Environment, Health, and Safety Guidelines

October 2008

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 ASM Thermal Spray Society
Safety Committee

The purpose of the Safety Committee is to develop and to make known practices of various elements of thermal spray
technology. This includes the collection of information, the unbiased evaluation of this information, the generation of
useful guidelines, achieving consensus within the committee, approval of the ASM TSS Board, and publication of the
final documents.
All documents created by the Safety Committee are available on the ASM/TSS website upon approval by the TSS Board.
This CD has been created as an additional means of disseminating the documents of the Safety Committee. The Safety
Committee hopes that you find the information on this CD to be a valuable learning tool for you, your co-workers, and
colleagues.
The Safety Committee would like to thank the following companies for their financial contributions to the production of
this CD:
¾ Sulzer Metco (US) Inc.
¾ Praxair Surface Technologies
¾ Progressive Technologies, Inc.
¾ Stony Brook University
¾ Thermal Spray Technologies, Inc.

Over the years both current and past members of the Safety Committee, as well as countless other reviewers, have
contributed to these documents. The current Committee thanks all involved for their efforts.
Listed below are the current members of the Safety Committee. If you have any questions or comments about the
documents you find in this CD please feel free to contact one of the members below.
The Safety Committee is actively looking for new members. If you are interested in joining the Safety Committee please
contact the Committee Chair, Greg Wuest, at the contact information listed below.

Committee Roster
As of 08/08

Mr. Gregory Wuest, Chair Mr. Larry Pollard, a member Mr. Daryl E. Crawmer, member
Director, Quality Environment Safety Application Manager Director of Technology
and Health Progressive Technologies, Inc. Thermal Spray Technologies, Inc.
Sulzer Metco (US) Inc. [email protected] [email protected]
[email protected]
Ms. Donna Guillen, a member Dr. Aaron C. Hall, a member
Ms. Lysa Russo, Co-Chair Advisory Engineer Sandia National Laboratories
Industrial Liaison Manager INEEL/BBWI [email protected]
Stony Brook University [email protected]
[email protected]
Dr. Peter Heinrich, advisor
Mr. Douglas Gifford, a member Manager, Thermal Spray
Director–Plant Support Tech. Geshaftsstelle Der GTS E.V.
Praxair Surface Technologies Linde Gas AG
[email protected] [email protected]
 CONTENTS

Safety Guidelines for the Handling and Use of Gases in Thermal Spraying…………………...……..4

Safety Guidelines for Performing Risk Assessments…………………………………………………..31

Thermal Spray Booth Design Guidelines………………………………………………………………..42

Guidelines for the Use of Personal Protective Equipment (PPE) in Thermal Spraying…………….89

OSHA Final Standard on Hexavalent Chromium……………………………………………………...122

 Designation SG001-02

Safety Guidelines for the Handling and Use of Gases in

Thermal Spraying

Prepared by the ASM-TSS Safety Guidelines Committee

Key Document Authors: Mr. Klaus Dobler, St. Louis Metallizing Company
Mr. Doug Gifford, Praxair Surface Technologies

Safety Guidelines Committee Members:

Richard Neiser, Co-Chair Sandia National Laboratories

Lysa Russo, Co-Chair SUNY at Stony Brook
Rick Bajan Walbar Specialty Processing
Daryl Crawmer Thermal Spray Technologies
Klaus Dobler St. Louis Metallizing Company
Doug Gifford Praxair Surface Technologies
Donna Hale Idaho National Engineering and
Environmental Laboratories
Peter Heinrich Linde AG
Terry Lester Metallisation, Ltd.
Larry Pollard Progressive Technologies
Gregory Wuest Sulzer Metco

Page 1 of 27
Copyright © 2008 ASM International® www.asminternational.org
All rights reserved.
 Designation SG001-02

Safety Guidelines for the Handling and Use of Gases in

Thermal Spraying
DISCLAIMER:
This document is a collective effort involving a number of volunteer specialists.
Great care is taken in the compilation and production of this document, but it should be
made clear that NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT
LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, ARE GIVEN IN CONNECTION WITH THIS DOCUMENT.
Although this information is believed to be accurate by ASM, ASM cannot guarantee
that favorable results will be obtained from the use of this document alone. This
document is intended for use by persons having technical skill, at their sole discretion
and risk. It is suggested that you consult your own network or professionals. Since the
conditions of product or material use are outside of ASM’s control, ASM assumes no
liability or obligation in connection with any use of this information. No claim of any kind,
whether as to products or information in this document, and whether or not based on
negligence, shall be greater in amount than the purchase price of this product or
document in respect of which damages are claimed. THE REMEDY HEREBY
PROVIDED SHALL BE THE EXCLUSIVE AND SOLE REMEDY OF BUYER, AND IN
NO EVENT SHALL EITHER PARTY BE LIABLE FOR SPECIAL, INDIRECT OR
CONSEQUENTIAL DAMAGES WHETHER OR NOT CAUSED BY OR RESULTING
FROM THE NEGLIGENCE OF SUCH PARTY. As with any material, evaluation of the
material under end use conditions prior to specification is essential. Therefore, specific
testing under actual conditions is recommended.
Nothing contained in this document shall be construed as a grant of any right of
manufacture, sale, use, or reproduction, in connection with any method, process,
apparatus, product, composition, or system, whether or not covered by letters patent,
copyright, or trademark, and nothing contained in this document shall be construed as a
defense against any alleged infringement of letters patent, copyright, or trademark, or
as a defense against liability for such infringement.
Comments, criticisms, and suggestions are invited, and should be forwarded to
The Thermal Spray Society of ASM International.

Page 2 of 27
 Designation SG001-02

1. SCOPE

1.1 The objective of this document is to provide members of the thermal spray
community with practical recommendations for the safe installation, operation,
and maintenance of gas equipment used in the thermal spray process. This
document should not be considered a complete design publication and its use
does not relieve the user from the responsibility of using competent engineering
judgment or involving, as required, qualified professionals and suppliers to
address specific installation needs.
1.2 This document will focus on safety issues concerning gas equipment used in
conjunction with thermal spray equipment at consumer sites. It covers the gas
sources (bulk or gaseous), the piping (hard and soft) leading to the gas console
or the torch, and the specific safety devices used help ensure safe operation.
1.3 This document is intended for personnel who are responsible for the safe and
efficient operation of thermal spray equipment.

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 Designation SG001-02

2. REFERENCED DOCUMENTS
Where standards and other documents are referenced in this publication, they refer to
the latest edition.
Publication Pub. ID Available from:
Standard Connections for Regulator Outlets, E-1 The Compressed
Torches, and Fitted Hose for Gas Association:
Welding and Cutting Equipment 1235 Jefferson
Davis Highway
Standard for Gas Pressure Regulators E-4
Arlington, VA 22202
Acetylene G-1
Oxygen G-4
Cleaning Equipment for Oxygen Service G-4.1
Industrial Practices for Gaseous Oxygen G-4.4
Transmission and Distribution Piping Systems
Hydrogen G-5
Safety Release Device Standards – Cargo and G5.1
Portable Tanks for Compressed Gases
Standard for Hydrogen Piping at Consumer G-5.4
Locations
Carbon Dioxide G-6
Standard for Low Pressure Carbon Dioxide G6.1
Systems at Consumer Sites
Safe Handling of Compressed Gases P-1
The Inert Gases Argon, Nitrogen and Helium. P-9
Oxygen Deficient Atmospheres SB-2
Safety Release Device Standards – Cylinders for S1.1
Compressed Gases

Page 4 of 27
 Designation SG001-02

Standard for Bulk Oxygen Systems at Consumer NFPA-50 National Fire

Sites Protection
Association:
Standard for Gaseous Hydrogen at Consumer NFPS-50A
Sites Battery March Park
Oxygen-Fuel Gas Systems for Welding, Cutting ANSI/NFPA Quincy, MA 02269
and Allied Processes, 51
Standard for Fire Prevention in Use of Cutting ANSI/NFPA
and Welding Process 51B,
Guide on Fire Hazards on Oxygen-Enriched NFPA 53,
Atmospheres,
Non-Flammable Medical Gas Systems, NFPA 56F
Standard for the Storage and Handling of ANSI/NFPA
Liquefied Petroleum Gases 58,
Scheme for Identification of Piping ANSI A13.1 American National
Standards Institute
Chemical Plant and Petroleum Refinery Piping ANSI/ASM
25 West 43rd Street
E B31.3
New York, NY
10036
American Welding
Safety in Welding and Cutting ANSI/AWS
Society
Z49.1
550 N.W. LeJeune
Road,
Miami, Florida
33126
National Association
Recommended Practice – Control of External RP0169-96
Corrosion on Underground or Submerged of Corrosion
Engineers.
Metallic Piping Systems
1440 South Creek
Drive
Houston, Texas
77084-4906 USA
Standard Guide for Designing Systems for ASTM G88 American Society
Oxygen Service for Testing and
Materials.
Standard Guide for Evaluating Metals for Oxygen ASTM G94
Service
Standard Guide for Evaluating Nonmetallic ASTM G63
Materials for Oxygen Service

Page 5 of 27
 Designation SG001-02

Publication Publication ID: Available

From:
MSDS – Acetylene P-4559 Material
Safety Data
MSDS – Argon P-4563 (gas) P-4564 (liquid)
Sheets
MSDS – Carbon Dioxide P-4574 (gas) P-4573 (liquid) P-4575 (solid)
Praxair Inc.
MSDS – Helium P-4602 (gas) P-4600 (liquid)
39 Old
MSDS – Hydrogen P-4604 (gas) P-4603 (liquid) Ridgebury
Road
MSDS – Natural Gas P-4627
Danbury, CT
MSDS – Nitrogen P-4631 (gas) P-4630 (liquid)
06810-5113
MSDS – Oxygen P-4638 (gas) P-4637 (liquid)
MSDS – Propane P-4646
MSDS – Propylene P-4648

3. Terminology
3.1 Definitions

Blow-down – A term applied to the process of depressurizing a piping system or source tank by
opening a valve, or valves, to atmosphere.

Bulk Supply – A bulk supply is typically a gas supply source that is permanently plumbed and
has a permanent location. It may be a liquid tank or cylinder, or a bundle of high-pressure
cylinders. A single cylinder, cylinder pack, or bottle would not normally be considered a bulk
supply unless a permanent position and connections are established.

Bursting Disk (Rupture Disk, or Safety Head) – This tank pressure relief device is designed to
rupture at typically 20% above the primary relief valve setting, and relieve bulk tank pressure. A
bursting disk is designed as a secondary resort to prevent tank damage or rupture. It will not re-
close. When a bursting disk ruptures, the tank will be vented to atmospheric pressure and the
disk must be replaced before pressure in the tank can be restored.

Check Valve – A valve that allows flow in only one direction and will prevent back-flow against
that direction.

Combustible liquid - Any liquid having a flash point at or above 100?F (37.8?C) at normal
pressure.

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 Designation SG001-02

Cryogenic – A term applied to liquefied gases that are stored at temperature below -200º F
(-129ºC).

Deflagration ? An intermediate chemical reaction between combustion and detonation that is

accompanied by a vigorous evolution of flame, heat, sparks, or spattering burning particles.
Flame travel in a deflagration is at a velocity below the speed of sound.

Design Pressure – The same as Maximum Allowable Working Pressure referenced in many
codes. The maximum gage pressure permitted at the design temperature. In a typical piping
system this pressure may be at least 15% greater than the system Operating Pressure; in a bulk
tank and associated components, the relationship of Design Pressure to the Operating Pressure
may be much higher.

Detonation ? An exothermic chemical reaction that propagates at the velocity of sound into the
surrounding unreacted material, producing a shock wave ahead of the advancing reaction zone.

Diverter ( 3-way Valve) – A valve with one input that is switchable to one of two outputs. Used
to “divert” the safety vent line of a bulk supply from one set of safety devices to another for
maintenance, repair, or incase of safety device failure.

DMF (dimethylformamide) – Bulk acetylene supplies or cylinders contain acetylene gas

dissolved in either acetone or (DMF) solvent. In addition to the solvent, the cylinders contain a
porous filler material and only a small area near the cylinder valve actually contains gas within
the cylinder

Dry Ice – (CO2 Snow) The solid state of carbon dioxide. Usually occurs when sudden pressure
release occurs such as spraying.

Excess Flow Valve - A valve that will automatically close when flow exceeds a designed "trip
point", thereby limiting high flow accidental releases.

Flash Arrestor – A device commonly used in acetylene or propylene piping to prevent the
passage of a flame from a downstream point back into the piping system, or into the gas supply
equipment.

Flashpoint - The minimum temperature at which a liquid gives off vapor within a test vessel in
sufficient concentration to form an ignitable mixture with air near the surface of the liquid. The
flash point is normally an indication of susceptibility to ignition.

Page 7 of 27
 Designation SG001-02

Normal Operating Pressure – The pressure at which a system normally operates; not the
pressure to which a system may be subjected during upset, or unusual circumstances. At the
inlet to the piping system, the Operating Pressure equals the supply pressure. The Operating
Pressure in a portion, or all, of a piping system may be reduced with a regulator (pressure
reducing valve).

Primary Relief Valve? The bulk supply relief valve that determines the point at which gaseous
tank contents must be relieved to atmosphere to limit tank or line pressure.

Pressure Regulator (Pressure Reducing Valve) – A device designed to reduce the incoming
gas pressure to a lower, constant output pressure in the downstream piping.

Relief Valve – A device designed to open and release pressure to prevent damage to
downstream components and/or to prevent pipeline pressure from exceeding the Design
Pressure. This type valve typically will re-close if the pressure returns to a level below the set
pressure.

Must – This document contains recommended practices. The use of this term indicates
commonly accepted practices considered fundamental to safe operation.

Should – This term indicates a recommendation, or that which is preferred.

Page 8 of 27
 Designation SG001-02

4. THERMAL SPRAY GAS CHARACTERISTICS AND APPLICATION-SPECIFIC

SAFETY HAZARDS/PRECAUTIONS
The Gas Characteristics and Safety Hazards in this section are excerpted from Material Data
Safety Sheets (MSDS) for the specific gases described. Consult the individual MSDS available
from the gas supplier for more detailed information.

4.1 Oxygen characteristics

Oxygen (O2) is a colorless, odorless, and tasteless gas. Oxygen supports and can vigorously
accelerate combustion. This gas is heavier than air (1.1 times the weight of air at 70ºF/21ºC
and 1 atmosphere). Oxygen normally makes up 21% of the atmosphere. Any atmosphere with
greater then 21% is considered oxygen-rich. Bulk oxygen supplies typically store this gas in
liquid form and vaporize it to the gaseous phase at entrance to facility pipelines for distribution
to thermal spray equipment.

4.2 Oxygen Safety Hazards

4.2.1 Liquid Oxygen or cold gas may cause severe frostbite to the eyes or skin. Liquid
oxygen temperature is –297oF (-183oC) at atmospheric pressure. Do not touch frosted
pipes or valves. If accidental exposure to liquid oxygen occurs, consult a physician at
once. If a physician is not readily available, warm the areas affected by frostbite with
water that is near normal body temperature.
4.2.2 Do not permit smoking or open flame in any area where oxygen is stored, handled, or
used.
4.2.3 Combustible compounds like grease and oil may ignite spontaneously when
subjected to an oxygen-enriched atmosphere. For this reason combustible materials and
sources of ignition must be kept away from oxygen piping and hoses. Keep all surfaces,
which may come in contact with oxygen, clean to minimize chances of combustion.
Oxygen should never be used to clean clothing, to “cool” work pieces, or to blow off
debris. All components of oxygen circuits must be specially cleaned to remove any
possibility of combustible material residue. Never use replacement parts in oxygen
service that are not clearly marked: Cleaned for Oxygen Service. Where lubricants are
required, use only oxygen-compatible products.
4.2.4 Oxygen may accumulate in areas containing oxygen equipment. Maintain adequate
ventilation to prevent and minimize combustion hazards.
4.2.5 Oxygen may saturate clothing or other fabric materials. Ventilate clothing saturated
with oxygen gas or liquid for at least 30 minutes, since it will be highly flammable and
easily ignited
.
4.3 Compressed Air
4.3.1 Compressed air should be referred to by its proper name to avoid confusing it with
oxygen or fuel gas. Compressed air should never be used to clean clothing. Similarly,
oxygen and fuel gas should not be used for this purpose.

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 Designation SG001-02

4.3.2 Compressed air for thermal spraying or blasting operations should not be used at
pressures other than those recommended by the equipment manufacturers.
Compressed air piping/hoses should be free of oil and moisture. A qualified air
compressor dealer or thermal spraying equipment manufacturer should be consulted for
recommendations regarding filters and after-coolers.

4.4 Nitrogen, Helium, and, Argon Characteristics

Nitrogen (N2), helium (He), and argon (Ar) are inert, colorless, odorless, and tasteless. These
gases can cause asphyxiation and death in confined, poorly ventilated areas. Argon is heavier
than air (1.38 times the weight of air at 70ºF/21ºC and 1 atmosphere); Helium is much lighter
than air (0.138 times the weight of air at 70ºF/21ºC and 1 atmosphere); and Nitrogen is normally
lighter than air (0.96 times the weight of air at 70ºF/21ºC and 1 atmosphere), but may be
heavier than air as a cold vapor from a liquid nitrogen supply. Bulk supplies of nitrogen and
argon typically store their product in liquid form and vaporize it to the gaseous phase at
entrance to facility pipelines for distribution to thermal spray equipment; helium bulk supplies are
typically in the gaseous phase.

4.5 Nitrogen, Helium, and, Argon Safety Hazards

4.5.1 Cryogenic liquid or cold gas may cause severe frostbite to the eyes or skin. Liquid
temperatures of these gases range from –302º to –452ºF (–186º to –269ºC) do not touch
frosted pipes or valves. If accidental exposure to liquefied nitrogen, helium, or argon gas
occurs, consult a physician at once. If a physician is not readily available, warm the
areas affected by frostbite with water that is near normal body temperature.
4.5.2 Nitrogen, helium, and argon can cause asphyxiation in a confined area by displacing
oxygen. Keep equipment areas well ventilated. Any atmosphere that does not contain
enough oxygen for breathing (at least 19.5%) can cause dizziness, unconsciousness, or
even death. When there is doubt about the adequacy of ventilation, use an oxygen
analyzer with a 0 to 25% scale to check for the proper amount of oxygen. It is important
to check at different levels in an area (low and high) to ensure that gases both heavier
and lighter than air are measured.

4.6 Carbon Dioxide Characteristics

Carbon Dioxide (CO2) is typically stored in bulk supplies in liquid phase, under pressure. At
normal distribution temperature and pressure, CO2 liquid flows like water, but pressure over the
liquid must be maintained at all times to keep the gas in its liquid phase. While not normally
considered a cryogenic liquid, liquid CO2 is extremely cold and will change from its liquid phase
to its gaseous phase, or to the solid (dry ice) phase, as its pressure and temperature drop. It is
the cooling properties that result from sudden pressure release that are useful in thermal spray
applications. The Triple Point of CO2 (where gas, liquid, and solid phases of CO2 exist in
equilibrium) is approx. 60 psig and ?70?F (410 kPa and ?56.6?C). Below this point, liquid CO2
will begin to change to the solid phase (dry ice) and may plug any pipe or vessel in which it is
contained. CO2 gas is heavier than air (1.5 times the weight of air at 70ºF/21ºC and 1
atmosphere).

