Application and Maintenance of Industrial Coatings.

One of the employees working on a medium-sized manufacturing plant last year collapsed on a routine paint job; he was hospitalised. The cause? A solvent-based coating fumes in a poorly ventilated place, and I did not see a single respirator. It became a wake-up call to the company, which had gotten comfortable with its minimal safety precautions. Paints, epoxies, and powder coatings fall under the umbrella of industrial coatings and are used in construction to protect surfaces, vehicles, and equipment from corrosion, wear, and weather. But these products are full of dangerous chemicals that are quite literally deadly when not properly used. Implementing the specific equipment, engineering controls, and training for worker safety during coating operations will help keep workers safe while complying with safety regulations.

Handling and Applying Industrial Coatings Safely

Personal Protective Equipment (PPE)

Firstly, one of the first levels of protection for those applying industrial coatings on the construction site is their personal protective equipment (PPE). Depending on the task and the chemicals involved, particular forms of PPE protect specific portions of the body.

• Eye and Face Protection: Face shielding devices, such as full face shields, offer extra protection when operations include spraying under high pressure or transferring solvents that may create splashes and airborne particulates.
• Respiratory Protection: Paints and coatings containing solvent vapours and isocyanates can also pose a significant risk by damaging the airways. A half mask or N95 mask with organic vapour cartridges will work well in case of adequate ventilation; otherwise, use a NIOSH-approved mask as per NIOSH guidelines in a well-ventilated area. On the other hand, if working in a confined space or with a very volatile coating, PAPR or a supplied-air respirator (either SAR/SCBA) may have to be used.
• Skin Protection: Workers should wear nitrile or neoprene gloves resistant to solvents. Standard work gloves are inadequate. Full-body chemical-resistant coveralls and rubber boots protect against skin exposure during mixing, spraying, or cleaning.
• Training and Hygiene: Merely wearing PPE isn’t enough. Workers must be trained on its correct use: how to put it on (donning), take it off (doffing), and dispose of or clean it properly. Eating, drinking, or smoking in application zones should be strictly prohibited to prevent ingestion of chemicals.

Ventilation Requirements

Ventilation is a crucial control measure to prevent inhalation of hazardous fumes or airborne dust. Proper ventilation not only protects workers but also helps keep vapour concentrations below dangerous levels.

• Local exhaust ventilation should be installed at the source of emissions, such as spray booths or mixing stations, to capture fumes at the point of generation.
• General exhaust systems can circulate and dilute vapours in open or semi-enclosed areas.
• Ventilation must direct air flow away from workers and ignition sources, and outside the building when possible.

Solvent vapours are explosive between their Lower and Upper Explosive Limits (LEL/UEL). Work must be stopped if vapours approach 10% of the LEL. Use calibrated gas detectors in enclosed environments to monitor conditions in real-time. Powder coatings pose a unique risk: combustible dust. Ventilation systems must be explosion-proof and dust-tight. Dust accumulation on surfaces, beams, or duct interiors can lead to catastrophic explosions if ignited. Even after application, ventilation must continue. It takes time for vapours to dissipate. Re-entry should only occur after air testing confirms safe levels.

Fire and Explosion Prevention.

Flammable solvents are a major hazard when applying industrial coatings. Most coatings have solvents with flashpoints under 200°F, and vapours can ignite in low areas if these solvents are utilised within a restricted area, due to static electricity, hot surfaces, or open flames. Flammability data from the product SDS must be understood by workers, and all ignition sources must be kept at bay. Flammable materials should not be permitted if there is smoking, hot work or use of non-rated electrical devices. In classified areas, tools and lighting should be explosion-proof rated.
Explosions can be triggered by static discharge in liquid transfer or spray. Containers, hoses, and sprayers must be electrically grounded and worn in a way to allow dissipation of static charges. Dust hazards are regulated by OSHA under the National Emphasis Program. A good strategy to prevent combustible dust includes regular cleaning to eliminate settled dust, proper handling of the material, and spark-proof tools.

Interpreting Safety Data Sheets (SDS)

Every industrial coating product comes with a Safety Data Sheet. It is vital to read and understand these documents before starting work.
Key SDS Sections to Know:

• Lists hazards, pictograms, signal words (e.g., “Danger”), and safety instructions.
• Contains fire-fighting measures and the type of extinguishers to use (e.g., CO₂, dry chemical, foam).
• Covers safe storage, ventilation, and handling procedures.
• Specifies PPE and occupational exposure limits.
• Technical data including flash point, autoignition temperature, and explosive limits.

Always check the SDS for flash point, vapour hazards, required PPE, grounding needs, and appropriate fire response. Keep SDSs accessible at the jobsite and train workers on how to read them.