Common Hazards in Spray Booths and How to Mitigate Them

At Egmont Air, we’ve been in the business of Spray Booths for over 25 years. Spray booths are essential in many industries, offering a controlled environment for applying paint and coatings. However, they also come with several hazards that, if not properly managed, can pose significant risks to workers, facilities, and the environment. Understanding these hazards and implementing effective mitigation strategies is crucial to maintaining a safe and efficient workspace. In this blog, we will explore some of the most common hazards in spray booths and provide actionable tips on how to address them.

1. Fire and Explosion Risks

The Hazard:

One of the most significant dangers in spray booths is the risk of fire and explosion. The materials used in spray applications, such as paints, solvents, and coatings, are often flammable. These substances can easily ignite if they come into contact with an ignition source, such as electrical equipment, static electricity, or even a spark from machinery. A key industry that needs diligence in this area is Collision Repair Services. Worksafe suggests that appropriate spray booths, regularly maintained, and with filters up-to-date is a key way to ensure safety in these high explosive environments.

Mitigation Strategies:

  • Proper Ventilation: Ensure that your spray booth is equipped with a high-quality ventilation system that can effectively remove flammable vapours from the air. This reduces the concentration of hazardous substances and minimises the risk of ignition.
  • Explosion-Proof Equipment: Use explosion-proof lighting, fans, and other electrical components within the spray booth. These are specifically designed to prevent sparks or other ignition sources that could lead to a fire or explosion.
  • Regular Maintenance and Inspections: Conduct regular inspections and maintenance of all equipment and systems within the spray booth. This includes checking for any potential sources of ignition and ensuring that all safety features are functioning correctly by trained and qualified personnel.
  • Fire Suppression Systems: Install automatic fire suppression systems within the spray booth. These systems can quickly extinguish a fire before it has a chance to spread, protecting both workers and the facility.

2. Exposure to Toxic Fumes

The Hazard:

Spray booths often involve the use of paints, solvents, and coatings that emit toxic fumes. Prolonged exposure to these fumes can lead to serious health issues, including respiratory problems, skin irritation, and even long-term conditions such as occupational asthma or cancer.

Mitigation Strategies:

  • Personal Protective Equipment (PPE): Workers should always wear appropriate PPE, such as respirators, gloves, and protective clothing, when working in a spray booth. This provides a critical barrier between them and the harmful substances they may encounter.
  • Effective Filtration Systems: Install high-efficiency particulate air (HEPA) filters and activated carbon filters within the spray booth’s ventilation system. These filters are designed to capture and neutralise harmful fumes and particles, ensuring cleaner air inside and outside the booth.
  • Air Monitoring: Implement air quality monitoring systems to regularly check the concentration of hazardous substances in the air. If levels exceed safe limits, take immediate action to improve ventilation or reduce the use of certain materials.
  • Training and Awareness: Ensure that all workers are trained on the risks associated with toxic fumes and the importance of using PPE and following safety protocols. Regular safety briefings can reinforce this knowledge and keep it top of mind.

3. Overspray and Contamination

The Hazard:

Overspray occurs when paint or coating particles do not adhere to the intended surface and instead become airborne. This can lead to contamination of the workspace, equipment, and even the final product. Additionally, overspray can create a slippery surface, increasing the risk of slips and falls.

Mitigation Strategies:

  • Proper Booth Design: Ensure that the spray booth is designed to contain overspray effectively. This includes using spray guns with appropriate pressure settings and maintaining the correct distance from the target surface to minimise overspray.
  • Regular Cleaning: Establish a routine cleaning schedule for the spray booth to remove any accumulated overspray. This helps maintain a clean working environment and prevents contamination of future projects.
  • Floor Mats and Slip-Resistant Coatings: Install slip-resistant floor mats or quick-change disposable covers in areas where overspray is likely to accumulate. This reduces the risk of slips and falls and ensures a clean working environment contributing to overall workplace safety.

4. Inadequate Ventilation and Airflow

The Hazard:

Inadequate ventilation and poor airflow within a spray booth can lead to a buildup of hazardous fumes and particles, increasing the risk of fire, explosion, and health issues. The law requires you to put controls in place that minimise the risk as far as reasonably practicable, and one such way to do this is by installing certified Spray Booth Equipment, maintaining it well and using it correctly. 

Mitigation Strategies:

  • Protection by Ventilation: The AS/NZS4114 standard for spraybooths specifies minimum rates of airflow for protection by ventilation. Along with this a dilution calculation should be provided by your spray-booth supplier which determines the maximum amount of solvents and flammable products permitted to enter the booth per hour, This ensures any hazardous vapours are adequately diluted to a safe level.
  • Balanced Airflow Design: Ensure that the spray booth is designed with balanced airflow that effectively captures and removes fumes and particles from the workspace. This includes proper placement of intake and exhaust vents to create a consistent flow of clean air.
  • Regular Ventilation Checks: Perform routine checks on the ventilation system to ensure it is functioning correctly. This includes inspecting ducts, filters, and fans for any blockages or signs of wear and tear by trained and qualified personnel.
  • Supplementary Ventilation: In cases where the primary ventilation system may not be sufficient, consider adding supplementary ventilation, such as portable fume extractors, to ensure adequate air quality.

Spray booths are critical in many industries, but they also present several hazards that must be carefully managed. By understanding the risks associated with fire, toxic fumes, overspray, and inadequate ventilation, and implementing the mitigation strategies outlined in this blog, you can create a safer and more efficient working environment. At Egmont Air, we specialise in providing top-of-the-line ventilation and filtration systems designed to meet the specific needs of spray booths, helping you protect your workers and your facility from these common hazards.

If you’re looking to enhance the safety and efficiency of your spray booth, contact Cameron, Todd or Richard at Egmont Air today to learn more about our comprehensive solutions.