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 Designation SG001-02

4.7 Carbon Dioxide Safety Hazards

4.7.1 CO2 liquid or snow may cause frostbite or skin damage on contact. Because of the
physical characteristics of carbon dioxide and the plumbing of delivery systems, the
piping to thermal spray processes may contain CO2 in liquid form because of a delivery
pressure that prevents it from becoming a gas. If this pressure is suddenly released, the
gas becomes CO2 "snow" or dry ice, the temperature of which is about 100 degrees
below zero.
4.7.2 Carbon dioxide can cause asphyxiation and death in confined, poorly ventilated
areas. Ventilation is essential when CO2 is present: Never work in an area with CO2 on
without adequate ventilation.
4.7.3 High concentrations of carbon dioxide will also affect breathing. Unlike other
asphyxiants, which simply displace oxygen, elevated CO2 levels affect the respiratory
system – changing pulse rates and blood pressure. Three percent (3%) CO2 can impair
judgment, increase pulse rate and blood pressure; unconsciousness can result from
concentrations of ten percent (10%) or above in less than one minute. Death can follow.
Where potential high concentrations of CO2 are a concern, monitoring CO2 levels – not
oxygen levels – is the appropriate approach -.

4.8 Hydrogen Characteristics

Hydrogen (H2) is a very flammable, colorless, odorless, and tasteless gas that is much lighter
than air (0.07 times the weight of air at 70ºF/21ºC and 1 atmosphere). Hydrogen gas in air is
extremely flammable in any concentration from 4% to 75% and can be EXPLOSIVE. As the
lightest of all elements, it has a tendency to accumulate in the upper portions of confined
spaces.

4.9 Hydrogen Gas Safety Hazards

4.9.1 Hydrogen is a very flammable gas. Hydrogen gas in the air is extremely flammable in
nearly any concentration. Any leak, no matter how small, must be addressed
immediately. A hydrogen flame is virtually invisible either in an explosion or a
deflagration. A flame from a leaky valve or fitting may go undetected.
4.9.2 Hydrogen can cause asphyxiation in a confined area by displacing oxygen. Keep
the equipment area well ventilated. Any atmosphere that does not contain enough
oxygen for breathing (at least 19.5%) can cause dizziness, unconsciousness, or even
death. Breathing moderate concentrations can cause headaches, drowsiness, dizziness,
and vomiting.
4.9.3 Isolate hydrogen from sources of ignition, and do not permit any accumulation of
gas. Hydrogen-air mixtures in nearly any concentration are easily ignited by a low
energy spark (such as static electricity) and may cause an explosion. Smoking, open
flames, unapproved electrical equipment, and other ignition sources must not be
permitted in hydrogen areas. Use non-sparking tools when working on or near hydrogen
equipment. . Any leak, no matter how small, must be addressed immediately.

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 Designation SG001-02

4.10 Acetylene Characteristics

Acetylene (C2H2) is an unstable gas that is flammable in air in any concentration from 2.5% to
100% and can be very explosive if ignited by a spark, flame or other ignition source. Acetylene
is lighter than air (0.91 times the weight of air at 70ºF/21ºC and 1 atmosphere). Unburned
acetylene gas has a distinctive odor similar to garlic. Piping systems that carry this gas must be
constructed of specific materials to prevent and contain reactions. Any ignition in an acetylene
line can cause a detonation that may propagate back through the acetylene plumbing. Any leak,
no matter how small, must be addressed immediately.

4.11 Acetylene Safety Hazards

4.11.1 Due to its unstable nature, Acetylene can explode or decompose with no oxygen or
air present. As a result, acetylene is stored in cylinders and is dissolved in a solvent
such as acetone or dimethylformamide (DMF). Specific requirements must be met
regarding piping and distribution pressures.
4.11.2 Under certain conditions, acetylene forms readily explosive compounds with
copper, silver, and mercury. Contact should be avoided between acetylene and these
metals, their salts, compounds, and high concentration alloys.
4.11.3 Acetylene is very flammable when mixed with air. Keep acetylene away from
sources of ignition. Do not permit any accumulation of gas. Concentrations of acetylene
between 2.5% and 100% by volume in air are relatively easy to ignite by a low-energy
spark and may cause an explosion. Use non-sparking tools when working on or near
acetylene equipment.
4.11.4 Acetylene cylinders require special storage conditions. Store cylinders in an upright
position outdoors or in other well-ventilated areas and away from any heat sources such
as furnaces, ovens, and radiators. Also keep cylinders away from flammable materials
such as gas, kerosene, oil and combustible solids. Never use equipment or a cylinder
that is leaking acetylene. Be certain that the regulator to cylinder valve, hose to
regulator, and torch to hose connections are leak tight before starting work.

4.12 Kerosene Characteristics

Kerosene is a clear, water-white combustible liquid with a mild, characteristic odor and a flash
point ranging from 110 to 150 ?F.

4.13 Kerosene Safety Hazards

4.13.1 Kerosene is classified as a combustible fuel, and must be kept from sources of
ignition. Do not permit smoking, open flame, unapproved electrical equipment, or other
ignition sources in any area where kerosene is stored, handled, or used. Do not permit
any accumulation of vapors. Kerosene vapors can be ignited by a low energy spark
(such as static electricity) and may cause an explosion.

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 Designation SG001-02

4.13.2 Leaking liquid may release flammable fumes and vapors. Never use equipment that
is leaking kerosene. Be certain that all connections are leak tight before starting work.
4.13.3 Kerosene can cause asphyxiation in a confined area by displacing oxygen.
Maintain adequate ventilation to prevent the accumulation of kerosene fumes in areas
containing this fuel. Store kerosene outdoors, or in other well-ventilated areas, away
from any heat sources such as furnaces, ovens, and radiators.

4.14 Propylene Characteristics

Propylene (C3H6) is a colorless, easily liquefied, flammable fuel gas with a faintly sweet odor.
Propylene is transported in liquid form in cylinders and tanks for greater density. At normal
atmospheric pressure and temperature, propylene is a non-toxic, colorless and odorless gas.
Typically, an identifying odor is added so that it can be readily identified. Under moderate
pressure, propylene becomes a liquid that vaporizes into a clean burning gas when released
from its storage container. Flammability Limits from 2% to 11.1% allow formation of explosive
mixtures with air. Propylene is a heavy gas in relation to air (1.45 times the weight of air at
70ºF/21ºC and 1 atmosphere), and has a tendency to accumulate in the lower portions of
confined spaces.

4.15 Propylene Safety Hazards

4.15.1 Short-term overexposure to fumes may have anesthetic effects, cause dizziness,
nausea, and dryness or irritation of the nose, throat, and eyes or may cause similar
discomfort; longer-term exposure may cause liver damage.
4.15.2 Propylene can cause asphyxiation in a confined area by displacing oxygen needed
for breathing. Maintain adequate ventilation to prevent the accumulation of propylene in
areas containing propylene.
4.15.3 Contact with cold gas or liquid may cause frostbite. If accidental exposure to liquid
occurs, consult a physician at once. If a physician is not readily available, warm the
areas affected by frostbite with water that is near normal body temperature.
4.15.4 Very flammable gas can easily ignite. Keep propylene away from sources of ignition,
and do not permit any accumulation of gas. Propylene is relatively easy to ignite by a
low energy spark (such as static electricity) and may cause an explosion. Smoking,
open flames, unapproved electrical equipment, and other ignition sources must not be
permitted in areas where propylene is used or stored. Use non-sparking tools when
working on or near propylene equipment.

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 Designation SG001-02

4.16 Propane Characteristics

Propane (C3H8) or liquefied petroleum gas (LP-gas) is a Colorless, easily liquefied, flammable
fuel gas with a faintly disagreeable odor. Flammability Limits from 2.1% to 9.5% allow formation
of explosive mixtures with air. Propane is readily liquefied under elevated pressure due to –43ºF
boiling point. It is transported in liquid form in cylinders and tanks for greater density. Propane
vaporizes into a clean burning gas when release from its storage container. Typically, an
identifying odor is added so that the gas can be readily identified if leaking. Propane is a heavy
gas in relation to air (1.52 times the weight of air at 70ºF/21ºC and 1 atmosphere) and has a
tendency to accumulate in the lower portions of confined spaces.

4.17 Propane Safety Hazards

4.17.1 Very flammable gas can easily ignite. Keep propane away from sources of ignition,
and do not permit any accumulation of gas. Propane is relatively easy to ignite by a low
energy spark (such as static electricity) and may cause an explosion. Smoking, open
flames, unapproved electrical equipment, and other ignition sources must not be
permitted in propane areas.
4.17.2 Contact with cold gas or liquid may cause frostbite If accidental exposure to liquid
occurs, consult a physician at once. If a physician is not readily available, warm the
areas affected by frostbite with water that is near normal body temperature.
4.17.3 Propane can cause asphyxiation in a confined area by displacing oxygen needed for
breathing. Overexposure to fumes may cause dizziness and drowsiness. Maintain
adequate ventilation to prevent the accumulation of gas in areas containing propane.

4.18 Natural Gas Characteristics

Natural gas is a very flammable gas with a faintly disagreeable odor. It is lighter than air (0.55
times the weight of air at 70ºF/21ºC and 1 atmosphere). Breathing moderate concentrations
can cause drowsiness, and dizziness. This gas is a mixture of 83% to 99% Methane, up to 13%
Ethane, and small percentages of Propane and Butane. Natural gas in the air is extremely
flammable in any concentration from 3.8% to 17% and can be explosive. Typically, an
identifying odor is added so that the gas can be readily identified if leaking.

4.19 Natural Gas Safety Hazards

4.19.1 Very flammable gas can easily ignite. Keep natural gas way from sources of ignition,
and do not permit any accumulation of gas. The gas is easily ignited by a low energy
spark (such as static electricity) and may cause an explosion. Smoking, open flames,
unapproved electrical equipment, and other ignition sources must not be permitted in
areas where this gas is used or stored. Any leak, no matter how small, must be
addressed immediately.
4.19.2 Natural gas can cause asphyxiation in a confined area by displacing oxygen needed
for breathing. Overexposure to fumes may cause dizziness, drowsiness, or death.
Maintain adequate ventilation to prevent the accumulation of gas in areas containing
propane.

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 Designation SG001-02

5. TYPICAL THERMAL SPRAY GAS PLUMBING CONFIGURATIONS

Process gas supply installations utilize a variety of configurations and technologies depending
on the type of gas, purity requirements, usage volume, delivery rate, and supplier capabilities.
The gas supplier must be relied upon in many cases to ensure safe gas supply installation and
plumbing to the limit of the bulk supply. From this point to the workstation (or use point) all
plumbing is typically the responsibility of the operator of the equipment. Gas installation types
for typical thermal spray applications can include:
1. Cryogenic liquid tanks (usually oxygen, argon, nitrogen, hydrogen)
2. Refrigerated liquid tanks or cylinders (usually carbon dioxide)
3. Trailer based systems (can be permanent or temporary)
4. Pressurized liquid tanks or bottles (typically propane, propylene)
5. Cylinders containing gas dissolved in solvent (acetylene)
6. High Pressure Cylinders (typically Ar, O2, N2, H2, He and others)
7. Manifolded or interconnected individual cylinders or bottles
8. Pre-assembled packs of cylinders or bottles.

Each of these gas supplies –- there can be many employed in one single Thermal Spray
workstation, or cell – has pressure and flow control requirements along its path to the torch or
gun used with the process. These also vary with the individual equipment. The complexity of a
system can range from a single gas cylinder with a regulator and flowmeter, to multiple bulk
supplies feeding elaborate spray booths with sophisticated gas control consoles, and many
levels in between. While this standard cannot define all these possibilities, the safe practices
that must be followed when using typical components are addressed in subsequent sections of
this standard.

Bulk Supply Cylinder

Supply

Piping, Safety Hoses and

Devices, and Supply

Console and Console and

Flowmete Flowmete
Process Process
r r

Torch/Gu Torch/Gu
n n
Typical Bulk Supply Typical Cylinder Supply
Plumbing Configurations Plumbing Configurations

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 Designation SG001-02

6. BULK GAS SUPPLIES – SUMMARY OF SAFE PRACTICE FOR: INSTALLATION,

OPERATION, AND MAINTENANCE

6.1 Bulk Supply Installation Considerations

6.1.1 The Design Pressure of a bulk tank and associated components is always greater than
its Operating Pressure. The safety margin between Design Pressure and Operating
Pressure depends on the product contained and its storage method (liquid or gas). i.e.
Liquefied gas bulk tanks typically have a Design Pressure at least 30% higher than the
normal operating pressure; while acetylene supplies typically have a Design Pressure
that is 50 times the Operating Pressure.
6.1.2 The bulk supply tank or system should have a system plumbing schematic attached to
the exterior of the tanks or other accessible location to provide instant reference to the
specifics of the tanks internal plumbing and external system plumbing.
6.1.3 All bulk liquid tanks typically have a dedicated dual sided safety line with a selector
(diverter) valve. With a dual safety configuration, both sides contain a primary relief
valve and a bursting disk (CO2 tanks are an exception in respect to a bursting disk).
These functions should not share lines with other tank functions such as blow-down or
vent lines.
6.1.4 The diverter valves should be clearly labeled as to their function and position.
6.1.5 Primary Relief valves and bursting disks must be sized for flow capability, and must have
pressure settings relative to operating pressure, maximum design pressure, and tank
test pressure
6.1.6 Each primary relief valve must be rated for the specific gas service where it is employed.
Primary Relief Valves must be protected from humidity and moisture that can freeze and
cause the valves to malfunction as ice restricts valve movement.
6.1.7 Lines that could contain normally gaseous product in the liquid phase should have
trapped liquid relief valves that are set to a higher cracking pressure (min. 20%) greater
than the primary relief valve. This is to relieve the dangerous buildup of pressure that will
result as liquid trapped between two closed valves warms and expands.
6.1.8 In cases where equipment downstream from a pressure-regulating device is
insufficiently rated to withstand full pressure resulting from a failure of the pressure-
regulating device, a suitable pressure relief valve should be incorporated.
6.1.9 Any bulk gas installation should receive a complete design review prior to pressurization
and subsequent placement in production. Technical representatives from both customer
and supplier should review all design and safety attributes of the system. Emergency
measures and plans as well as responsibilities of both customer and supplier should be
reviewed, agreed to and documented.
6.1.10 Cylinders when manifolded into a bulk supply must be secured against a wall, a column,
or some other stiff fixture using a chain, or strap above the center of gravity. It is
important that every effort is made to assure that a cylinder will not fall over.
6.1.11 Cylinder bundles (i.e. 12 packs) should be rolled onto flat surfaces and secured in place.

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 Designation SG001-02

6.2 Oxygen Specific Requirements

6.2.1 All metal and metal alloy pressure-reducing valves or regulators should be constructed
from brass, bronze, or copper. Aluminum bronze should not be permitted.
6.2.2 Other materials such as stainless steel or carbon steel require flow restrictions. All other
components where high velocities and particle impacts can be expected should be made
from non-sparking materials.
6.2.3 Regulations for the location of the bulk oxygen storage tank with respect to other
structures and storage facilities should be strictly adhered to.
6.2.4 Bulk storage systems should be installed outdoors and at grade level.
6.2.5 Where oxygen is supplied as a liquid, the area under and around the bulk storage tank
should be free of debris, vegetation and any combustible materials. This area should
also include the area covered by the delivery vehicle.
• Oxygen trailers (or at least the sections that dispense liquid product) should be atop a
concrete slab
6.2.6 Cylinder bundles containing oxygen should be rolled onto flat concrete surfaces and
secured so they cannot move.
6.2.7 All nonmetallic materials used for oxygen service must be certified for oxygen service.
6.2.8 Rapid pressurization (adiabatic compression) is a potential ignition source in oxygen
supply systems. Valves should be opened slowly; safe system designs will avoid the
use of fast-acting valves (such as 1/4 turn valves).
6.2.9 Aluminum components or component parts should not be allowed. Atmospheric
vaporizer fins are an exception to this requirement.
6.2.10 All components used on oxygen systems must be cleaned for oxygen service.
Particulate contamination (such as fine metal particles, etc.) can be ignition sources in
oxygen systems - keep systems clean and free of particulate contamination.
6.2.11 Oil or grease should never be used on oxygen equipment. Only special oxidation
resistant lubricants may be used with oxygen equipment.
6.2.12 Where thread sealants are employed in oxygen piping, oxygen-compatible materials are
required. Teflon tape, while oxygen compatible, requires proper installation technique to
ensure tape fragments do not enter the piping system and inhibit the operation of other
components.

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 Designation SG001-02

6.3 Supply Piping to the Thermal Spray Cell (Underground, Above ground)
6.3.1 Material selection is a critical aspect to piping gases (copper, brass, or bronze alloys that
contain more than 60% copper may cause decomposition in acetylene piping and are
not appropriate for that gas). Make certain that pipe, tubing, flanges, valves, fittings, and
other components are suitable for the design pressure of the system and the specific
gas involved. Special design consideration should be given to components installed in a
corrosive atmosphere or subject to high fatigue. Brass, copper, or stainless steel piping
should be considered for installation in corrosive atmospheres or where concealed
construction prevents routine inspection and maintenance. Forged or cast steel,
stainless steel, malleable iron, copper, or copper alloy flanges and fittings are
recommended where compatible with the gas being carried.
6.3.2 To avoid possible damage to equipment and injury to personnel, pipes and hoses should
be routed where they will not be exposed to excessive temperature changes or contact
with power lines. Pipes should be placed in locations where it will not be damaged by
moving objects (machinery, vehicles, conveyors) and protected from contamination by
oil and grease.
6.3.3 Overhead piping should be adequately supported with the appropriate parts. Pipe
expansion or contraction due to temperature variation should be included in the design.
6.3.4 For underground piping, the piping should be installed 3 feet below the ground surface
or below the frost line – whichever is deeper. The trench bottom should be graded to
assure continuous and firm pipe support. The soil or sand around the pipe should not
contain any rocks, stones, or slag.
• Underground piping should employ welded joints.
• Underground piping should be protected from corrosion using cathodic protection
methods and/or corrosion protective coatings or wrapping.
• A protective casing should be provided for underground piping when it is routed
underneath roadways or railroad tracks.
6.3.5 Piping system Design Pressure ratings should typically be specified to be at least 15%
above the normal operating pressure range, however, Acetylene piping typically requires
a Design Pressure 50 times the Operating Pressure.
6.3.6 Valves that can shut-off gas flow should be specified with a working pressure rating
equal to or greater than the primary line safety relief device.
6.3.7 For liquid fuel (e.g. kerosene), check valves are recommended to help prevent flow-back
and air entrapment

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 Designation SG001-02

6.3.8 Pressure relief valves must be installed between all components that could contain
normally gaseous product in the liquid phase and can cut off gas flow.
• Pressure relief valves should be rated at least 10% to 15% above the normal line
pressure to prevent unnecessary product loss. These flow capacity valves should
also be sized to be equal or greater than the maximum flow that could enter the line
under any circumstances.
• Pressure relief valves should be located as close as possible to the potential source
of overpressure. The discharge of safety relief valves located indoors should be
piped to an outdoor location.
6.3.9 Pressure reducing valves or regulators should contain a 40 mesh or finer strainer on its
upstream side to filter out rust, welding scale, dirt and other foreign material that might
interfere with valve or regulator operation.
6.3.10 Properly cleaning of pipes and components is extremely important. The appropriate
standard should be reviewed for the proper procedure.
6.3.11 Pipes should be identified by legend (name), color code, and direction of flow. Refer to
ANSI publication A13.1, “Scheme for the Identification of Piping Systems”.
6.3.12 Piping should be inspected on a regular basis to detect problems and institute corrective
action. A procedure for periodic inspection of each component and for each type of gas
should be available. The repair procedures for pipes and components can vary widely
due to the gases involved.
6.3.13 Before any new or repaired piping is put into operation, it should be pressure and leak
tested as per the appropriate standard.
6.3.14 Do not use gas lines for grounding!

