Dermatitis, acute respiratory problems
Vehicle fuels Mechanical Dermatitis
Other hazardous substances in MVR
Vehicle fuels – Petrol, Diesel, Biofuels • Flammable
– Safe draining, storage• Dermatitis
– Avoid contact– Wear gloves– Check skin
General
• Good standard of washing facilities
Key messages summary
Skin conditions1. Dermatitis is common in MVR2. Materials can cause problems by
irritation, drying out the skin or allergy
3. Used engine oils can cause cancer4. Risk of skin problems can be reduced
byAvoiding contactProtect with suitable glovesCheck for early signs of disease
Information and references
• Topic Pack• Isocyanate spraying
– Inspection pack– Inspection checklist
http://www.hse.gov.uk/mvr/index.htm