motor vehicle repair – peter woolgar. motor vehicle repair (mvr) industry structure – main...

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

mailto:http://www.hse.gov.uk/mvr/index.htm

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




Bodywork fillers and dusts Bodyshops Dermatitis, respiratory irritation, lead?



Asthma, pneumonia






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






Vehicle exhaust fumes

Mechanical Eye and respiratory irritation, lung cancer?


Asthma, pneumonia







• Vehicle exhaust fumes – carbon monoxide– diesel fume

• Local exhaust ventilation

• Beware pits








Asthma, pneumonia







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








Asthma, pneumonia







Used engine oils• Dermatitis• Skin cancer

– Avoid contact– Wear gloves– Check skin








Asthma, pneumonia







Solvents - wide range• Dermatitis

– Avoid skin contact – Wear gloves– Check skin

• Inhalation – Good ventilation

• Flammable


Adhesives/sealants• Some 2 pack are skin irritant/sensitisers• Dermatitis

– Avoid contact– Use dispensers– Wear gloves








Asthma, pneumonia







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

motor vehicle repair – peter woolgar. motor vehicle repair (mvr) industry structure – main...

Documents

sprayer slide

floor slide

baking slide

spray boothroom slide

sprayer exposure slide

taste isocyanate slide

free guidance slide

average worker slide