6.4 Bulk Supply Operation and Maintenance Considerations

6.4.1 A gas supplier should have the primary responsibility for installing, filling/replacing, and
maintaining bulk gas sources.
6.4.2 Even when a gas supplier has the primary responsibility for maintaining the bulk supply
source, the gas user should be familiar with the following issues for emergency
purposes:
• The location and operation of safety devices (check valves, pressure relief valves,
removal of vegetation)
• The piping arrangement of the gases/liquids
• The factors that can cause product to leak
• The maximum pressure that the bulk source can safely withstand.
• Emergency procedures (i.e. shutting down the flow of gases, handling leaks or fires)
• The gas user should ensure that key personnel are trained in basic function and
emergency procedures for bulk gas sources.

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 Designation SG001-02

7. COMPRESSED GAS CYLINDERS

Storage, handling, and operation of compressed gas cylinders shall be in accordance with
ANSI/AWS Z49.1, Safety in Welding and Cutting, and with CGA Pamphlet P-1, Safe Handling of
Compressed Gases. The improper connection, storage, handling, and use of gas cylinders
constitute a safety hazard in the thermal spraying workplace.

7.1 Cylinder Storage

7.1.1 Local, state, municipal, and federal regulations relative to the storage of cylinders should
be investigated and followed
7.1.2 Cylinders should be stored upright and where they will not be exposed to physical
damage, tampering by unauthorized persons, or subject to temperatures that would
raise the contents above 125?F (52?C).
7.1.3 Anytime cylinders are not being moved they must be secured to prevent accidental tip
over that could damage the cylinder valve and allow the release of dangerous pressures
and large volumes of gas.
7.1.4 Cylinders in storage must be separated from flammable and combustible liquids and
from easily ignitable materials (wood, paper, oil, grease) by at least 20 feet (6.1 meters).
7.1.5 Oxygen cylinders in storage must be separated by at least 20 feet (6.1 meters) from fuel
gas cylinders or reserve stocks of calcium carbide.
7.1.6 Cylinders must be secured against a wall, a column, or some other stiff fixture using a
chain, or strap above the center of gravity. It is important that every effort is made to
assure that a cylinder will not fall over.
7.1.7 Connecting several cylinders together with a manifold is frequently required in thermal
spray installations to obtain a greater gas capacity. If this is done the cylinders must still
be properly secured. Similarly, cylinder bundles (i.e.12 packs) must also be secured if
the possibility exists that the bundle may roll or tip over.

7.2 Cylinder Transport

7.2.1 Cylinders must be transported only by using an appropriate device such as a crane,
cradle or gas cylinder hand truck. Slings or electromagnets should not be used.
7.2.2 Cylinders must not be dropped. Cylinders, cylinder valves, or safety devices, must not
be struck, or permitted to strike other objects. Damage to any of these components may
allow the release of dangerous pressures and large volumes of gas.
7.2.3 When moving cylinders, they must be kept upright, the cylinder valves must be closed
and a valve protection cap should be screwed on. Valve protection caps must always be
in place and hand tight – except when the cylinder is secured and connected for use.

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 Designation SG001-02

7.3 Cylinder Operation

7.3.1 Pressure reducing regulators must be installed and used properly. Only regulators
appropriate for the gas/cylinder should be used. A regulator must not be used on liquid
phase product. Only acetylene regulators may be used on acetylene tanks or manifold
systems. It is important to use the correct size non-sparking wrench to connect the
regulator to the cylinder valve outlet: never force or over tighten a connection.
7.3.2 When connecting oxygen and fuel gas cylinders, pressure reducing regulators, and flow
meters, the connecting nuts should be drawn up tight, but should never be over
tightened. (Over tightening is likely to collapse the nose of the nipple.) If the fitting
cannot be sealed without undue force, the fitting should be replaced.
7.3.3 Adequate ventilation of the work area should be provided before opening any of the gas
valves on compressed gas cylinders. The operator should stand to the side of the
pressure reducing regulators when opening cylinder valves, and open the valves slowly,
to protect against the rupture of a faulty regulator.
7.3.4 In the United States: Acetylene pressures in excess of 15 psig (103 kPa) are considered
dangerous and must not be used; In Europe this threshold is 22psig (150 kPa).
Acetylene may detonate at pressures above these points. When acetylene pressure
below these levels is insufficient, special precautions must be taken, or another fuel gas
should be used.
7.3.5 Pressure regulators should never be set to pressures higher than those recommended
for the process. If oxygen and fuel gas pressure required for a process are both more
than 3 psi (21 kPa) over recommended pressures, a problem may be indicated with the
thermal spray equipment (fouled nozzle or incorrect air cap adjustment). Pressures that
are too low usually indicate a serious leak. Equipment should be shut down and the
condition corrected before attempting to reuse the system.
7.3.6 Flame arrestors should be considered when installing multiple acetylene cylinders or an
acetylene backup supply system.
7.3.7 Regulator adjusting screws should be turned in slowly to prevent surges that may crack
or burst flow meter tubes. Hoses should be blown out to remove any dust that may be
present internally.
7.3.8 Acetylene and liquefied gas cylinders must be used upright (valve end up) to prevent
liquid flow into hoses and regulators.
7.3.9 If a cylinder is frozen to the ground, use warm but not boiling water to free it. Pry bars
under valves or valve protection caps should never be used to pry cylinders loose!
7.3.10 Cylinders must never be used as rollers or supports – whether empty or full.
7.3.11 Safety devices should not be tampered with.

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 Designation SG001-02

7.4 Cylinder Leaks/Fires

7.4.1 If a leak is found around the valve stem of a fuel gas cylinder, the packing nuts should
be tightened, or the cylinder valve closed immediately.
7.4.2 If a leak is found in a fuel gas hose or line, the cylinder valve or in line shut-off valve
should be immediately closed.
7.4.3 If tightening the packing nuts does not stop a valve stem leak, or if a fuel gas valve is
leaking at the seal and can not be stopped by closing the valve firmly, or if a leak should
develop at a cylinder fuse plug or other safety device, then the fuel gas cylinders should
be moved to a safe location outdoors, away from any source of ignition, and marked
properly. The supplier should also be advised.
7.4.4 When a leaking cylinder cannot be moved safely to a location outdoors, the area or
building should be immediately evacuated and the fire department notified of the
emergency.
7.4.5 A Warning sign should be posted telling others not to approach the leaking cylinder with
a lighted cigarette or source of ignition.
7.4.6 If a small fire at a fuel gas cylinder does occur, it is usually better to allow the fire to
continue to burn and consume the escaping gas; otherwise it may re-ignite with
explosive violence. If circumstances permit, it is often better to allow the cylinder fire to
burn out in place rather than attempt to move the cylinder.
7.4.7 If the cylinder is located where the fire should not be allowed to burn out in place,
attempts may be made to move it to a safer location, preferably outdoors. Personnel
should remain as distant as possible, and the cylinder should be kept cool with a water
stream.

8. REGULATORS, FLOWMETERS, AND HOSES

Only pressure reducing regulators, flowmeters, and hoses approved/certified by the
manufacturer for the specific gas and application should be used. Refer to ANSI/AWS Z49.1
Safety in Welding and Cutting, and CGA pamphlet E-4, Standard for Gas Regulators for
Welding and Cutting for more information. Hose and hose connections should be installed and
used in accordance with ANSI/AWS Z49.1, and CGA pamphlet E-1, Regulator Connection
Standards, published jointly by the Rubber Manufacturers Association and the Compressed Gas
Association.

8.1 Regulators
8.1.1 Pressure reducing regulators should be used only for the gas and gas pressures for
which they are labeled. Interchanging regulators will lead to contamination and can then
lead to explosions and fire.
8.1.2 Union nuts and connections on regulators should be inspected for damage before use.
If any defective nuts or connections are found, they should be immediately replaced.

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 Designation SG001-02

8.1.3 Oxygen regulators and components should be marked with the label “USE NO OIL”. Oil
or grease should never be used on a regulator.
8.1.4 Pressure regulators should be set to zero pressure before they are attached to a
cylinder, manifold or before a cylinder valve is opened. In addition, cylinder or manifold
valves should be opened slowly to control the pressure increase.

8.2 Flowmeters
8.2.1 Flow meters should be installed and used in accordance with ANSI/AWS Z49.1. If a flow
meter with glass tubes is used, a protective shield should be placed between the flow
meter and the gun. In addition, backflow prevention devices should be used in
conjunction with flow meters to avoid unsafe operating conditions and to ensure proper
flame balance.

8.3 Hoses/Hose connections

8.3.1 Hose connections should be able to withstand twice the normal operating pressure
without leaking or at least 300 psi – whichever is greater. Oil free air or an oil free inert
gas should be used for testing.
8.3.2 The hoses to the thermal spray gun should be periodically checked for leaks at all
connections, with leak check solution. Soapy water may be used with some gases, but
only oxygen compatible leak check solutions are appropriate for oxygen leak checks.
Leak check solutions are applied to each joint while the system is under pressure. A
flame should never be used to check for gas leaks. Solutions are safer and provide a
more sensitive test than a flame.
8.3.3 The frequency of inspection depends upon how often the hose is used and the severity
of usage. Bending areas, particularly at the regulators and the torch connections, are
prone to cracking and leaking.
8.3.4 When connection leaks are found, the following operations should be performed: lock
out/tag out the gas supply as required; depressurize the affected piping; open the
connection, wipe clean the sealing surfaces; ensure that the threads are clean; retighten,
pressurize, and retest the section or leaks. If a leak persists, the system should be
depressurized. Leaking thermal spray equipment should never be used. A “Danger—Do
Not Operate” tag should be placed on the defective equipment.
8.3.5 Damage to hoses should be avoided. Obstructions in the gas lines caused by defective
hoses, collapsed hose stems, or dirt in the gas passages of the gun head or the nozzle
jets will require excessive pressure to obtain proper gas flow.

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 Designation SG001-02

9. CHECK VALVES, FLASHBACK ARRESTORS, AND EXCESS FLOW VALVES

9.1 Check Valves should be used in any circumstances where the prevention of a reverse
flow of any gas is required, and installed per manufacturer’s recommendations -
examples include cylinder manifolds, and mixing chambers where oxy-fuel gases are
mixed prior to combustion.
9.2 Flashback arrestors must be specifically rated for the gas in use and should be
considered for every thermal spray system. They provide protection against flashbacks,
and reverse flow of fuel gases or oxygen or air. In addition, some of the safety features
that are found singly or in combination in flashback arrestors include:
• Flame arrestor – This feature attempts to cool the flame below the self-ignition
temperature of acetylene or other fuel gases mixed with oxygen to prevent the
flashback from reaching the source of supply.
• Gas non-return valve – These devices give protection against slow and/or sudden
gas reverse flow by shutting off the flow of gas when an excessive pressure is
reached.
• Temperature activated valve – This type valve cuts off the flow of fuel gas and/or
oxygen automatically once an excessive temperature is reached. The temperature
may be achieved via repetitive flashbacks, burn backs or external fires.
9.3 Excess flow valves should be considered as safety devices for lower flow systems to
prevent high flow accidental releases.

10. PRESSURE RELIEF VALVES AND VENTS

10.1 Pressure Relief Valves should be a standard part of every thermal spray system. They
ensure that gas lines or compressed gas bottles will not burst due to excessive pressure.
10.1.1 Pressure Relief Valves must be rated for the specific gas service where they are
employed (i.e. pressure relief valves on CO2 systems must be rated for CO2 service - not
other low temperature service such as liquid nitrogen).
10.1.2 Pressure Relief Valves are rated by pressure and flow. It is possible that extreme
temperature can effect the pressure relief valve’s operation. The relief valve’s normal
operating position is closed and when the valve’s excessive pressure value is reached,
the valve opens to relieve pressure.
10.1.3 Pressure Relief Valves should be added to gas piping wherever the potential for over
pressurization of a gas line or component exists. A burst line can cause a fire or
explosion and damage equipment. It could also injure an operator by asphyxiation, a
fire, and/or an explosion.
10.1.4 Pressure relief devices should be vented to the outside of a facility. In the event that a
pressure relief valve opens, operators will be safe from asphyxiation dangers and/or the
operators and equipment will be safe from a possible fire or explosion

Page 24 of 27
 Designation SG001-02

10.2 Vent Lines. The basic purpose of a vent or vent line is to ensure that gases escaping
from a pressure relief valve are directed to a safe location where they will not cause any
harm. Typically this means directing the gas out of the spray booth, spray area, or from
a gas storage area to the outside of the building.
10.2.1 Listed below are recommended practices for installing and maintaining vent lines and
are applicable for the gases covered by this standard and addressed in Section 4:
• Pressure Relief Valve vent line material should be carbon steel, stainless steel, or
copper (copper, brass, or bronze alloys that contain more than 60% copper may
cause decomposition in acetylene piping and are not appropriate for that gas).
• Vent lines should be constructed so that they do not restrict the full flow of the
pressure relief valve.
• Vent line joints should be welded, threaded, or tubing joined with compression
fittings.
• Vent lines should terminate outside the facility at a safe location.
• Vent lines for oxygen should be cleaned for oxygen service.
• Flammable gas vent outlets should be adequately separated from any other vent
outlet, air intakes, and potential sources of ignition.
• Vent lines should not be interconnected. They should lead separately to the outside.
• Low points in vent stack piping should be avoided, but a low point where moisture
can collect should have drip legs, or pots installed. Drain valves having outlets
normally closed with threaded caps or plugs should be installed to permit draining of
condensate from the stack.
• If tubing is used, tube compression fitting material should be brass or stainless steel.
• Vent lines should be constructed so that they will not be obstructed as a result of
weather conditions, or living things (i.e. bugs).
• Each tube should have a durable, legible label at each end to identify the gas that
would pass through it.
• Each vent outlet should be inspected on a regular basis for damage.

Page 25 of 27
 Designation SG001-02

11. GAS ANALYZERS / DETECTORS

11.1 Permanently Installed Units
Gas analyzers and combustible gas detectors are often incorporated in the design of thermal
spray equipment to provide indication of potentially unsafe conditions. Depending on the
specific gases in use and the hazards they present, these devices typically either detect
improper concentrations of oxygen (too high or too low) or provide warning regarding the
presence of unacceptable percentages of combustible or other gases. They may be interlocked
with shutoff valves or exhaust systems in some cases.
11.1.1 The use of gas detection equipment can enhance operator and other personal safety. It
is important to note that these devices are not substitutes for good design and operating
practices/procedures. Improperly selected, installed or maintained gas detectors will
only result in a false sense of security.
11.1.2 Typically thermal spray equipment can be designed and installed such that the chances
for gas leakage are minimized and, in the case of a leak, little opportunity is provided for
accumulation of any appreciable gas concentration. Physical configuration of consoles
and gas control panels should maximize the effects of natural ventilation and air
circulation to dilute small gas leaks. Positioning and mounting of equipment and
individual components should avoid closely confined areas with poor ventilation and – in
the case of flammable gases – areas containing potential ignition sources.
Manufacturers recommendations regarding installation, maintenance and periodic leak
checking must be followed. In addition, a program of periodic inspection and leak
checking of supply systems and plumbing must be established.
11.1.3 When either design or installation issues result in concerns regarding maintaining a safe
atmosphere, gas detection equipment should be considered. Guidelines as to the proper
and most effective use of such equipment are as follows:
Sensing technologies - Various technologies employed for sensing gases can
result in significant performance differences. A review should be conducted with the
supplier to ensure the sensor type being considered is appropriate for the
application.
Mounting - The physical location(s) of the sensing element can have a significant
effect on the sensor's ability to detect certain gases as well to protect against certain
hazards. Facts regarding whether a gas will likely rise or fall (See: specific Gas
Characteristics Paragraph 4.x) and typical locations of personnel in work areas
should be considered in determining sensor location.
Calibration/Maintenance - Each type of sensor will present differing calibration /
maintenance requirements. Some devices require that sensor elements be replaced
as often as twice yearly and require regular calibration. Consult the manufacturers
literature to develop calibration intervals, then follow regular maintenance and
calibration procedures, and conduct regular performance testing without fail.

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 Designation SG001-02

11.2 Portable Gas Detector Units

Portable gas detectors can provide a significant, additional measure of safety during operation
and maintenance of thermal spray equipment.
11.2.1 Routine gas pack change-out, new equipment installation, maintenance, and calibration
activities often result in opening lines and operating valves as well as in the moving and
disturbing of normally fixed pieces of equipment. Often these activities present a prime
situation in which leaks develop. Use of a handheld gas detector can significantly
increase safety during such operations by confirming plumbing integrity, or providing
local and immediate detection of leaks.
11.2.2 Units typically are battery powered and have adjustable sensitivity. Proper operation of
the unit should be confirmed prior to each use.

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 Designation SG002-02

Safety Guidelines for Performing Risk Assessments

Prepared by the ASM-TSS Safety Guidelines Committee

Key Document Author: Lysa Russo, SUNY Stony Brook

TSS Safety Guidelines Committee Members:

Richard Neiser, Co-Chair Sandia National Laboratories

Lysa Russo, Co-Chair SUNY at Stony Brook
Rick Bajan Walbar Specialty Processing
Daryl Crawmer Thermal Spray Technologies
Klaus Dobler St. Louis Metallizing Company
Doug Gifford Praxair Surface Technologies
Donna Post Guillen Idaho National Engineering and
Environmental Laboratories
Peter Heinrich Linde AG
Terry Lester Metallisation, Ltd.
Larry Pollard Progressive Technologies
Gregory Wuest Sulzer Metco (US) Inc.

Page 1 of 11
Copyright © 2008 ASM International® www.asminternational.org
All rights reserved.
 Designation SG002-02

DISCLAIMER:

This document represents a collective effort involving a substantial number of volunteer

specialists. Great care has been taken in the compilation and production of this document, but it
should be made clear that NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT
LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, ARE GIVEN IN CONNECTION WITH THIS DOCUMENT. Although this information is
believed to be accurate by ASM International®, ASM cannot guarantee that favorable results will
be obtained from the use of this document alone. This document is intended for use by persons
having technical skill, at their sole discretion and risk. It is suggested that you consult your own
network of professionals. Since the conditions of product or material use are outside of ASM’s
control, ASM assumes no liability or obligation in connection with any use of this information. No
claim of any kind, whether as to products or information in this document, and whether or not
based on negligence, shall be greater in amount than the purchase price of this product or
publication in respect of which damages are claimed. THE REMEDY HEREBY PROVIDED
SHALL BE THE EXCLUSIVE AND SOLE REMEDY OF BUYER, AND IN NO EVENT SHALL
EITHER PARTY BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES
WHETHER OR NOT CAUSED BY OR RESULTING FROM THE NEGLIGENCE OF SUCH
PARTY. As with any material, evaluation of the material under end use conditions prior to
specification is essential. Therefore, specific testing under actual conditions is recommended.
Nothing contained in this document shall be construed as a grant of any right of manufacture,
sale, use, or reproduction, in connection with any method, process, apparatus, product,
composition, or system, whether or not covered by letters patent, copyright, or trademark, and
nothing contained in this document shall be construed as a defense against any alleged
infringement of letters patent, copyright, or trademark, or as a defense against liability for such
infringement.
Comments, criticisms, and suggestions are invited, and should be forwarded to the Thermal
Spray Society of ASM International®.

1. SCOPE
1.1 Introduction to the approach and concept of a Risk Assessment.
1.2 Steps that can be taken to improve workplace safety.
1.3 Examples of thermal spray hazards

2. REFERENCED DOCUMENTS

Where standards and other documents are referenced in this publication, they
refer to the latest edition.

