Motor Vehicle Repair

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• Motor Vehicle Repair Peter Woolgar

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Motor Vehicle Repair (MVR)

• Industry structure
• Main dealers and franchises
• Independent/Family
• Self employed
• Industry structure
• Mechanical
• Bodyshop
• Mobile/peripatetic

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HSE approach to MVR

• HSE dedicated team
• Working with the industry
• MVR HS 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

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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
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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

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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.

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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.

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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

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Campaign - Other activity

• Training and inspection packs for labour
  inspectors
• Updates to HSE website
• 10 myths
• Videos
• Revised free guidance

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Key controls(1)

• Paint contents - labels and information
• Beware alternative names
• eg 2 pack, 2K,

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Key controls(2)

• Paint mixing
• Well ventilated (10 air changes/hour)
• Proprietary system with built in extraction (if
  possible)
• Replace lids
• Trays for spillages

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Key controls(3)
Paint Spraying - Use of spray booth/room
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Isocyanate Exposure limits

• UK exposure limits for isocyanate
• 20 microgram/m3 (8 hours)
• 70 microgram/m3 (15 mins)
• microgram (ug) 10-6 gm
• What are exposures like during spraying?

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Spray rooms

• Rooms have an extraction fan, usually in a side
  wall. Entry of replacement air may be planned, or
  more usually unplanned.

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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

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Isocyanate Exposure

• Spray room
• In the room 1500 7000 ug/m3
• Sprayer 1000 5000 ug/m3
• Spray booth
• In the booth 500 1500 ug/m3
• Sprayer lt600 ug/m3
• UK exposure limits
• 20 ug/m3 (8 hours)
• 70 ug/m3 (15 mins)

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5 minute exposure pattern
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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)

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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

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Theory of spray room
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Reality of spray room
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Effect on sprayer
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Theory of downdraught booth
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Reality of downdraught booth
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Sprayer exposure
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Effect of spray gun
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Effect on sprayer
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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?

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Typical clearance time

• Spray booths clearance time 1 5 mins
• Spray rooms clearance time 3 20 mins

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How to check clearance time?

• Fill booth with smoke, using party smoke
  machine.
• Measure time to clear, check annually

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Commercial vehicle spraying

• Spray booths for commercial vehicles
• large volume
• need professional type smoke generator

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Show clearance time

• Put up sign on booth/room
• Not exact round up the time.

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Key Controls (4)

• Respiratory Protective Equipment
• types

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Unsuitable RPE

• Do not accept any kind of filtering device
• Easily overloaded, cannot smell or taste
  isocyanate

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Key controls (5)

• Gun cleaning
• Clean in spray booth or use proprietary equipment

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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

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Key controls (7)

• Biological monitoring
• Urine sample at end of shift
• Analysis for diamine metabolite
• Only method to check whether all controls working

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Isocyanate exposure from SMART

• SMART small/medium area repair technique
• Mini spray gun lt 2bar
• Exposure time lt 1 min
• Sprayer wears air-fed RPE
• Indoors room/booth clearance time, or 30 mins
  in workshop
• Outdoors - no exposure gt 5-10m

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Key messages summary

• MVR Paint spraying
• Isocyanate paints used in virtually every
  bodyshop
• Spraying gives invisible mist - that can be
  breathed in
• Booths/room take time to clear know the
  clearance time
• Isocyanates cause occupational asthma - it can
  ruin lives
• Wear air fed breathing apparatus
• Check controls are working
• Have regular health surveillance

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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
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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

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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
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Other hazardous substances in MVR

• Vehicle exhaust fumes
• carbon monoxide
• diesel fume
• Local exhaust ventilation
• Beware pits

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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
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Other hazardous substances in MVR

• Welding
• Fume
• Asthma
• Pneumonia
• Local exhaust ventilation

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Welding fume control
Cross Draught
75mm
150mm
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Welding - flammability risk

• Hot work flammable fuels etc
• Gas welding/cutting
• Safe storage
• Turn off valves after use
• Hose maintenance

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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
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Other hazardous substances in MVR

• Used engine oils
• Dermatitis
• Skin cancer
• Avoid contact
• Wear gloves
• Check skin

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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
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Other hazardous substances in MVR

• Solvents - wide range
• Dermatitis
• Avoid skin contact
• Wear gloves
• Check skin
• Inhalation
• Good ventilation
• Flammable

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Other hazardous substances in MVR

• Adhesives/sealants
• Some 2 pack are skin irritant/sensitisers
• Dermatitis
• Avoid contact
• Use dispensers
• Wear gloves

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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
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Other hazardous substances in MVR

• Vehicle fuels Petrol, Diesel, Biofuels
• Flammable
• Safe draining, storage
• Dermatitis
• Avoid contact
• Wear gloves
• Check skin

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General

• Good standard of washing facilities

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Key messages summary

• Skin conditions
• Dermatitis is common in MVR
• Materials can cause problems by irritation,
  drying out the skin or allergy
• Used engine oils can cause cancer
• Risk of skin problems can be reduced by
• Avoiding contact
• Protect with suitable gloves
• Check for early signs of disease

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Information and references

• Topic Pack
• Isocyanate spraying
• Inspection pack
• Inspection checklist
• http//www.hse.gov.uk/mvr/index.htm