Painting

Spray application of isocyanate-containing coatings requires supplied-air respiratory protection as minimum standard. Air-purifying respirators, including those with organic vapour and particulate cartridges, do not provide adequate protection against isocyanate exposures during spray application. Acceptable respiratory protection includes Type-C supplied-air respirators with continuous flow or pressure-demand operation connected to breathing quality compressed air, or self-contained breathing apparatus. The respiratory protection must be selected based on atmospheric contamination levels, with escape provisions if air supply fails. Workers must be clean-shaven where the respirator seals to the face, as facial hair prevents effective seal and allows contaminated air to bypass the protection. Fit testing using quantitative or qualitative methods must verify the specific respirator model and size provides adequate seal for each individual worker. All workers using supplied-air equipment require training in donning procedures, breathing techniques, emergency protocols, and equipment limitations. Health surveillance including baseline and periodic respiratory function testing is mandatory for workers exposed to isocyanates. The SWMS must specify the respiratory protection class required, inspection and maintenance procedures, and emergency response actions if equipment fails during work.

Lead paint testing is required before any sanding, scraping, dry abrasion, or heat treatment of painted surfaces in buildings constructed before 1970, as these structures commonly contain lead-based paints. Testing uses X-ray fluorescence analysers or laboratory analysis of paint chip samples to determine lead concentration. If testing confirms lead presence at 0.1% or greater, the work becomes lead risk work under WHS Regulations requiring specific controls. These include obtaining a lead risk work licence for Class A work (removal) or engaging licensed contractors, implementing containment systems preventing dust spread beyond the work area, providing supplied-air respiratory protection or air-purifying respirators with P3 filters depending on airborne lead levels, establishing decontamination facilities including shower and change areas with separate clean and dirty zones, implementing strict hygiene protocols prohibiting eating or drinking in work areas, providing laundry services for contaminated clothing, conducting airborne lead monitoring to verify control effectiveness, implementing health surveillance including blood lead testing before work commences and periodically during ongoing exposure, and disposing of lead-contaminated waste as hazardous waste through licensed facilities. Wet methods, chemical strippers, or encapsulation should be considered as alternatives to dry abrasion to minimise dust generation. All workers require specific training in lead hazards, control measures, and hygiene requirements before exposure occurs.

Spray painting in enclosed spaces requires mechanical ventilation providing minimum 30 air changes per hour for general spray painting, or higher rates for large-scale spray operations or use of particularly hazardous coatings. Ventilation must create airflow from clean to contaminated areas, preventing vapour spread to adjacent spaces. Fresh air intake must be from uncontaminated outdoor sources, and exhaust discharge located where vapours cannot re-enter buildings or affect other workers. The ventilation system must operate continuously during coating application and for sufficient time afterward to clear residual vapours based on the specific solvents used. Verification requires measuring actual air changes using airflow measurement instruments, confirming airflow direction using smoke tubes or similar indicators, and conducting atmospheric monitoring to verify solvent vapour concentrations remain below half the exposure standard during work. For confined space spray painting, supplied-air respiratory protection is required regardless of ventilation provided, as local concentrations can exceed safe levels during application. Natural ventilation through open doors and windows is generally inadequate for spray painting operations and should not be relied upon. The ventilation system design must address ignition source elimination in exhaust pathways, as vapour-laden air presents explosion hazards if it contacts sparks or hot surfaces. All ventilation systems require regular maintenance including filter replacement and airflow verification to ensure ongoing effectiveness. The SWMS must specify ventilation requirements for different painting scenarios and document the verification testing demonstrating adequate performance.

Abrasive blasting operations require workers to hold a high-risk work licence (Class CB: perform abrasive blasting work) issued by the relevant state or territory regulator. To obtain this licence, applicants must complete a nationally recognised training course delivered by a registered training organisation covering abrasive blasting safety including respiratory protection, dust hazard management, equipment operation, and health surveillance requirements. The training must include practical demonstration of competency in equipment setup, operation, maintenance, and emergency procedures. Applicants must provide evidence of medical fitness through examination by an occupational health physician assessing respiratory function, hearing, and overall health suitable for wearing supplied-air respiratory protection and working in physically demanding conditions. Vision testing must demonstrate adequate visual acuity for detailed surface inspection work. Upon successful completion of training and medical assessment, applicants submit a licence application to the state or territory work health and safety regulator including training certificates, medical examination results, proof of identity, and applicable fees. The regulator issues the licence which typically remains valid for five years before renewal is required. Licence holders must carry the licence when performing abrasive blasting work and produce it on request by safety inspectors. Employers must verify all abrasive blasting workers hold current valid licences before allowing them to operate equipment, maintain records of licence verification, and ensure licence conditions are complied with. The SWMS must specify that only licensed operators perform abrasive blasting work and document the verification process for confirming worker licensing status.

Managing fire and explosion risks requires comprehensive controls addressing ventilation, ignition source elimination, and emergency preparedness. Adequate ventilation must prevent flammable vapour concentrations reaching 25% of the lower explosive limit, verified through atmospheric monitoring using combustible gas detectors before and during work. All potential ignition sources within 15 metres of painting operations must be eliminated or isolated including hot work activities, electrical equipment not rated for hazardous areas, static electricity generation, smoking, and heating systems. Where electrical equipment must operate in spray areas, it must meet AS/NZS 60079 standards for explosive atmospheres with appropriate zone classification and temperature class ratings. Spray equipment requires proper earthing and bonding to prevent static electricity accumulation during coating transfer and application. Coatings, thinners, and solvents must be stored in approved flammable liquids storage cabinets meeting AS 1940 requirements, located away from heat sources and incompatible materials. Only quantities required for immediate work should be present in work areas, with containers kept closed except during actual use. Solvent-soaked rags, rollers, and used protective clothing must be deposited in self-closing metal waste containers and removed from site daily to prevent spontaneous combustion. Emergency equipment including fire extinguishers appropriate for Class B flammable liquid fires must be readily accessible, and workers trained in their use. Emergency evacuation procedures must address the rapid spread potential of flammable liquid fires. The SWMS must identify specific ignition sources relevant to the project site, document control measures eliminating each identified source, specify atmospheric monitoring requirements, and detail emergency response procedures for fire incidents.