Publication Pub. Edition Available from:

TSSEA Code of Practice for the Safe Mr. Ivor Hoff:
Operation of Thermal Spraying [email protected]
Equipment
Thermal Spraying: Practice, Theory American Welding Society
and Application (Chapter 11) 550 N.W. LeJeune Road
Miami, Florida 331326
www.aws.org
Recommended Safe Practices for Reprint No. American Welding Society
Thermal Spraying 2, 1983 550 N.W. LeJeune Road
Miami, Florida 331326
www.aws.org
Page 2 of 11
 Designation SG002-02

A guide to the Health and Safety at (UK) 1974, L1, ISBN 0 7176 044441 1
Work etc. Act
Free Risk Radar software download www.spmn.com/products_software.html

3. TERMINOLOGY

3.1. Definitions
3.1.1. Risk Assessment – The steps involved in identifying, documenting and putting in
place the necessary controls to minimize or eliminate the potential risk of an
activity.
3.1.2. Frequency Rating – A measure of how often a particular activity with a potential
risk is performed.
3.1.3. Severity Rating – A measure of the potential for injury of a particular activity.

3.2. Keywords-- Risk Assessment, Safety, Frequency Rating, Severity Rating, Engineering
Controls, Administrative Controls, Confined Spaces, Hazard

4. RISK ASSESSMENTS

Every activity that is carried out on a daily basis, from driving a car to work or flying on
an airplane, poses a certain level of risk. It is the assessment of the risk (acceptable or
unacceptable) and then putting in place a plan of action to control the unacceptably high
risk, that can ultimately provide for a safer work environment.

The purpose of performing a risk assessment, or RA, is to make the workers and their
management aware of the hazards in the work environment. With this knowledge, each
risk can be identified in a methodical manner and a plan put in place to mitigate the
hazard. More time and effort should be spent mitigating hazards that pose the highest
risk, although no hazard should go unaddressed.

So, how does one perform a risk assessment? The information contained within this
document provides a logical approach that can be taken to minimize risk and maximize
safety. More formal descriptions of Risk Assessments are available and should also be
consulted. The purpose of this document is to introduce the concept in enough detail
that thermal spray practitioners can use it to improve safety in their work places.

Risk Assessments need to be customized to the specific workplace and to the actual
work being performed. Therefore, no two Assessments will be the same.

There are basically four steps to improving operational safety by using a risk
assessment. These are described in the sections below. Two case studies are given as
examples to illustrate the concepts involved. Please note that the specific ratings that
are used in this document are not as important as the methodology and approach that
has been taken.

4.1 Identifying the Risks for Each Activity

The initial step of a RA is to carefully think about the various risks that are associated
with each activity and to document the hazards posed by these risks. The level of
hazard may be minimal or quite high, but anything that poses a real risk should be
Page 3 of 11
 Designation SG002-02

identified and written down. Trivial risks, or risks that are always present (such as
walking into a wall or falling out of a chair) need not be addressed since they will only
dilute the effectiveness of the RA.

When identifying risks, a systematic, methodical approach is always required so that all
risks will be identified. This task can be quite complex and is sometimes overlooked.

Risk Assessments are recommended for use during the design stage for a new spray
facility. In this way, safety can be incorporated up front and costly upgrades and
modifications can be avoided. RA’s are also useful for examining the safety of existing
spray facilities. Flowcharting a process or operation can help in identifying risks
associated with certain actions. RA’s should be reviewed for completeness on a regular
basis. Significant changes in personnel, operating procedures or equipment should
trigger a review. At a minimum, annual reviews are recommended.

Some typical examples of activities performed in the thermal spray industry would be arc
spraying, combustion spraying, plasma spraying, handling of gas cylinders, the use of
cranes during lifting of parts to be sprayed, chemical cleaning, grit blasting, working in
confined spaces, handling hazardous materials, working with robotic equipment, etc.

4.2 Rating the Risk, (R)

In order for a RA to be practical and useful, the identified risks listed in step one need
to be rated. This will help to determine the most serious risks - those that need to be
given priority of action. A Risk Assessment number ( R ) is calculated by multiplying the
Frequency Rating ( F ), how often this risk is likely to occur, by the Severity Rating (S),
when the risk occurs, how severe is it :

R = F x S.

The following guidelines may be used in the frequency and severity rating:

Frequency Rating (F):

1 = Highly unlikely occurrence
2 = Remotely possible occurrence
3 = An occassional occurrence
4 = A fairly frequent occurrence
5 = A frequent and regular occurrence
6 = Almost certain that the event will occur

Severity Rating (S):

1 = Negligible injuries (i.e. scratches, hole in the wall, no downtime)
2 = Minor injuries (i.e. cuts and bruises, 1-2 days of downtime)
3 = Major Injuries (i.e. concussion, broken bone(s), loss of limb or eye, major structural
damage, 3 or more days of downtime)
4 = Possible/Probable death or total loss of building

Example: An activity where accidents are recognized as a fairly frequent occurrence

has a Frequency Rating of 4. When the past records of these accidents are reviewed, it
is determined that these injuries have been minor, so a Severity Rating of 2 is given.
Therefore the Risk Rating ( R) is calculated as (Frequency x Severity) 4 x 2 = 8.
Page 4 of 11
 Designation SG002-02

When performing the Risk Rating, it is important to note what the initial assumptions may
have been. Meaning, unskilled labor performing a skilled task would carry a higher risk
than skilled labor performing the same task. Other assumptions may be that equipment
is calibrated and working properly (i.e. has not been tampered with or modified),
operators have received proper training, etc.

4.3 Putting in Place the Actions Required to Minimize Risk

Once all of the risks have been identified and prioritized for each activity, it is now
important to identify the steps that are necessary to minimize or control each risk. It is
the implementation of these steps that ultimately improves safety.

Risk mitigation can be accomplished by several different means. Employee awareness

and training play a key role in mitigating work place hazards. Engineering controls that
prevent unsafe conditions from occurring are also important. An example of an
engineering control is the micro-switch that prevents the operation of a microwave oven
when the door is opened. The other major risk mitigation tool is Administrative Control.
These controls include such items as operational checklists, training, safe operating
procedures, maintenance schedules, and so on. A judicious combination of engineering
and administrative controls can often significantly reduce the risk of a potentially
hazardous task without being too expensive to implement or too complex to work with on
a daily basis. Ultimately, however, the successful reduction of risk relies on the
willingness of management and employees to initiate and maintain safe working
practices. Without the “buy-in” of operators, engineering staff and management, the
safety improvements possible through engineering and administrative controls can be
rendered useless.

It is highly recommended that all levels of employees participate in the risk assessment.
Identification of a risk is greatly dependent upon the perspective of the person
performing the task. What one person sees as a high level risk, another may see as
being only a moderate risk. Many organizations have a “stop work” policy that enables
any worker at any level to authorize a “stop work” if unsafe working conditions exist.
Operations cannot be resumed until the hazard is corrected.

4.4 Review and Update the Risk Assessment on Regular Basis

Because change is inevitable and these changes may affect the validity of the
actions/control measures that were put into place, it is very important that the Risk
Assessment be reviewed and updated on a regular basis. The review process is also a
helpful tool in determining how useful/practical a given control measure has been in
minimizing the associated risk. Sometimes what seemed like a good idea at the time
proves to be too costly or difficult to manage.

There is no set rule as to how often this needs to be done, but rather is left up to the
discretion of the responsible party (company’s Health and Safety Officer, manager in
charge, etc). A good rule of thumb would be to review RA documents annually or
whenever a significant change (i.e. new equipment installation, new employee hire)
occurs.

Page 5 of 11
 Designation SG002-02

In summary, an effective Risk Assessment should:

• Be systematic and logical in approach first looking at all of the activities / tasks that
are necessary to accomplish a given task and then looking at the risks for each
activity.
• Ensure that all relevant risks hazards have been addressed and identified.
• Focus on real risks and not obscure the RA with trivial risks or excess information.
• Prioritize the control measures / actions dealing with the highest, most significant
risks first.
• Identify what assumptions were made (skilled or unskilled labor, calibration of
equipment, etc.).
• Be regularly reviewed and updated / revised as necessary.
• Be signed off by the Manager responsible for the spray shop.

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 Designation SG002-02

Appendix I: Some Typical Thermal Spray Risks to Consider

When Performing a Risk Assessment

1. Explosion and suffocation/asphyxiation hazards from Compressed and

Combustible Gases, which may be at high pressures.
2. Old, worn or cracked cables and hoses can cause gas leaks or electrical shocks.
3. UV/ infrared from plasma/arc torches can cause burns to face/skin/eyes.
4. High sound levels from equipment can cause hearing damage.
5. High voltage and high currents/improper grounding connections can cause
electrical shocks that can be lethal.
6. Hot-sprayed parts or particles can cause burns and fires if directed at
combustible materials (i.e. paper, rags, clothing, etc).
7. Chronic exposure to powder and spray process dust, fumes and mists can cause
severe respiratory ailments.
8. Slippery floors from powder/water spills.
9. Mechanical pinch hazards from robots, turntables, automatic doors, etc.
10. Fire and explosions from fine metal powders and dust.
11. Handling Components: Manually or by crane, lifting or fork lift truck.
12. Risks associated with spraying of hazardous or toxic materials.

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 Designation SG002-02

Appendix II: Typical Engineering Control Procedures that can be used

In the Thermal Spray Process

1. Interlocks that: prevent walking into a spray booth that has robotic
manipulation, allow exhaust systems to vent rooms in cases of gas leaks, etc.
2. Warning lights and audible sounds (sirens)s
3. Lockout/tag out stations.
4. Required use of respirators and other personal protection equipment (PPE).
5. Use of gas leak detectors and oxygen sensors.
6. Properly designed sound attenuation spray booths.
7. Properly designed ventilation and filtration equipment.
8. Proper assessment of, and compliance with all local, state and federal
codes/norms/standards/regulations.
9. Selection of properly designed thermal spray equipment.
10. Properly designed part fixtures and tooling.
11. Maintaining and updating operator personnel records confirming safety and
training approvals.
12. Properly reviewing Material Safety Data Sheets (MSDS).

Page 8 of 11
 Designation SG002-02

Appendix III: Typical Administrative Control Procedures

that can be used in the Thermal Spray Process

1. Written start-up and shutdown checklists.

2. Written and read standard operating procedures (SOPs).
3. Personnel safety training including respiratory/hearing training.
4. Equipment Maintenance/Calibration Schedules.
5. Scheduled thermal spray process and operation training.
6. Accident/incident procedures (reporting, investigation, corrective action, etc.).
7. Fire extinguisher training.
8. First-aid training, e.g., certified CPR training (required in some states).

Page 9 of 11
 Designation SG002-02

Case Study #1: Risk Assessment of Working in a Confined Space

Step 1: Define Risks of Activity.

In the case of working in a confined space, the specific risks could be: limited access
into and out of the booth, fumes, asphyxiation from gases, oxygen
enrichment/deficiency, an explosive or combustible atmosphere, excessive noise or
heat, etc.

Step 2: Rate the Risk (R).

Based upon the frequency (F) and severity (S) of each risk identified in Step 1, a table
can be made up which would weight the risk (R) and identify the hazards.

Activity: Working in a Confined Space

No HAZARD RISK F S R
1 Access / Exit Difficulty in entering / exiting 2 3 6
2 Fumes Inhalation causing illness 2 3 6
3 Asphyxiation (Oxygen Becoming unconscious / death 3 4 12
Depletion)
4 Oxygen Enrichment Fire and/or explosion 2 4 8
5 Explosive atmosphere Fire, explosion, death 3 4 12
6 Noise Hearing Damage 2 3 6
7 Heat Heat exhaustion 3 3 9

Step 3: Actions to Put in Place to Minimize/Reduce Risk:

For the activity of working in a confined space, the following steps would need to be put
into place to minimize the risk:

No Action / Control Measure

1 Test for explosive as well as breathable atmosphere (install gas detection system
which is interlocked with gas and exhaust system; keep space well ventilated
with clean and breathable air)
2 Install fire extinguishing equipment and alarms
3 Wear forced air breathing apparatus to minimize risk of oxygen depletion
4 All exits must be clear from blockage and identifiable even in the event of a power
loss
5 Hearing protection must be worn when necessary
6 Employees must undergo training for gas handling / hearing protection / fire
safety/respiratory protection
7 Use of a “buddy system” ensuring that someone else is always present

Step 4: Regularly Review and Update Process Risks and Actions to ensure that
assessment is still valid and being implemented appropriately.

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 Designation SG002-02

Case Study #2: Spraying a Bridge with Zn-Al Arc Sprayed Wire

Step 1: Define Risks of Activity.

In the case of performing this on-site arc spray job, some of the risks would be:
shock/electrocution from the spray wires, falling off scaffolding, breathing spray fumes.

Step 2: Rate the Risk (R).

Based upon the frequency (F) and severity (S) of each risk identified in Step 1, a table
can be made up which would weigh the risk (R) and identify the hazards.

Activity: Working in a Confined Space.

No HAZARD RISK F S R
1 Touching Wires Electric shock/Electrocution 2 3 6
2 Entanglement in Falling off scaffolding/death 3 4 12
Processes
wires/cables
3 Fumes Inhalation causing illness 2 3 6

Step 3: Actions to Put in Place to Minimize/Reduce Risk:

For the above activity, the following steps would need to be put into place to minimize
the risk:

No Action / Control Measure

1 Limit distance of exposed feed wires in set-up and provide protective barrier so
that wires can not be touched
2 Personnel must wear protective harness equipment to prevent falls.
3 Wear appropriate and approved respirators to minimize inhalation of zinc and
aluminum fumes. Note: Personnel must be “fit-tested” by a qualified industrial
hygienist before the use of a respirator.
4 Comply with all local, state and federal codes relating to this type of “construction”
related work as well as obtain all necessary permits.

Step 4: Regularly Review and Update Process Risks and Actions to ensure that
assessment is still valid and being implemented appropriately.

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 Designation SG003-03

Thermal Spray Booth Design Guidelines

Prepared by the ASM-TSS Safety Committee

Key Document Authors:

Douglas J. Gifford, Praxair Surface Technologies, Inc.
Larry Pollard, Progressive Technologies, Inc.
Gregory Wuest, Sulzer Metco (US), Inc.
Randy C. Fletcher, Praxair Surface Technologies, Inc.

TSS Safety Committee Members:

Gregory Wuest Chairman Sulzer Metco (US), Inc.

Richard Neiser Sandia National Laboratories
Lysa Russo SUNY at Stony Brook
Daryl Crawmer Thermal Spray Technologies, Inc.
Klaus Dobler St. Louis Metallizing Company
Douglas J. Gifford Praxair Surface Technologies, Inc.
Donna Guillen Idaho National Engineering and
Environmental Laboratories
Larry Pollard Progressive Technologies, Inc.

Page 1 of 47
Copyright © 2008 ASM International® www.asminternational.org
All rights reserved.
 Designation SG003-03

Thermal Spray Booth Design Guidelines

DISCLAIMER:

This document represents a collective effort involving a substantial number of volunteer specialists.
Great care has been taken in the compilation and production of this document, but it should be made
clear that NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION,
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE GIVEN IN
CONNECTION WITH THIS DOCUMENT. Although this information is believed to be accurate by ASM
International®, ASM cannot guarantee that favorable results will be obtained from the use of this
document alone. This document is intended for use by persons having technical skill, at their sole
discretion and risk. It is suggested that you consult your own network of professionals. Since the
conditions of product or material use are outside of ASM’s control, ASM assumes no liability or obligation
in connection with any use of this information. No claim of any kind, whether as to products or information
in this document, and whether or not based on negligence, should be greater in amount than the
purchase price of this product or publication in respect of which damages are claimed. THE REMEDY
HEREBY PROVIDED SHOULD BE THE EXCLUSIVE AND SOLE REMEDY OF BUYER, AND IN NO
EVENT SHOULD EITHER PARTY BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL
DAMAGES WHETHER OR NOT CAUSED BY OR RESULTING FROM THE NEGLIGENCE OF SUCH
PARTY. As with any material, evaluation of the material under end use conditions prior to specification is
essential. Therefore, specific testing under actual conditions is recommended.
Nothing contained in this document should be construed as a grant of any right of manufacture, sale,
use, or reproduction, in connection with any method, process, apparatus, product, composition, or
system, whether or not covered by letters patent, copyright, or trademark, and nothing contained in this
document should be construed as a defense against any alleged infringement of letters patent, copyright,
or trademark, or as a defense against liability for such infringement.
Comments, criticisms, and suggestions are invited, and should be forwarded to the Thermal Spray
Society of ASM International®.

Page 2 of 47
 Designation SG003-03

CONTENTS

1. SCOPE............................................................................................................................................. 5
2. OVERVIEW...................................................................................................................................... 5
3. SPECIAL TERMINOLOGY USED WITHIN THIS GUIDELINE........................................................ 6
4. RELATED STANDARDS AND DOCUMENTS ................................................................................ 7
5. TERMINOLOGY/DEFINITIONS..................................................................................................... 10
6. BOOTH STRUCTURE AND SOUND SUPPRESSION ................................................................. 14
6.1 Scope......................................................................................................................................... 14
6.2 Configuration ............................................................................................................................. 15
6.3 General Construction................................................................................................................. 15
6.4 Sound Hazards and Control ...................................................................................................... 17
6.5 Powder and Dust Control........................................................................................................... 20
6.6 Radiation Control ....................................................................................................................... 21
6.7 Safety Interlocks ........................................................................................................................ 22
6.8 Warning / labeling ...................................................................................................................... 23
6.9 Maintenance Issues (Safety Related)........................................................................................ 23
7. ROBOTICS AND TORCH/PART MANIPULATION ....................................................................... 24
7.1 Scope......................................................................................................................................... 24
7.2 Robotic Arms and Robot Systems............................................................................................. 24
7.3 Installation Configuration and Restricted Space........................................................................ 25
7.4 Teach Mode ...............................................................................................................................26
7.5 Other (Non-Robotic) Torch/Part Manipulation Systems ............................................................ 27
7.6 ANSI Risk Assessment.............................................................................................................. 27
8. VENTILATION AND FILTRATION................................................................................................. 28
8.1 Scope......................................................................................................................................... 28
8.2 Reasons for Ventilation and Filtration........................................................................................ 28
8.3 Types of Dust Collection Equipment ......................................................................................... 29
8.4 Design Considerations............................................................................................................... 29
8.5 Operation/Maintenance Considerations .................................................................................... 34
8.6 Example Case ........................................................................................................................... 36
9. PIPING GUIDELINES .................................................................................................................... 37
9.1 Scope......................................................................................................................................... 37
9.2 Typical Gases/Fluids ................................................................................................................. 37
9.3 Supply Planning......................................................................................................................... 37
9.4 Piping Materials ......................................................................................................................... 38
9.5 Piping Design............................................................................................................................. 40
9.6 Piping Components ................................................................................................................... 40
9.7 Flammable Gas Piping Components......................................................................................... 41

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 Designation SG003-03

9.8 Area Classification ..................................................................................................................... 41

9.9 Piping Fabrication ...................................................................................................................... 41
9.10 Piping System Integrity Monitoring ............................................................................................ 42
10. ELECTRICAL GUIDELINES .......................................................................................................... 43
10.1 Scope......................................................................................................................................... 43
10.2 General Topics .......................................................................................................................... 43
10.3 Gas and Electrical Interlocking .................................................................................................. 44
10.4 Area Classification ..................................................................................................................... 45
11. ERGONOMICS .............................................................................................................................. 46
11.1 Scope......................................................................................................................................... 46
11.2 Design Considerations............................................................................................................... 46
11.3 Repetitive and Force of Operations........................................................................................... 47

Page 4 of 47
 Designation SG003-03

1. SCOPE
The scope of this document discusses the safety issues associated with the design and operation of thermal
spray booths and boxes. The document’s scope is limited to thermal spray booth or spray box structures and
the equipment, or systems – internal and external – required to operate the thermal spray processes within
these enclosures. This includes the mitigation of sound, dust and fume, ultraviolet light, and mechanical
(robotics) hazards that must be contained or controlled by a properly designed and properly used enclosure.
This document does not cover the Personal Protective Equipment (PPE) needs of any operator that may enter
the booth before or after the process is active. It addresses only the design of spray booths that allow normal
operation of the process from outside the booth itself (sometimes referred to as a “closed system”). This
document does not address manual operation of the process with the operator inside the booth itself. The
document does not cover vacuum plasma spray (VPS) chambers because they are substantially different from
atmospheric enclosures in their design, operation and safety considerations.

These guidelines are written within the context of the prevailing internationally accepted practices and
standards, as well as United States laws and regulations. They are intended to have worldwide application. It is
incumbent upon each individual, company, or institution referencing these guidelines, to ensure compliance with
all relevant local country/community laws, rules and regulations, and to apply generally accepted, good
engineering practice to the design, fabrication, and installation of thermal spray systems that are safe, reliable,
and legal.

Thermal Spray booth design is complex and involves many different engineering disciplines. Because of the
diverse nature of thermal spray process requirements, this document alone cannot provide all the information
needed for booth design. Suppliers/professionals with expertise in specific aspects of booth design (ventilation,
sound suppression, piping, etc.) should be consulted to ensure design safety and integrity.

This guideline is intended for use in conjunction with the other reference publications, local publications, and
applicable standards. An extensive, but not comprehensive, list of these is included in Section 4, RELATED
STANDARDS AND DOCUMENTS

2. OVERVIEW
The primary role of a thermal spray enclosure is to contain and/or control various hazards associated with
thermal spray processing of materials. Historically, thermal spray booths were used to shield the shop floor from
the intense sound pressures, dust and fumes, and ultraviolet light generated during spray operations. In the past
decade, the introduction of robotics has led to an expanded role for booths as barriers to protect humans from
being struck by fast-moving robotic arms. The most modern spray enclosures are now designed to minimize
operator exposure to a variety of thermal spray hazards. Spray boxes and fully automated spray booths that do
not require an operator to be present in the spray environment are becoming more common, and in many
situations have become an accepted requirement.

The use of an enclosed space to reduce hazards has considerably increased the safety of thermal spray
operators and shop personnel that work in the vicinity of thermal spray devices. However, an enclosure
introduces new hazards that must be dealt with. A wide variety of gases are used in thermal spray processing.
Unless proper care is taken, it is possible to create dangerous situations within an enclosure. An inert gas leak
can displace the air, leading to an asphyxiation hazard. A fuel leak or build-up of an explosive metal powder
can set up the possibility of a violent explosion. Thermal spray enclosures must be designed to provide simple
egress of operators during an emergency situation. Operators inside a spray booth may be unaware of
emergency situations on the shop floor, such as fire alarms, unless special provisions are made.

Page 5 of 47
 Designation SG003-03

The thermal spray enclosure is the most important safety device used in thermal spray processing. Because the
spray operations are conducted within its confines, all of the energy sources (gas, electricity, and water), the
feedstock materials, and all of the process effluents (heat, dust, fumes, sound and ultraviolet light) are present.
Proper mitigation of all of these hazards requires careful thought in the design and operation of a spray booth.

3. SPECIAL TERMINOLOGY USED WITHIN THIS GUIDELINE

Within this document, distinct terminology is employed to differentiate between Requirements,
Recommendations, and Considerations. The meanings of these terms in any word form are defined below
and wherever these terms are used in these guidelines in the context of a safety practice, they are presented in
bold italic typeface.

A Requirement is a safety practice that must be conformed to at any thermal spray facility. Typically a
requirement is already an industry-accepted or government-regulated practice about which there is little or no
debate regarding the importance of its safety-related issues, and the methods by which identified hazards are
mitigated. An example of a Requirement would be that the piping used to carry acetylene may not be fabricated
from alloys that contain more than 65% by weight of copper or other identified reactive constituents. It is well
known that that the use of copper tubing for carrying acetylene is very dangerous, due to the formation of
unstable compounds, and it is difficult to imagine any thermal spray installation in which copper tubing is
acceptable for carrying acetylene.

A Recommendation is applied to a safety practice that should be carefully considered before a reader chooses
to ignore it. Recommendations should not be dismissed lightly. There may be certain situations in which a
recommendation can be ignored, but in general, most thermal spray facilities should implement all
recommendations. An example of a Recommendation would be the installation of a manual shutoff valve
(Station Outlet valve) for each gas at each spray booth in a facility. There may be situations in which installing
this valve is not appropriate; however, before deciding to ignore this recommendation, the thermal spray facility
designer should carefully think through how isolating the gases from an individual booth would be accomplished,
if necessary.

A Consideration is a safety practice that may be contemplated for implementation at a thermal spray facility.
Considerations are safety enhancements that may not be essential or applicable to all situations. An example of
a Consideration would be the installation of an oxygen or combustible gas monitor in a spray booth, the
purpose of which is to detect the formation of a dangerous atmosphere. The ability to detect an asphyxiating or
combustible atmosphere is a measure that improves safety. However, these sensors are prone to failure, and
can be expensive to install and maintain. By properly designing a booth with various interlocked solenoid valves
and natural ventilation, the possibility of forming a dangerous atmosphere can be reduced to the point that
monitors do not provide a substantial increase in safety.

Page 6 of 47
 Designation SG003-03

4. RELATED STANDARDS AND DOCUMENTS

Where standards and other documents are referenced in this publication, they refer to the latest edition.

U.S. Standards
Publication Title Available from:
ASTM Publications: Specification for Pipe, Steel Black and American Society for Testing and
A53 Hot-Dipped, Zinc-Coated Welded and Materials
Seamless 100 Bar Harbor Drive
A105 Specification for Forgings, Carbon West Conshohocken, PA 19428-
Steel, and Piping Components 2959
A106 Specification for Seamless Carbon www.astm.org
Steel Pipe for High-Temperature
Service
A182 Specification for Forged or Rolled
Alloy Steel Pipe Flanges, Forged
Fittings and Valves and Parts for High
Temperatures
A312 Specifications for Seamless and
Welded Austenitic Stainless Steel
Pipes
E-84 Surface Burning Characteristics of
Building Materials
E-447 Compressive Strength of Laboratory
Constructed Masonry Prisms
CGA Publications: Acetylene The Compressed Gas Association
G-1 1235 Jefferson Davis Highway
G-1.3 Acetylene Transmission for Chemical Arlington, VA 22202
Synthesis www.cganet.com
G-4 Oxygen
G-4.1 Cleaning Equipment for Oxygen
Service
G-4.4 Industrial Practices for Gaseous
Oxygen Transmission and Distribution
Piping Systems
ANSI Publications: Chemical Plant and Petroleum American National Standards
ANSI/ASME B31.3 Refinery Piping Institute
A 13.1 Scheme for Identification of Piping 1430 Broadway
R15.06 Safety Procedures for Industrial New York, NY 10018
Robots and Robot Systems www.ansi.org

Page 7 of 47
 Designation SG003-03

Publication Title Available from:

rd
EPA Publications Industrial Ventilation, 23 edition, U.S. Environmental Protection
1998 Agency
Ariel Rose Bldg.
1200 Pennsylvania Ave., N.W.
Mail Code 3213A
Washington D.C. 20460
www.epa.gov
NFPA Publications: Sprinkler Systems National Fire Protection Assoc.
13 Battery March Park
51 Design and Installation of Oxygen- Quincy, MA 02269
Fuel Gas Systems for Welding, www.nfpa.org
Cutting and Allied Processes
68 Explosion Deflagrations (Venting)
69 Explosion Prevention Systems
70 National Electric Code, Article 500,
Hazardous Locations
255 Std. Method of Test of Surface
Burning Characterizations of Building
Materials
484 Combustible Metals, Metal Powders,
and Metal Dusts.
496 Purged and Pressurized Enclosures
for Electrical Equipment
497M Classification of Gases, Vapors,
Dusts for Electrical Equipment in
Hazardous Locations
TSS Publications: Safety Guidelines for the Handling ASM International®
SG001-02 and Use of Gases in Thermal 9639 Kinsman Road
Spraying Materials Park, OH 44073-0002
SG002-02 Safety Guidelines for Performing Risk www.asminternational.org
Assessments
OSHA Publications Occupational Safety and Health
Administration
1-800-321-OSHA for nearest
location
www.osha.gov

SMACNA SMACNA HVAC Duct Construction SMACNA, Inc.

Standards – Metal and Flexible 4201 Lafayette Center Dr.
Chantilly, VA 22021
Ph. 703-803-2980; Fax: 703-803-
3732

Page 8 of 47
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INTERNATIONAL STANDARDS

Available from:
Publication Title
International Organization
EN ISO 2063 Thermal spraying -- Metallic and other inorganic
For Standardization
coatings -- Zinc, aluminium and their alloys
1, rue de Varembé, CH-1211
Geneva 20, Switzerland
EN ISO 14231 Acceptance inspection of thermal spraying
equipment Phone +41 22 749 01 11

EN ISO 14232 Powders -- Composition and technical supply Fax +41 22 749 09 47
conditions
E-mail [email protected]

EN ISO 14917 Thermal spraying – Terminology, classification

Page 9 of 47
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5. TERMINOLOGY/DEFINITIONS
ACGIH – American Council of Industrial Hygienists.

Administrative Controls – Reducing the risk of injury through management of the processes and workforce.

ANSI – An abbreviation for American National Standards Institute.

ASTM – An abbreviation for American Society for Testing and Materials.

AWS – An abbreviation for the American Welding Society.

Approved – Acceptable to the authority having jurisdiction.

Branch Lines – The piping that leads from the Main pipeline to Station Outlet Valves supplying the Process
equipment.

CGA – An abbreviation for the Compressed Gas Association.

Detonation Gun – A thermal spray device that employs rapid detonation of an oxygen-fuel mixture to heat and
carry coating powders to the surface of a part in order to apply a coating that enhances the part’s surface
performance properties.

Dead Air – Areas where there is little or no air motion such that dust or particulates in the air will fall and
accumulate on the booth interior surfaces.

Decibel (dB) – A numerical expression of the relative loudness, or intensity, of a sound. The difference in
decibels between two sounds is ten times the logarithm of the ratio of their power levels. The “A” suffix when
used with dB (dBA) signifies a non-linear averaging of noise levels across ten octave bands to compensate for
human ear sensitivity to sound at various frequencies.

De-ionized Water – Water from which nearly all ions (electrically charged particles) have been removed
returning it to its purest state to minimize corrosion, or other chemical reactions. Often required or
recommended by manufacturers for cooling water.

Design Pressure – The same as Maximum Allowable Working Pressure referenced in many codes. This
pressure is typically at least 15% higher than system Operating Pressure,

Dry Ice (CO2 Snow) – the solid state of carbon dioxide. Usually forms when a sudden pressure release of CO2
occurs such as spraying.

Effluent – A term used to encompass all the gases, coating, fumes, etc. emitted from a thermal spray gun or
torch.

Enclosure – The cabinet or housing of apparatus or the fence or wall surrounding an installation to prevent
personnel from personal injury hazards or to protect the equipment from physical damage.

Engineering Controls – Reducing the risk or potential for injury by incorporating safety systems, features,
interlocks, etc. into the design of machines, tools, layouts and processes.

EPA – abbreviation used for the Environmental Protection Agency (USA).

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Equipment - A general term including materials, fittings, devices, appliances, fixtures, apparatus and the like
used as a part of, or in connection with, a thermal spray installation.

Ergonomics – The process or science of adapting workstations, tools, equipment and work techniques to be
compatible with human anatomy and physiology so as to reduce the risk of injury due to occupational activity or
stresses.

Fuel Gas – Any combustible gas, including hydrogen, propane, propylene, acetylene, MAPP, etc. used in a
thermal spray process.

Fuse – An over-current protective device incorporating a fusible component or link that is heated by excessive
current flow and subsequently separates, or opens, halting the flow of current. A fuse is typically not reusable.

Fumes – Particulate matter consisting of particles generated by the condensation of gases created by
evaporation of melted substances.

Frequency – The number of cycles-per-second of a device, signal, or parameter. Generally expressed in

Hertz (Hz).

Ground Fault (Circuit) Interrupter (GFI or GFCI) – A protection device designed to remove the electrical
power from a circuit when an imbalance of current exists between the supply conductor and the return
conductor indicating the presence of a leakage fault path, usually to ground or earth. Such a fault path could be
a result of malfunctioning or damaged equipment. For example: water leaks and subsequent corrosion, or
contact with tools or personnel. Early detection of faults and disconnection of power by a GFI device can often
avoid or minimize damage or injury.

HEPA – An abbreviation used for High Efficiency Particulate Air. In reference to air filters, it specifies that
99.97% of particles larger that 0.3 micron will be removed from the air stream.

HVOF – High Velocity Oxygen Fuel. This type of high velocity coating process uses a liquid or gaseous fuel
combusted with oxygen to heat and carry coating material to the surface of a part in order to enhance the part’s
surface performance properties.

HVAF – High Velocity Air Fuel. This type of high velocity coating process uses a gaseous fuel with air to heat
and carry coating material to the surface of a part to enhance its surface features.

Interlock – A switch or other device that prevents the activation of a piece of equipment when a protective door
is open or other hazards exist.

LPPS – Low Pressure Plasma Spray. See preferred term Vacuum Plasma Spray Deposition.

Lock-out/Tag-out – The process of locking and tagging any energy source (typically a valve or electrical
shutoff) to isolate sources of energy during maintenance/repair and prevent inadvertent operation – or release of
energy or hazardous material.

Main Piping – That portion of a gas piping system that leads from a gas supply source to the branch piping.

MSDS – An abbreviation used for Material Safety Data Sheets.

Negative Pressure – An area or volume, such as the interior of a spray booth, which is at a lower pressure than
the surrounding area..

NFPA (National Fire Protection Association) – A U.S. based organization providing advisory standards
offered for use in law and for regulatory purposes in the interest of life and property protection.

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NIOSH – National Institute for Safety and Health

Noise - Unwanted sound which may be hazardous to health, interferes with communications, or is disturbing.

Operating Pressure – The pressure at which a system normally operates; not the pressure to which a system
may be subjected to during upset, or unusual circumstances. At the inlet to the piping system, the Operating
Pressure equals the Supply Pressure. The Operating Pressure in a portion, or all, of a piping system may be
reduced with a pressure regulator (pressure reducing valve).

OSHA – Occupational Safety and Health Administration (USA).

Permissible Exposure Limit (PEL) – is the maximum amount or concentration of a chemical that a worker may
be exposed to under OSHA regulations.

Piping – The parts of a fluid/gas system that consist of conduits in the form of rigid pipes, tubing (flexible),
interconnecting fittings, and in-line accessories.

Process Equipment – The mechanical and/or electrical devices and associated control systems that are used
to produce coatings or produce surface enhancements, and whose operation directly affects the chemistry, or
the physical properties, of the final product. Typically, this includes gas consoles, regulator panels, hose
bundles, powder feeders, gases and gas supplies, and the thermal spray gun or torch.

Purging – The process of admitting an inert gas into one end of a pipeline or container and venting the other
end for a specific period of time. Used to remove (purge) hazardous or combustible materials from the pipeline
or container.

PVC – (Polyvinyl Chloride) – A type of material commonly called plastic pipe. It is used for its corrosion
resistance and ease of fabrication, but usually has lower impact resistance and pressure ratings as compared to
metal piping.

RIA – Robotic Industry Association. A co-publisher, with ANSI, of robot safety standards.

REL (Recommended Exposure Limit) – An 8 or 10-hour time-weighted average (TWA) or ceiling (C) exposure
concentration recommended by NIOSH that is based on an evaluation of health effects data.

Safeguarded Space – Shielded, fenced, covered, enclosed or otherwise protected by means of suitable covers,
casings or barriers to remove the likelihood of unsafe approach.

SMACNA – Sheet Metal and Air Conditioning Contractors National Association.

Sound – A vibrational disturbance, exciting hearing mechanisms, transmitted in a predictable manner

determined by the medium through which it propagates.

Sound Pressure – Fluctuations in air pressure caused by the presence of sound waves.

Sound Pressure Level - The intensity of a sound, expressed in decibels (dB).

Spray Booth – An enclosure for thermal spray processes that is specifically designed to mitigate process
hazards. A spray booth is NOT designed for human occupancy during routine spray operations; however, it is
routinely occupied for maintenance and process setup.

Spray (Coating) Box – A spray (coating) box is an enclosure for thermal spray processes that is specifically
designed to mitigate process hazards. These boxes are NOT designed for human occupancy during routine
spray operations, process setup and routine maintenance.

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Spray Enclosure – A term used in this document whenever a statement is equally applicable to either a spray
booth or a spray (coating) box.

Station Outlet Valve – The shut-off valve located at the downstream end of the branch piping or the point at
which process equipment is connected to the piping system.

Test Pressure – The pressure to which devices/piping are subjected for design testing purposes. Typically this
pressure is 1.3 to 1.5 times greater than the Operating Pressure for pressure vessels; often many times greater
for piping.

Threshold Limit Value (TLV) – are guidelines prepared by the American Conference of Governmental
Industrial Hygienists, Inc (ACGIH) to assist in making decisions regarding safe levels of exposure to various
hazards found in the workplace. A TLV reflects the level of exposure that the typical worker can experience
without an unreasonable risk of disease or injury.

Turbulent Flow – Flow of air that is not uniformly distributed over a cross section of a pipe, tube or hose,
resulting in unpredictable eddies, vortices, back-flow, and areas where little movement of air occurs.

Vacuum Plasma Deposition (VPD) – A thermal spraying process variation utilizing a plasma gun confined to a
solid enclosure. The enclosure is evacuated and the spraying performed under low pressure, also known as
®
Vacuum Plasma Spray (VPS), Low Pressure Plasma Spray (LPPS ).

Ventilation System – A complete air handling and filtration system for a thermal spray booth from the intake of
air into the process to the exhaust of the air back into the atmosphere. In this document, the spray booth is
considered as part of the exhaust system in regard to air flow.

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6. BOOTH STRUCTURE AND SOUND SUPPRESSION

6.1 Scope

This section on Booth Structure and Sound Suppression provides information intended to promote increased
safety awareness in the design and configuration of basic booth enclosures for thermal spray installations.

The focus of this section is on the key elements of booth structure and how structure and configuration issues
impact the safety of operators and employees. The structure of a typical thermal spray booth has the primary
function of controlling exposure to the following major hazards:

ƒ Excessive sound levels

ƒ Powder / dust from the process
ƒ Gases / Fumes
ƒ Visible light and ultraviolet (U.V.) radiation

The configuration of a typical thermal spray cell, in most cases, centers on an enclosure structure that works
with other sub-systems (interlocks, controls, ventilation/ filtration, etc.) to provide effective control and protection
from these major hazards.

Ventilation System

Thermal Spray Booth

Operator’s
Booth Control
Ventilati on Contro ls Console
C ontro ls Spray Equipment

Figure 6-1. Typical Thermal Spray Booth Configuration

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6.2 Configuration

Typical thermal spray installations include an enclosure that protects the operator and the surrounding areas
from the hazards associated with the thermal spray process while it is in operation. There are three main types
of enclosures used to contain the process and allow its operator to remain outside its confines:
Walk-in style booth – A Walk-in booth consists of an enclosure that surrounds the process, the part, and the
gun or torch manipulating equipment in such a manner that the operator need not be present in the booth during
normal operation. The operator or other personnel are typically in the booth for job setup and routine
maintenance of the equipment, but operation of the process, and the manipulating equipment used to perform
the actual thermal spray coating, may be initiated remotely only by the operator with controls located outside of
the booth. Interlocks between gases, the process, ventilation, and operator entry are designed accordingly.
This style of thermal spray booth is the most common type. This is largely due to its flexibility to accept
components, fixtures and equipment with considerable variation in size and configuration with minimal
modification and associated costs. Such a configuration, with proper interlocks and safety systems, can
satisfactorily limit the exposure of the operator and other personnel to the major hazards associated with
thermal spray process and support equipment.
Spray (Coating) box – A Spray box has its enclosure closely fitted to the thermal spray device and part
manipulation equipment. This arrangement allows the operator to load parts for coating through a door while the
process is shut off, and never requires entry onto the area where coating takes place. Such an arrangement
affords maximum efficiency for dust collection (smallest ventilated volume) and provides the greatest operator
safety. Eliminating the need to enter the confines of the spray box provides the maximum level of protection
from exposure to particulate matter, fumes, gases, noise, and radiation as well as improved protection from
moving mechanical components.
Thru-the-Wall booth – Either of the above types can be configured to allow the passing of parts through a port
or load-lock while the process is in operation, often providing higher productivity than other configurations.
Proper design must be followed to limit operator exposure to the major hazards of sound, radiation, or dust.
Additionally, care must be taken to properly interlock manipulation equipment operation to protect the operator
from potential pinch/crush points associated with the door.
Both the Spray box and Thru-the-Wall booth designs see limited application because of reduced flexibility to
changing needs and resultant increased costs of tooling. Both types share many of the same design
requirements of the Walk-in style booth but typically differ considerably in the area of interlocking.

6.3 General Construction

Construction of the basic booth (wall, ceilings, door panels, etc.) must meet the sound attenuation requirements
for the specific process in use. Typically, materials that meet sound attenuation requirements easily meet
radiation (thermal/visible/UV) and dust control requirements. Thermal spray booth construction is most often of
modular acoustical panels or, in some cases, of conventional block and mortar construction.
Modular construction - This construction method typically comprises sheet steel panels filled with a form of
non-flammable insulation such as fiberglass. The panels typically consist of solid steel sheet on one side and
perforated metal on the other. The enclosure is normally constructed with the perforated side of the panels
toward the sound source.
Block and Mortar – This construction method is rarely used today due to economic constraints and lack of
portability. However, this method of construction can easily meet basic safety requirements for operator
protection.

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General Requirements
Non-flammable – The nature of the thermal spray process requires that general booth construction materials be
non-flammable.
Sound Suppression – The design and construction of the booth is the single most significant factor determining
the attenuation of sound associated with the thermal spray process. It is required that sound be attenuated to
acceptable levels as dictated by local codes and standards to ensure operator protection. Additional information
on this topic can be found in Section 7.5.

Access Doors / Windows

Design and construction of booth doors are critical to providing adequate sound suppression and operator
protection from powders, dusts, gases, fumes, and UV radiation.
It is required that doors be provided with positive latches, hinges and seals that ensure continued protection of
personnel from the above hazards.
The weight of the door, its frequency of access, and difficulty of operation should be considerations in
determining whether the door should be mechanized.
It is required that observation windows be constructed of multi-layered transparent plastic material or tempered
glass for breakage resistance and safety. Windows employed in spray booths using plasma or wire arc spray
processes require the appropriate level of shading for UV protection. This may be a roll-up style shade. A
prominently displayed warning sign is required advising of the dangers of UV exposure.

Booth Wall and Ceiling Penetrations

Penetrations, or openings, through sound control walls are a necessary conduit for electrical cables and gas
and/or water hoses and pipes. Suitable sound absorbent materials are typically used to control the sound
conducted and radiated through such openings. It is required that all openings be sealed to minimize sound
leakage and maintain an adequate seal against powder / dust leakage.
Penetrations through typical panels are required to be lined such that hoses and cables are not exposed to
sharp edges.
Booth Ceilings / Roofs
Often the ceiling or roof area of a thermal spray booth is utilized as a location for the mounting of equipment
such as fans, power sources, and filtration equipment. Additionally, the ceiling inside of a booth is often required
to support small hanging hoists and/or other parts handling devices. Sound insulation panels are often of
lightweight construction that needs adequate reinforcement to meet equipment support needs. Adherence to all
local building codes for such areas is required.
The typical thermal spray cell ceiling, or roof, is primarily designed for sound control, and as such is typically not
designed for carrying loads. It is recommended that due consideration be given to the design load capacity of
the ceiling/roof of the thermal spray booth if these surfaces and areas are to be used for mounting and storage.
Consideration should be given to:
• Proper reinforcement for the mounting of all hoists and other part-handling devices.
• Appropriate reinforcement of roof areas to properly support mounted equipment.
• Adequate walk areas to facilitate safe servicing of equipment.
• Railings, toe boards, and other appropriate fall-protection devices to ensure that the top of the booth
is a safe workplace. Openings in the railing must be chained or gated.
• Ladders or stairs to provide easy and safe access to the booth roof area.
• Suspension of heavy items from the facility roof to avoid load on the cubicle.

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Booth Cleaning
Consideration should be given to regular cleaning of the interior of a thermal spray booth. The frequency of
cleaning requirements depends on the process type, coating material type, part configuration and vent system
design.
Since many thermal spray powders are considered hazardous materials, often the safest cleaning method is a
HEPA vacuum cleaner. In some cases, washing of floors and/or walls may be necessary. In many cases, the
waste cleaning liquid will be considered hazardous waste and will require handling that complies with local
regulations.
Typical perforated sound panels become impregnated with thermal spray particulate over years of booth
operation. Although this does not seem to affect sound absorption performance, washing of such used panels
with liquid presents unique problems and should be avoided. In addition, used panels, when shipped or
disposed of, often must be categorized as hazardous waste.

6.4 Sound Hazards and Control

Noise and Noise Level

Noise is defined as an unneeded and objectionable sound. Excessive noise, common to most all thermal spray
devices, can reduce productivity, slow reaction times, and can cause tension, hearing impairment, and
nervousness.

The Occupational Safety and Health Administration (OSHA) and similar organizations worldwide require
employers to provide safe working conditions. These organizations typically do not provide guidelines specific to
an industry or process but they do establish general rules for the control of unsafe and unhealthy conditions.

Noise level is a measurement of sound wave energy (pressure). The standard unit of sound measurement is
decibels (dB). The use of the decibel, a unit based on the logarithm of the sound intensity power, provides a
scale that better represents how loud the sound or noise is perceived by a typical human.

Typical Sound Power Levels of Various Sources

Source Sound Power, Decibel, dBA

Watts
Saturn Rocket 100,000,000 200
Afterburner, Jet Engine 100,000 170
75 Piece Orchestra 10 130
Centrifugal Fan at 0.1 110
13,000 cfm
Automobile on Highway 0.01 100
Food Blender 0.001 90
Dishwasher 0.0001 80
Voice, Normal 0.00001 70
Conversation Level
Duct Silencer, self noise 0.00000001 40
at 1,000 fpm
Quietest Audible Sound 0.000000000001 0

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Typical Thermal Spray Noise Levels / Noise duration tolerance

Thermal spray processes generate high noise levels. The following table shows typical noise levels of various
processes. Parameter settings and coating types have significant impact on overall sound levels.

Thermal Spray Device Decibel, dBA

Detonation gun 145
HVOF liquid fuel 133
HVOF gaseous fuel 125 - 135
HVAF 133
Wire Flame Spray 118-122
Powder Flame Spray 90-125
Rod Flame Spray Gun 125
Electric Arc 105-119
Air Plasma Spray (APS) 110-125
Vacuum Plasma Deposition (VPD)/LPPS® Ambient 1
Cold Spray 110
Water Stabilized Plasma 125
RF Plasma 95

The table below shows typically accepted tolerable noise limits for various exposure times: the louder the noise
level present, the shorter the permissible exposure time.

Tolerable Noise Limits of Various Exposure Times

(Source NIOSH – ACGIH)
Exposure Duration (Per Day) Sound Level (dBA)
Hours
16 82
8 85*
4 88
2 91
1 94
Minutes
30 97
15 100
7.5 103
2 109
* OSHA Requirements state that any exposure over this level requires hearing protection.

Typical Booth Acoustical Construction

1
Some processes, such as VPS (also known as Low Pressure Plasma Spray, or LPPS®), are carried out within a vacuum
chamber that takes the place of a conventional acoustic enclosure. In many instances, noise from the main process is
attenuated beyond the point of being any concern. However, in many cases, continuous noise from pumps, fans and other
ancillary equipment is at such a level that steps must be taken to protect personnel appropriately.

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Modular construction typically will consist of panels approximately 4 inches (102 mm) in thickness with sheet
metal inner and outer walls packed with a sound absorbent material such as fiberglass. More often the inner
panel is perforated to better allow the acoustic energy to enter and thus dissipate within the absorbent material.
It is common for plasma, electric arc, and HVOF devices to utilize single-walled booths while the lower
frequency sound signatures associated with detonation devices typically will require double-walled booths often
with heavier mass sound absorbent materials.

Typically, the supplier of the acoustic enclosure can provide access door and window designs to suit the needs
of the installation. It is critical that door seals remain tight and receive regular maintenance attention such that
the full acoustic effectiveness of the enclosure can be maintained. Particular attention needs to be given to
windows, seals around windows and wall penetrations, seals against the floor, sound reflections of building
ceilings, etc.

Numerous alternative solutions can provide good performance for thermal spray processes. Consult with the
supplier of the thermal spray device or similar devices to obtain the best advice on solutions for specific acoustic
spray booth application and configurations.

Exposure Control

In most situations, it is the employer that has the ultimate responsibility for protecting employees from excessive
noise. In the case of new equipment construction, be sure that the vendor provides adequate noise control and
that the proper tests are conducted during equipment acceptance to ensure compliance with local safety and
health regulations.

Used equipment can often present difficult problems if the appropriate noise control qualities are not designed
into the equipment. Given a specific equipment design, certain engineering, administrative and personal
protective schemes may help. Some examples are:

Work Area Isolation

Increasing the distance between the noise source and the employee lowers the sound pressure level. The
following table lists how increasing distance can reduce decibels in a free field.

Using Distance to Reduce Decibels

Distance from Theoretical dBA
Source Reduction
3 feet (1 m) 0
10 feet (3 m) 10
30 feet (9 m) 20
90 feet (27 m) 28

Blocking the path of sound transmission by adding sound absorbing materials to the work area will provide
significant noise reduction. Consult noise control experts for material recommendations. Noise may also be
isolated by moving its source away from affected personnel or placing the equipment in an acoustically insulated
enclosure. Often adding insulation to an existing enclosure can provide additional attenuation.

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Plan and Schedule to Reduce Exposure Time

Engineering controls focus on eliminating, reducing, or containing the noise hazard. Administrative controls
attempt to reduce exposure time.

Planning and scheduling are best used where spraying is intermittent. Usually, spraying time is a small
percentage of the total job compared with setup, surface preparation, and finishing.

If spraying time exceeds the permissible levels for noise exposure, schedule jobs over more than one shift or
day to keep exposure within maximum limits. More than one operator can spray jobs to keep the exposure of
any one person within limits. Spraying outside of regular plant hours can control exposure of persons near the
operation. Also, rotate personnel assignments in the vicinity of the thermal spraying operation to control
exposure.

Use of Personal Protective Equipment (PPE)

If generally accepted or local regulatory requirements cannot be met regarding sound exposure, it is required
that employers supply and mandate the use of appropriate personal protective equipment.

6.5 Powder and Dust Control

Powder and dust control are mainly provided by the ventilation/filtration system discussed in Section 8; however,
some issues are more specifically related to booth structure and controls and as such are deserving of coverage
here:

Integrated Design

The booth design needs to be linked with good ventilation flow and control. Often, the early design selections
regarding booth or coating box layout can have a major impact on the ability to establish good ventilation flow
and the ability to carry waste powder to the filtration system. Specific ventilation areas impacted by booth layout
are:

Total air flow and local velocities – Booth layout will affect total air flow capability and will determine local
velocities. Local air velocities will have a significant impact on the ability of the system to capture dust particles
and carry them into the ductwork leading to the filters rather then having them settle and accumulate on the
booth floor, walls and tooling.

Laminar flow – The smoothest possible flow of air is very beneficial to the effective removal of dust from the
process area carrying it into the ducts leading to the filters. Turbulent flow often will create eddies and low
pressure areas that cause dust to be trapped or dropped from the air stream. Necessary and sometimes
unnecessary booth obstacles such as tooling, parts to be sprayed, robots, and fixtures in practice detract from
smooth air flow however steps can still be taken to maximize performance for any given installation.

Negative Pressure – Exhaust fans, inlet fans (if so equipped) and dampers should be adjusted such that a slight
negative pressure is maintained within the thermal spray booth when closed and operating. Typical booths are
not completely airtight. The effect of a slight negative pressure is that small leaks are in an inward direction
carrying dust to the interior and the filters rather than leaks in an outward direction that carry dust and fumes into
the shop areas.

Entry Timer – A timer should be considered to prevent entry into the booth until a preset time has elapsed after
the shutdown of the process. This allows the ventilation system to clear the air of hazardous dust.

Important: A spray booth with poor ventilation or one that allows entry before the ventilation flow can
adequately remove airborne dust particles may result in unacceptable exposure of entering personnel to dust
inhalation hazards. If entry is required, appropriate PPE must be worn.

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6.6 Radiation Control

Typical thermal spray processes radiate energy in both electromagnetic and acoustic forms. Emission of sound
(acoustic) energy and its control are adequately covered elsewhere in this document. Electromagnetic radiation
associated with thermal spray processes is typically divided into two classes. Such radiation can occur in the
visible (or near visible) range and also as un-wanted electromagnetic radiation in the power and radio frequency
portions of the electromagnetic spectrum.

Ultraviolet, Bright Visible, and Infrared Radiation are common when using thermal spray devices and certain
precautions are required in order to adequately protect employees from their effects. Typically direct effects will
include temporary and/or permanent damage to the eyes as well as burns to the skin.
Electromagnetic Radiation can take the form of unwanted radio-frequency (RF) waves capable of transmission
through the air or along wiring, piping and metal based construction materials. At levels commonly associated
with thermal spray devices, it is not likely that RF radiation can approach the levels necessary to cause injury
(such as might be experienced in a microwave oven). However, radiated RF energy from machinery (especially
thermal spray equipment using electric arcs and arc starters) can cause malfunctions of other equipment which,
in turn, could have serious affects on the health and well-being of personnel in the area. Steps are often
required to minimize such radiation and ensure the posting of warnings announcing its presence.

Protection - Ultraviolet, bright visible and infrared radiation

Increasing distance from a radiation source has a considerable effect on the energy level and thus the resultant
hazard to personnel. A typical properly interlocked thermal spray booth affords some protection for the operator
in that it prevents close observation such as might be an issue with a process such as manual welding.

Arc burns and permanent eye damage can still occur from exposure to the radiation from plasma, electric arc,
and some flame processes through windows in the spray booth wall. Proper use of tinted glass and/or pull-down
shades can prevent such injuries. A protection scheme suited to the specific process and booth configuration is
required. Consult with the manufacturer of the thermal spray process equipment to determine what steps are
appropriate and in keeping with locally established regulations.

Protection – Electromagnetic radiation

Electromagnetic radiation from thermal spray process, also known as EMI/RFI, is most often the result of
electric-arc-based processes (electric arc spray, DC and RF plasma). Substantial electric currents in gun cables
and ground paths as well as in high-frequency arc starting circuitry are often the cause. Shielding of high-current
cables, although effective, is often not possible due to performance degradation.

The problem is often best controlled by arranging equipment such that gun-to-power source electrical cables are
the shortest length possible. Also high frequency arc starter assemblies should be located as close to the
process gun as possible. Cables such as these can behave as radio frequency transmitting antennae and need
to be kept as short as possible. Also, if such process power cables are run parallel and close to metal
conductors such as pipes, structural supports, other cables, etc. transmission and re-radiation can occur. These
recommendations will minimize radiation and control potentially hazardous effects.

Equipment marketed in Europe is now required to meet the EMC (Electromagnetic Compatibility) Directive.
This unified European directive requires that machinery pass tests regarding emission of electromagnetic
radiation as well as tests verifying the equipment’s resistance to radiation from other equipment.

The equipment supplier is the best source of information regarding radiation and adequate protection from it as
well as the appropriate posted warnings that may be required by local codes.

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6.7 Safety Interlocks

Safety Interlocks should be incorporated into any good thermal spray booth layout. Such interlocks provide
protection from hazards by techniques including, but not limited to: removing power, preventing entry, limiting
equipment travel, starting a fan, sounding a warning and the like.

The following is a listing of some typical interlocks used to mitigate hazards associated with thermal spray
processes that provide the necessary level of safety in relation to that hazard. Note: This cannot be a complete
list as the hazards are as many as there are variations in booth configuration. Completing a design review and a
risk analysis is recommended to help identify hazards and thus ensure the appropriate steps are taken to
reduce those hazards. In many cases local codes and/or laws require such attention.

Access Door Interlocks – Switches that require doors to be fully closed to enable process start, and stop the
process if opened during operation.

Electrical cabinet Interlocks – Typically remove internal power when a cabinet is opened and are often required.

Emergency Stop – Typically push to lock – pull to release button(s) provided to remove power (as appropriate)
in an emergency. It is highly recommended that all E-stop buttons in a spray system perform the same
function.

Gas Interlocks – Used to block gas flows under certain conditions in addition to problems with lack of ventilation.

Lock-out/Tag-out − System shutoff means are required to allow all energy sources to be disconnected and
isolated from the thermal spray system or cell. Such shutoff devices must be equipped to accept a lockout
device and associated tag to prevent accidental re-energizing of the equipment and subsequent exposure of
personnel to hazards

Power interlocks – Used to prevent power application unless certain conditions are met.

Presence sensing switches – Often used to ensure the operator is in a safe position during an activity.

Travel limit switches − Used to protect personnel and hardware from equipment over-travel.

Travel speed limit interlock – Used to limit robot speeds during teach mode and is required.

Ventilation/Gas flow interlock – It is recommended that all spray equipment should have appropriate interlocks
to prevent operation unless there is adequate ventilation flow. It is also required that all fuel gas lines entering a
spray booth be interlocked to ensure adequate ventilation flow is detected prior to enabling process gas flow.
Ventilation/Spray Booth access – To ensure time for the booth atmosphere clearance, it is recommended that
cubicle access be interlocked by a timer that requires ventilation flow to continue for a specific time after the
process is stopped before allowing cubicle entry.

Local codes and regulations have much to say regarding interlocks and how they are to be implemented. It is
recommended that the equipment supplier be consulted to ensure compliance with local requirements.

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6.8 Warning / labeling

As is the case with all industrial equipment thermal spray equipment, warning labeling is required to ensure that
employees are aware of the associated hazards and the steps and/or equipment required to allow them to
perform their job in a safe manner.

The following list represents some examples of hazards normally found in thermal spray installations that may
require labeling:

• Metal powders and associated dangers of inhalation and ingestion

• Gaseous and volatile substances or other chemical by-products
• High velocity ventilation systems
• Robot arms
• Doors and other mechanisms
• High voltage/high frequency ignition systems
• Combustible gases
• High current DC power sources
• Ultraviolet and/or infrared radiation
• High intensity noise
• Pressurized powder feeders

Local codes and regulations again have much to say regarding the proper use of warning labels. The European
Union countries require labeling in the native language of the country where the equipment is used. It is
recommended that the equipment supplier be consulted regarding compliance with local requirements
regarding this subject.

6.9 Maintenance Issues (Safety Related)

Preventive Maintenance (PM) of thermal spray equipment, as with any piece of complex industrial equipment,
will directly impact efficiency and reliability of the installation as well as the quality of the coatings produced.
Even more importantly, many maintenance requirements and procedures have a direct impact on safe operation
and the safety of the employees operating and in proximity of the equipment. Larger organizations often have
PM programs that help to document, prompt and report on maintenance activities. If such a system is in place it
is recommended that the thermal spray systems maintenance requirements are incorporated.

Should such a system not exist, it is recommended that, at a minimum, safety-related PM requirements for the
system are documented and posted at the thermal spray cell. The following is a partial list of safety-related PM
items often considered unique to thermal spray (or similar) equipment.

• Vacuuming booth floor* 2

• Vacuuming booth walls*
• Vacuuming fixturing*
• Checking the integrity of visible radiation (UV) shields
• Checking the function of critical interlocks
• Testing/verification of pressure relief devices
• Checking and ensuring proper use of any required Personal Protective Equipment (PPE)
• Testing of emergency stops
• Leak checking and/or visual inspection of hoses / cables
• Calibration and maintenance of any gas monitoring devices

* HEPA equipment required.

2
Powder accumulation on booth floors can be very slippery, and may create a fall hazard if not regularly removed.

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7. ROBOTICS AND TORCH/PART MANIPULATION

7.1 Scope
The scope of this section is limited to the design elements necessary to mitigate hazards presented by the
movement of robotic or X-Y-rotary torch mounts or part-positioning equipment within the coating booth. During
normal operation, the spray booth itself is designed to isolate the operator and others from robotic arm
movement and other hazards. Process control is from outside the booth itself and access door(s) are interlocked
to terminate robot operation if the doors are opened during operation. This section is concerned with
operation/maintenance safety during setup and maintenance functions inside the booth itself when the coating
process is not running. Other elements of booth design in this document address the containment of
sound/fume/gas hazards during the coating process.

7.2 Robotic Arms and Robot Systems

Defining Space in and around the Robot Arm

Figure 7-1. Areas of Arm Movement Defined as Specific Spaces

The ANSI/RIA R15.06 Standard defines the Operating, Restricted, Maximum, and Safeguarded Space
around a robot arm. These are terms applied to a 3-dimensional envelope through which the arm can move, or
a larger area where a safety hazard may result from unexpected arm movement with the potential for pinch
hazard creation between the arm and other physical elements of the booth interior (walls, part positioning
equipment, etc.).

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The Operating Space is the arm's normal-operation, 3-dimensional space, as defined by its control system and
its software or electrical limits while coating parts.

The Restricted Space defines a limited area through which the robotic arm and all tooling or process equipment
mounted on the arm can move, before it encounters mechanical movement restricting stops, barriers, limits of
travel, etc. if something goes wrong with the control system.

The Maximum Space defines the maximum area through which the robotic arm and all tooling or process
equipment mounted on the arm can move without restricting stops, barriers, limits of travel, etc.

Safeguarded Space is the volume of space defined by perimeter Safeguarding devices – which in the case of a
thermal spray booth, is the space within the booth itself, if it is closed and interlocked while the process is
operated from outside the booth. All the previously defined spaces are contained within the Safeguarded Space.

The Restricted Space is of greater significance for safety design because it represents the limits of possible
robotic arm travel in all directions before the arm encounters mechanical stops or barriers. This space is
considered hazardous while teaching or operating the robotic arm for setup or maintenance. The Restricted
Space is, by definition, larger than the Operating Space and requires definition by examining the range of
possible arm movement and its proximity to all booth walls and fixtures at every point over its articulation range.

It is recommended that the area of the Restricted Space be conspicuously identified by marking/painting a
prominent color to define this critical area.

The design of a robot system requires anticipation of all potential pinch points and their elimination wherever
possible. Any hazards identified must be made conspicuous by one or more of the following devices:

• Mechanical Movement Restricting Stops,

• Warning/Interlock Devices,
• Awareness Barriers,
• Warning Signs,
• Written Procedures,
• A combination of the above. Joint 2
These remedies should be employed in the priority listed, with
(lift)
elimination of pinch points by mechanical means given the
highest priority. Joint 1
(Rotate)
7.3 Installation Configuration and Restricted
Space

The configuration used for a robot installation affects the

method for defining the Restricted Space of robotic arm
movement. Below are descriptions of three types of
installations that utilize robot arms: Fixed, Portable, and Track-
mounted.
Figure 7-2. Robot Joint Identification

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Fixed Robot Installations require mechanical stop, motion-limiting restrictions that physically attach to the major
rotation and lift joints of the robot arm. These are typically identified as Joints 1 and 2 (see Figure 7-2). Stop kits
for this purpose are normally available from the robot arm manufacturer. These will restrict pinch points between
the arm and booth walls or other fixtures/structures. In addition, signs and labels must be applied to all areas
that cannot be restricted by mechanical means. Finally, the limits of the Restricted Space must be clearly
marked or painted on the floor of the work area in such a manner that the scope of robotic arm movement is
immediately obvious to an uninitiated individual.

Portable Robot Installations require mounting in predefined and repeatable locations so that they can be treated
as fixed installations where all of the above precautions can be accommodated. If these locations are not in a
booth considered to be a Safeguarded Space, suitable “Awareness Barriers” and interlocks must be employed
to create a Safeguarded Space and protect plant personnel.

Track-mounted Robot Installations. In large booths where the robot arm is moved along a track, a careful
analysis of hazards is necessary and hard stops are recommended to limit the motion of the robot to the
Restricted Space. Awareness Barriers are strongly recommended as well. These are devices that may be used
to make it difficult to enter a restricted area. They may not prevent entrance; but like a knee-high plastic fence,
they call attention to the fact that entering the protected area may present danger.

7.4 Teach Mode

When the robot is to be operated in a Teach Mode, for either teaching or verification (playback) of motion
programs, this attended operation requires access to an interlocked booth which would normally prevent access
to the Safeguarded Space of the robot. In some cases, the Teaching function may require the operator to
actually be in the Restricted/Operating Space.

Operation of a robot in Teach mode typically involves only selection of that operating mode at the robot control
console and depressing a Teach Pendant enabling device. It is recommended that the control system require
the operator’s presence inside the booth, but outside the Restricted Space in case any sudden unexpected
movement of the Robot occurs. This can be accomplished by using a presence-sensing switch in a safe location
inside the booth near the robot, but outside the Restricted Space. The position for this switch is selected to allow
visual observation of Restricted Space prior to enabling the robot in Teach mode.

Three-position enabling devices permit operators to stop machine motion by simply releasing, or tightening, a
grip on a safety switch. These have the advantage of stopping motion when the device is either released or
tightly squeezed in a panic situation, or even if the operator is trapped or unconscious. Speed-limited teach
modes that allow only careful deliberate motion are recommended during an operation where a mishap, or
involuntary action, can occur.

When using the enabling device in combination with the presence-sensing switch the following safeguards can
be implemented:

• If a speed-limited Teach Mode is selected, the operator may be allowed into the Restricted Space after
the Robot is enabled.
• If full-speed capability Teach Mode is utilized, circuit design must require the operator to remain outside
the Restricted Space in order to enable the robot, and additional clearance around the Restricted Space
is required by ANSI/RIA R15.06 Standard.
• Appropriate Warning Signs and teach-enabled strobe lamps to warn others of a teach operation in
progress.

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7.5 Other (Non-Robotic) Torch/Part Manipulation Systems

Thermal spray coating booths use a wide variety of torch and part positioning equipment that is capable of
movement in X, Y, Z or rotary axes. These manipulators may not be called Robots, but have similar safety
concerns. The manipulation equipment may be under software or hardware control and is frequently operated
from inside the booth to effect setup of the process. The movement of this equipment with an operator in close
proximity presents the possibility of pinch hazards between the equipment and other physical elements of the
booth interior (walls, part positioning equipment, etc.).

It is recommended that the design of any manipulation system include the study of all movement hazards that
may be created, by examining the range of equipment movement and its proximity to all booth walls and fixtures
at every point in its range.

A Risk Assessment is recommended for all installations where torch and part-positioning equipment motion
during setup or maintenance may present a pinch or other hazard to operating or maintenance personnel. A
Risk Assessment requires anticipation of potential hazards and elimination where possible. Any hazards
identified must be made conspicuous by one or more of the following devices:

• Mechanical movement restricting stops or limits,

• Warning/Interlock devices,
• Awareness barriers,
• Warning signs,
• Written procedures,
• A combination of the above.

7.6 ANSI Risk Assessment

ANSI/RIA standards require that safeguards be designed into a system to protect operators and maintenance
personnel. These safeguards may include presence-sensing devices, barriers, awareness signals, procedures,
and training. The means selected for safeguarding personnel is required to be based on a formal Risk
Assessment that meets ANSI/RIA standards and must consider the following:

• The size capacity and speed of the robot/manipulator axes arm.

• The process.
• The tasks required for continuous operation.
• The hazards associated with each task.
• Anticipated failure modes.
• The probability of occurrence and probable severity.
• The level of expertise of exposed personnel and their frequency of exposure.

For Risk Assessment procedures, consult ANSI/RIA R15.06 Standard: Safety Requirements for Industrial
Robots and Robot systems, or TSS SG002-02 Safety Guidelines for Performing Risk Assessments.

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8. VENTILATION AND FILTRATION

Building
Outside/Inside
Exhaust to Ventilation Ductwork
Atmosphere

Dust
Collector Air Flow

Blower Spray Cell/Spray Process

Figure 8-1 Typical Equipment Layout.

8.1 Scope

This section covers the basic elements of booth ventilation and filtration to be considered when designing,
installing, and maintaining an exhaust system for use in thermal spray booth applications. It is intended to give
the reader an overall background into the technical and regulatory requirements as well as other
recommendations and considerations important to designing a spray booth.
It is common to have considerable ongoing legislative activity concerning ventilation systems and the release of
harmful materials into the atmosphere. Details of any specific pending regulatory requirements are beyond the
scope of this document and are typically focused on specific materials used in the thermal spray process. It is
required that ventilation/filtration systems comply with local regulations and consider pending and future
regulatory requirements. Consult a ventilation professional expert in requirements for your area to ensure
compliance.

8.2 Reasons for Ventilation and Filtration

The use of air flow in the thermal spray process is required to meet world-wide operator safety and
environmental regulations. The reasons for having an exhaust system are as follows:
• Provide adequate airflow through the booth to prevent the buildup of combustible or explosive gases in the
enclosed area in order to allow safe operation of the thermal spray process.
• Proper air flow removes gases, fumes, reaction by-products (metal compounds and gases), and dust
particles from the air inside the spray booth, and prevents inhalation by personnel working in the area, and
filtration prevents contamination of the environment.
• Thermal spray processes use gases to convey the coating materials to the flame, plasma or arc. During the
coating process, the effluents from the coating process that are not consumed by the process, or deposited
on the part, must be removed from the spray environment to protect the equipment and prevent operator
exposure to hazards.
• Thermal spray processes produce heat, which if not removed will slowly elevate the booth temperature to
unsafe levels.
• Improper ventilation can have detrimental effects on coating quality.

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8.3 Types of Dust Collection Equipment

Of the many types of dust collection components available, the combination of equipment utilized must be
based upon the specific thermal spray process, application, applicable codes, and installation requirements.

Water wash units used primarily before the 1980s, are a wet method of dust collection. The dirty effluent gases
and fumes from the process are passed through a water curtain or water cyclone to remove particulates. In most
locations around the world these units no longer meet environmental requirements as this type of equipment is
not very efficient at removing particles, and proper disposal of the wet waste has become increasingly cost
prohibitive.

Dry dust collection units used primarily since the 1980s, use highly efficient dry filters to capture the particulates.
Exhaust air is forced through the filter media in these units and can remove much higher percentages of the
particles. Current designs use replaceable cartridges (typically 99% efficient), or bags that achieve efficiencies
in excess of 95% in order to meet EPA, state, and local regulations on industrial plant emissions. This type of
unit is generally recommended for thermal spray installations.

High Efficiency Particulate Air (HEPA) filters are used as secondary filters in addition to primary filtration. These
filters enhance the cleaning efficiency of dry systems. These units consist of a housing that holds layered cubes
of filter media. Air is passed through the media to capture 99.97% of fine particles as small as 0.3 microns.
These units must be used in conjunction with regular dust collectors as they are not designed to handle
substantial amounts of particulate matter.

Cyclones, used in addition to dry dust collection, enhance the cleaning efficiency of dry systems by enabling the
capture of larger amounts of dust entrained in the air stream before they reach the primary dust collector. They
help prevent damage to the fragile dust collection cartridges and/or bags by trapping large and/or hot particles
that could otherwise damage these filters. A cyclone works by swirling the dirty air in a downward direction
around the outside of a spiral path then pulling the air straight up the middle. Large particles are forced down
into a collection drum, unable to travel upward with the air. The overall efficiency of dust removal is rather low
but these devices excel at removing large amounts of particulates.

Recirculation Systems for the ventilation system are being used in some installations. These systems circulate
a portion of the exhaust air in the interest of minimizing heat loss in cold climates and reducing energy
consumption (and the associated CO2 emissions). These systems require careful design and close monitoring
of their operation as the re-circulated gases will contain by-products of the thermal spray process (such as
ozone, carbon monoxide, and nitrous oxide) as well as dust and fumes from the powder being used, and
therefore are generally not recommended.

8.4 Design Considerations

Spray Process

When considering the design of a complete exhaust system for a thermal spray process, attention must be paid
to the specific process(s) and output of the process(s) intended for the spray operation. In particular the
following must be considered with the design of an exhaust system.

Gases − The gases used and produced vary between thermal spray processes. A plasma gun uses mostly inert
gases, but can use hydrogen, which is an explosive gas. Combustion processes, including HVOF, use explosive
or combustible gases and oxygen. Other gases that may be used include air and carbon dioxide. The prevention
of the buildup of combustible gases in an enclosed spray booth is required in order to allow safe operation of
the thermal spray process. Under no circumstances can the buildup of combustible products be allowed in any
spray booth as the thermal spray process itself is a guaranteed source of ignition. The total flow of gas should

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be considered in the calculations used to determine the necessary ventilation air flow. The types of gases as
well as the safe dilution of all leaks or other gas release contingencies (including full flow) must be considered in
the design of safe ventilation/filtration systems.

The types and forms of materials − Materials used in the spray process also vary. As the hazardous properties
of materials can vary greatly, the proper selection of components and air flow requirements are important. It is
recommended that the actions taken in the design, with regard to the materials used, be documented. There
are many regulations regarding emissions that may require this documentation. The following information is
needed at a minimum:

• Types of materials to be sprayed and their general classification with regard to toxicity and
flammability. This information can be readily obtained from each material’s MSDS sheet.
• The allowable exposure levels (TLV, PEL, REL, etc.) must be known, to allow system design to
control these levels.
• Annual consumption of each material based upon spray rates and hours of operation.
• Expected inflow of each material (overspray) into the dust collector for a given unit of operating
time.
• Calculated emission of each material into the atmosphere on an annual basis given the information
above and the efficiency of the dust collection system.
• Calculated air-to-media ratio in the exhaust stream along with the manufacturers recommended
ratio for the filters.

Fumes − Most thermal spray processes produce fumes that need to be taken into consideration during the
selection of components and air flow requirements. The Electric Arc process generally produces a high volume
of fumes. Filters with lower air to media ratios are typically required in order to properly handle fumes without
clogging the exhaust stream.

Heat −Thermal spray processes produce excess heat which elevates the exhaust air temperature. Process heat
input is diluted by the presence of air flow. Insufficient air flow can result in dangerous exhaust air temperatures.
It is recommended that air temperatures never be allowed to exceed the design specifications of the filter
elements.
Reaction by-products –Thermal spray processes use different gases and materials that may generate various
reaction by-products. Control of these materials must be considered in the overall design of the system. For
example, water vapor can condense from the exhaust gases of a combustion process and come in contact with
dust particles that have accumulated in the air handling and filtration systems. This interaction can release
hydrogen gas resulting in a potentially explosive or flammable condition. Additionally exothermic reactions can
occur resulting in sufficient heat build-up to start a metal fire. Also, metal powders can form complex metallic
compounds (such as hexavalent chromium or nickel carbonyl) as a result of their exposure to the high
temperature of the spray process. The compounds can have risks and exposure limits which are different than
the starting material. It is required to follow the recommendations of thermal spray equipment/consumables
suppliers to alleviate potential hazards by incorporating booth design considerations to minimize the
effects/hazards of these by-products.

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Exhaust Equipment and Facility Layout

The design of the overall exhaust system is dictated by the physical layout and size of the spray booth
enclosure and the exhaust equipment locations. The following steps are recommended:

• The dry dust collection components and exhaust blower should be located outside the building,
preferably near the spray booth. Depending on the process and materials to be sprayed,
consideration should be given to incorporating explosion relief panels in the filter housing and
using flame-resistant filter media. In situations where hazard levels are controlled and understood,
inside locations or collectors within the booth itself may be considered. Locating dust collector and
blowers inside of occupied buildings may require additional measures for hazard control and may
not be permitted by local codes. At the very least, locating dust collection systems inside a building
will involve additional costs for fire/explosion prevention measures.

• Larger spray booths typically require a higher air velocity to capture and carry particles to the
collection system. Spray booths should be sized just large enough to allow for safe processing,
where practicable, including spray equipment clearances, without additional space.

Air Flow Design Considerations

Proper air flow in a spray booth is a necessary engineering control used to reduce operator exposure to thermal
spray dust particles, fumes, gases, and volatile substances. This control, however, does not eliminate the need
for a suitable respiratory protection program for each thermal spray facility, in order to determine the necessary
Personal Protective Equipment (PPE) required to protect the operator during all aspects of job performance.
Such a program is typically the responsibility of the employer.

The airflow for a thermal spray process is dependant upon several factors and must provide adequate
ventilation of the spray booth. The factors that follow include considerations for the coating quality, personnel
safety, and overall cleanliness.

1. Air Flow Velocity – To remove airborne particles from a thermal spray booth, typical airflow velocities in the
range of 75 to 200 feet per minute (23 to 61 m/min.) are recommended. In larger booths it is more difficult
to obtain the higher velocities in this range, and the velocities at the lower end of the range may be
insufficient to capture and remove all particles. However, the higher the velocity achieved – the closer to the
upper end of the range – the cleaner the booth will remain.

a. For spray booths where robotic or automated equipment is performing the spray operation, it is
recommended that air velocities within this range be achieved for the purpose of keeping the spray
booth clean.
b. For spray booths equipped with a spray hood and where all activities associated with the spraying of
parts occur near a hood positioned at the source of the process effluents, capture velocities at the face of
the hood should be near the upper end of the recommended range.
c. For spray boxes, the typically smaller internal volumes will allow capture velocities greater than the upper
end of the range.
d. Air velocities in the vicinity of 300 feet per minute (91 m/min.) may adversely affect the thermal spray
process, especially in cases where the spraying is done at right angles to the air stream.

2. Heat Dissipation – The total air flow to a spray booth is required to be sufficient to prevent exhaust air
temperatures from exceeding the design temperature specification of the filter media and ductwork.

3. Total Air Flow – The total recommended air flow for the spray booth should provide for a minimum of 5 air
changes of the entire spray booth volume per minute. For typical large booths, the rate may vary from 1.5 to
5 air changes per minute due to lower practicable flow rates because of the larger volume of these facilities.

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In any configuration, the greater the number of air changes per minute, the better. For adequate dilution of
full-flow process gases, necessary to prevent excess accumulation during leaks or other malfunctions, the
ventilation system needs to be designed to provide sufficient dilution of process gas leaks to levels safe
enough to prevent the accumulation of explosive or hazardous atmospheres.

4. Negative Booth Pressure –The spray booth air intake and exhaust should be balanced at the design air
flow to provide a negative pressure relationship between booth and the rest of the building with the exhaust
system operating and all spray booth doors closed. This is to ensure that any leaks in the booth structure
will allow plant air into the booth, and will not allow gas, fume, or dust leaks into the plant environment. If
ventilation system intake air is from inside the building, this negative pressure should be 0.3 to 0.5 Inches of
water (0.75 to 1.24 mBar) of static pressure drop between the spray booth and the plant atmosphere.
Pressure differential values lower than these may result in interaction between the changes in building and
spray booth pressure due seasonal changes or air makeup systems. If the ventilation system intake air is
from outside the building, the negative pressure range may be from 0.1 to 0.5 Inches of water (0.25 to 1.24
mBar)

Pressure drops higher than 0.5 Inches of water (1.24 mBar) will result in negative pressures sufficient to
exceed OSHA standard for ingress/egress using the spray booth doors. The following exceptions apply:

a. Spray booths that need to be accessed only for maintenance purposes.

b. Spray booths and chambers with door actuators that supply mechanical assistance for operation.

5. Dual-Speed Exhaust systems – Dual speed exhaust fans are recommended to allow the system to
maintain a low-level ventilation mode at all times when the booth door is open and when the booth may be
occupied for maintenance or setup, and revert to a high-level or normal operation when the booth is closed
for process operation. This type of system improves air quality and sweeps away any small quantities of
residual gas and dust particles that might remain in or be leaking into the booth during maintenance or setup
operations when the booth is occupied

6. Sound Control – It is recommended that air intakes to the spray booth located inside the building provide
sound control in the form of acoustic insulation, duct silencers, etc. to attenuate noise emitted by the
process within the spray booth.

7. Inlet Air Flow – The inlet air flow for the thermal spray process can be from inside the facility in which a
booth is installed, or from outside the building.

a. When the inlet flow is from inside the building, air exhausted from the building must be
considered for its overall effect on the building ventilation system. This can be accomplished in
several ways and varies depending on local codes and heating and cooling energy conservation
concerns. Check with a professional industrial ventilation expert for specific local requirements
and recommendations.
b. In installations where air is to be fed to the air intake of the spray booth directly from outside the
building, consideration must be given to conditioning (heating or cooling) the air to the interior of
the booth, as may be required.

8. Airflow Distribution – The airflow within the spray booth should be uniformly distributed through careful
placement of the air intake and exhaust plenums. The smoothest possible flow of air (Laminar flow) is very
beneficial to the effective removal of dust from the process area and carrying it into the ducts leading to the
filters. Laminar flow can best be achieved using an inlet plenum with many small evenly-distributed inlet air
openings– fewer larger opening create turbulent flow. Smooth air flow through the booth minimizes dead
areas that allow accumulation of effluent. Turbulent flow can create eddies and low pressure areas that
cause dust to be trapped or dropped from the air stream. Booth obstacles such as tooling, parts, and
fixtures detract from smooth air flow. Exhaust plenum placement on opposite ends of the spray booth from

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the air intake is recommended as part of an overall design to enhance smooth flow. Positioning of the
exhaust plenum is typically on the wall or floor just beyond the process.

The layout of the spray booth interior should take into consideration the effect that objects in the booth may
have on air movement within the booth. The following layout guidelines are recommended:

a. Process control equipment that must be placed inside the spray booth such as powder feeders, flow
meters, etc, should be placed in the spray booth near the air inlet and away from the actual spray
process. Process equipment requiring maintenance operations, such as adding powder, etc. is
recommended to be positioned in the ventilation stream so as to minimize operator exposure to
additional dust or fume hazards during the maintenance operation.
b. Robots, gun manipulators, and spray operators should be placed near the center of the spray booth
facing the exhaust plenum/spray hood with the part to be sprayed between the exhaust plenum and the
robot/manipulator.
c. The workpiece to be sprayed and any workpiece manipulation equipment such as turntables or spindles
should be placed in front of the exhaust plenum.
d. A combination of floor/cross-flow ventilation is sometimes used to minimize accumulation of heavier
particles on the floor nearest the thermal spray process. In this type of system, additional ventilation
ducting is added under the floor (via grate or other means) with capture exhaust inlets near the coating
point itself to prevent accumulation at that location.

Ventilation Ductwork

Due to the nature of entrained particulates in the exhaust air stream, consideration must be given to the design
of the overall ductwork. For specific details on duct layout and design consult SMACNA (Sheet Metal and Air
Conditioning Contractors National Association). It is highly recommended that a competent local contractor be
used to fabricate and install the ductwork in compliance with federal, state and local codes. The following are a
few safety-related concerns:

Duct Velocity − The recommended air velocity inside the ductwork between the spray booth and the dust
collector should be a minimum of 3,500 feet per minute (fpm) (17.78 m/s) to a maximum of 4,000 fpm (20.32
m/s). A lower air velocity will allow particulates to settle out of the air stream and build up in the ductwork leading
to potential fire hazards, placing additional weight on ducting, and possibly blocking airflow. Inlets to dust
collection equipment will often need lower velocities to prevent possible erosion of filter media and to disperse
the air flow across the filters.

Duct Bends −The ventilation system exhaust air stream carries a large amount of momentum as a result of the
relatively high velocity and entrained particulate. Give consideration to limiting the number of bends the air
must make between the spray booth and dust collector. Bends increase pressure drops, and can create
locations where material can build up.

Back-draft Damper − At the point where the ductwork leaves the building, a back-draft damper installed into the
ductwork is recommended. The back-draft damper serves to prevent the reverse flow of air from outside the
building back into the spray booth when the exhaust system is off, and also serves to prevent smoke from any
potential fire in the dust collector from backfilling into the building.

Duct Class/Shape − Ductwork can be either rectangular or circular in cross-section depending upon contractor
or local supply preferences/availability. Duct sections are recommended to be of a heavy-duty gauge and
construction to handle the pressure and powder loadings presented by the booth ventilation requirements and in
compliance with any local codes. Ventilation ductwork used primarily for air conditioning systems is not normally
considered adequate for this task.

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Local Codes − Many state and local codes have restrictions on how the air can be exhausted. Of concern is the
need to prevent accidental intake back into the building or other contamination factors. Even though the air is
clean of particulates it will still contain spent process gases, or volatile by-products, which in many cases can be
harmful.

Intrusion − Protection against animal and weather intrusion into the ductwork is required at the point where the
ductwork ends.

8.5 Operation/Maintenance Considerations

Consideration must be given to the safe operation and maintenance of the overall exhaust system, during the
selection of dust collection components. Specifically, the following concerns need to be addressed:

Operation Concerns

Cleaning − During operation, all of the types of collection units mentioned require regular maintenance to
remove the buildup of collected material. The frequency of maintenance depends upon actual usage; the
methods vary depending upon the system. Dry collection and cyclones are generally emptied directly into 55
gallon (208 L) drums or other suitable containers. HEPA secondary filters capture dust particles within their filter
layers and typically cannot be cleaned. They must be properly discarded when full. Most waste from the dust
collection system is considered HAZARDOUS WASTE and must be disposed of in accordance with all
applicable regulations.

Fire and Explosion Prevention – Due to the hazardous nature of some of the materials and gases used,
attention must be paid to reducing the risk of fire and/or explosion within the dust collector and ductwork. As
each situation varies greatly in the potential risks and applicable codes, it is advisable that an expert be
consulted. The use of explosion venting, thermal cutouts, back-draft dampers, and associated fire/explosion
prevention devices must be considered for each application, and in some cases, are required by law.

Where there exists a general concern for combustibility of loaded filter media, the following steps should be
considered as minimum preventative measures:
• Control main ignition source - Often the ignition source of main concern is hot particles from the
process, parts, tooling or masking. Duct work of sufficient length, duct inlet screens, etc. can be
beneficial in preventing hot particles from reaching filters and collected waste. Tooling and masking
should be made of non-combustible materials.

• Detect the fire - A temperature sensor downstream from the filter media can be considered as an
inexpensive method for detecting a filter fire.

• Warn and control - Upon detection a warning should sounded. Additionally, in most situations, fans
should be turned off and dampers on both sides of the filter housing should be closed. This serves to
limit air to the fire and slow combustion.

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Sprinkler Systems - Although systems exist that use different materials such as special chemicals, foams and
gases to suppress fires, in many cases the use of water sprinkler systems is considered due to wide usage of
such systems in general industrial and residential applications. Water is, in most situations, not a good solution
for various reasons:

• Leaking or inadvertently activated sprinkler systems can permanently damage filter media.

• Water can cause potentially dangerous reactions with some materials and metal dusts found in thermal
spray filter systems (spray material history dependant).

• Water can turn dry hazardous waste into liquid hazardous waste leading to unplanned environmental
releases and cleanup issues.

Sprinkler or spray materials other than water require confirmation of compatibility with the media and waste
materials found in the filter system. In many cases the supplier of the thermal spray equipment or the filtration
system can provide recommendations regarding safe and cost effective methods to control fire/explosion
hazards.

Vent Gas − Prior to turning on gases, powering up equipment, or entering the booth, it is recommended that
the exhaust system be turned on and allowed to run for a few minutes to purge the spray booth and exhaust any
potential buildup of hazardous gases should a gas leak occur.
Smoking − It should be a local requirement that no smoking be allowed in a spray booth. The likelihood of a
smoldering particle of smoking media making it to the dust collector filters is very high and has been known to
start fires.

Vent System Maintenance Concerns

Exhaust equipment should be checked for proper operation at regular intervals depending on the characteristics
of the process/facility. An inspection schedule is recommended for regular examination of ventilation ductwork,
and exhaust system components in accordance with the manufacturer’s instructions. The following items should
be checked as a minimum:
• Level of material collected for emptying.
• Pressure drop across filters.
• Traps and screens in hoods and plenums for material buildup.

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8.6 Example Case

This example case of a robotic spray booth depicts a typical situation that serves as a model of the layout and
functionality recommended. Always check local codes for additional requirements that may not be shown in the
examples.

Typical Robotic Spray Cell

The typical robotic spray booth depicted in Figure 8-2 shows the arrangement of equipment and airflow for the
system. It should not be considered a complete representation as there are many details in the design and
fabrication of the components that cannot be shown. Note the following features:

1. The flow of air through the spray booth from the back to the front, supplying a clean wash of air across the
robot and turntable.

2. The relatively (not to scale) small size of the exhaust duct from the spray booth to the dust collector to keep
air velocity high enough to prevent particulates from settling out in the ductwork.

3. The robot placed near the center of the spray booth facing the exhaust plenum/spray hood with the part to
be sprayed between the exhaust plenum and the robot.

4. The workpiece to be sprayed and turntables placed in front of the exhaust plenum.

5. At the point where the ductwork leaves the building, a back-draft damper is installed into the ductwork to
prevent the reverse flow of air from outside the building back into the spray booth when the exhaust system
is off.

6. A HEPA filter is not shown. If required it would be normally placed after the blower.

BACKDRAFT
DAMPER
EXHAUST DUCT
EXPLOSION
VENTS
EXHAUST STACK 2D AIR INTAKE

FIRE
SUPPRESSION

RAIN
CAP
SPRAY BOOTH
ABRASION
BUILDING WALL

INLET
DUST
COLLECTOR
SPRAY
EQUIPMENT

ROBOT

TURNTABLE

BLOWER
PLENUM
WASTE
DRUM

Figure 8-2. Typical Robotic Spray Booth Configuration

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9. PIPING GUIDELINES

9.1 Scope

The section on gas handling and piping is designed to provide information to increase safety awareness and
use of safety practices with regard to gas and liquid piping to and around typical thermal spray installations.

The focus of this section is the process piping leading to the thermal spray cell and to specific thermal spray
equipment within the cell. A typical thermal spray installation will involve Branch process piping leading to the
thermal spray booth, usually terminating in the Station Outlet valves at the booth. A combination of piping and
hoses is typically utilized from these station outlet valves to various devices around the booth. This section is not
intended to apply to plumbing within manufacturer supplied consoles or equipment nor will it address bulk gas
supplies and main line process piping within the facility.

9.2 Typical Gases/Fluids

The following is a list of common gases and fluids used in typical thermal spray installations.

• Compressed air
• Carbon Dioxide
• Argon
• Nitrogen
• Helium
• Hydrogen
• Acetylene
• Propane
• Propylene
• Methane
• Natural gas
• Oxygen
• Water
• Kerosene
• Carbon Dioxide
• Custom mixes (MAPP, Crylene, etc.)

9.3 Supply Planning

For most thermal spray installations, gas and/or fuel supplies will be piped into the building from either a
permanent or temporary bulk source installation located external to the building. Flow demands will dictate the
capacity of the bulk gas supply, which is typically installed in a secure location outside the building to meet the
requirements of various building fire codes and regulations.

For some installations, however, flow needs can be handled by a single local supply tank or cylinder located
nearer to the thermal spray booth. In some cases it is acceptable, and sometimes preferable from a safety
perspective, to store such a container within the building. Local codes vary considerably on this issue and
should be consulted if considering internal storage and supply of any gas. In some instances, regulations state
the maximum size of a cylinder or container that may be housed or stored inside. This depends on the type of
building or the type of storage. The nature of the installation, either temporary or permanent, can also be a
factor in determining which regulations apply. The gas supplier can be an excellent resource regarding proper
configurations and locally acceptable practices.

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Main Oxygen Line

To Gas
Other Main Fuel Gas Line Supplies
Facility
Locations Main Aux Gas Line

Branch Lines

Station Outlet
Valves

Thermal Spray Booth

Ventilation System Gas C ontrol

Console
Sp ray Equ ipment

Flexib le Hose
Bundle

Figure 9-1. Typical Thermal Spray Booth - Gases will vary with the process.

9.4 Piping Materials

For typical gases and fluids used in thermal spray applications, branch piping is normally implemented using
black iron, carbon steel, or stainless steel hard piping with welded or threaded joints. The individual physical or
chemical characteristics of each gas or fluid require that specific piping materials are employed to ensure
compatibility and safety. In addition, local standards and governmental regulations are often specific regarding
materials or types of piping utilized for specific gases and fluids.

The gas supplier, building contractor, or thermal spray equipment supplier can all be valuable resources in
determining proper plumbing materials and types. The following list suggests typically accepted materials by the
gases and fluids carried --None of these may be considered as complete requirements for gas/fluid piping
materials:

Argon, nitrogen, and helium are typically piped using black iron, carbon steel, or stainless steel with welded or
threaded fittings. An additional preferred material is drawn copper piping which is permitted because of the inert
nature of these gases.

Hydrogen is typically piped in black iron, carbon steel, or stainless steel with welded or threaded fittings. Low
temperature or soft materials such as copper or brass are not permitted due to susceptibility to heat or abrasion
damage and the flammable nature of this gas.

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Acetylene piping typically employs black iron, carbon steel, or stainless steel pipe with welded or threaded
fittings. Due to the chemically unstable nature of acetylene it has the ability to support combustion and powerful
detonations without the presence of an oxidizer. For this reason, specific and stringent construction codes
require that the piping materials used for acetylene provide sufficient strength to contain such incidents without
damage. Construction codes differ throughout the world. Contact the local gas supplier for recommendations.
Copper or alloys containing copper must not, under any circumstances, be used for acetylene supply or venting
applications. Acetylene and copper chemically react to form unstable compounds which themselves can be
hazardous.

Propane, propylene and natural gas are typically piped in black iron, carbon steel, or stainless steel with
welded or threaded fittings. Propane and propylene are typically stored in liquid form at room temperature under
moderate pressure. The fuel is vaporized to gaseous form prior to distribution through building piping. Fuels in
liquid form, due to their greater density, can present an increased fire hazard compared to those in gaseous
form. Leak containment is also a concern with liquid fuels. For these reasons fuel gases stored in liquid form are
subject to different regulations than those applicable to fuels stored in gaseous form.

Oxygen is, by itself, not a fuel gas and is not combustible, but it does vigorously accelerate the combustion of
other materials and, as such, can present a significant hazard. This characteristic becomes more serious at
higher pressures and flow rates. For this reason it is required that oxygen piping be constructed of specific
materials known to be compatible with the pressures and flows in the system. Typically, thermal spray
equipment that utilizes oxygen operates at pressures under 300 PSI (20.7 Bar). For these installations, black
iron or stainless steel piping can be used. Copper piping can also be utilized.

All devices used in oxygen plumbing require special cleaning to ensure oxygen compatibility. For the reason,
they must be labeled by the manufacturer “Cleaned for Oxygen Service.”
Compressed air is typically piped in black iron, carbon steel, or stainless steel with welded or threaded fittings.
The use of copper or various types of plastic or PVC pipe may be considered where careful attention is given to
specific pipe pressure ratings. Local codes often dictate specifically what can be utilized in compressed air
service.

Water from a City or Closed-Loop cooling supply is typically piped in black iron, carbon steel, or stainless
steel with welded or threaded fittings. The use of copper or various types of plastic or PVC pipe may be
considered where careful attention is given to specific pipe pressure ratings. Plastic pipe ratings must receive
specific considerations for maximum water temperatures. Local codes often dictate specifically what can be
utilized in water service.

De-ionized Water. Specific cooling requirements often dictate the use of de-ionized water. Plastic or PVC pipe
is often preferred for these applications. Manufacturer’s manuals and local installation codes should be
consulted.

Kerosene is the only common fuel utilized in thermal spray applications that is piped to process equipment and
utilized in its liquid form. For thermal spray devices, kerosene is normally piped in small diameter steel, stainless
steel, or copper tubing.

Indoor storage of quantities of kerosene is typically closely regulated and leak containment is a concern for
liquid fuels. For these reasons, kerosene is subject to different regulations than those applicable to gases.
Consult local building codes for proper application.

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Carbon dioxide is occasionally used for part cooling in the thermal spray industry. For these applications liquid
CO2 is often plumbed to the process. The recommended material for piping liquid CO2 is copper. The use of
iron and steel piping and components is often prohibited and should always be carefully reviewed due to the
effects of low-temperature embrittlement. Certain types of stainless-steel and carbon-steel alloys are acceptable
for liquid CO2 applications. The piping for liquid CO2 and other cryogenic liquids require appropriate pressure
relief devices on every pipe section between components that might be capable of trapping liquid. Warming,
expanding, liquid entrapped between two closed devices, if not released, will cause extreme pressure rises and
may cause pipe/component rupture and potentially serious damage.

Custom mixes (MAPP, Crylene, etc.) are occasionally used in thermal spray processes. Consult the gas
supplier for the recommended materials for these gases.

9.5 Piping Design

Piping material selection requires all piping materials used in thermal spray applications be compatible with the
chemical and physical characteristics, as well as the temperature, flow, and pressure requirements of the
gas/fluid to be conveyed.
• Determine the proper piping material specification for the gas to be piped from ANSI, CGA, or similar
other applicable published piping standards/safety practices.
• The manufacturer’s literature for the specific thermal spray equipment being installed is the
recommended source for determining the pressure and flow requirements for the piping of each gas or
liquid to be piped.
• The Design Pressure (Maximum Allowable Working Pressure) of a gas piping system is typically
required to be greater than the system Operating Pressure by a minimum percentage (15% is often
specified). This requirement depends on the flow rate and operating pressure requirements of the gas
being conveyed. See published gas piping standards to ensure design, Operating and Test pressure
relationships meet the requirements for each gas piping system.
• Flexible hoses may be used for connections to process equipment downstream of the station outlet
valve and related components. When used, flexible hoses require a manufacturer’s rating for use with
the specific gas/liquid to be carried. It is recommended that such hoses be color coded per local
conventions.

9.6 Piping Components

A Station Outlet valve is recommended at the end of branch lines supplying each individual thermal spray cell.
These should be conveniently located and clearly identified so as to provide emergency shut-off capability and a
place for support of lockout tag-out maintenance activities.
Pressure Relief valves are required to protect downstream plumbing and devices from over-pressure such as
from the failure of a regulating device. When used, pressure relief devices must release at a pressure no higher
than the maximum design pressure of the system. Pressure relief devices must be designed to handle the full
flow of the supply piping.
Excess Flow Valves should be considered for flammable gas branch lines. These self-actuating valves
automatically close when gas flow exceeds a predetermined rate. They deliver positive, automatic shut off when
the pre-selected flow rate is exceeded, to stop gas release in the event of downstream line, hose, or instrument
rupture.

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Pressure relief devices are often part of pressure regulators and not individually identified. Consult the regulator
manufacturer regarding such devices and their suitability to any specific task.
It is recommended that relief ports for pressure-relief devices used with gases other than air be piped to the
building exterior. This is to prevent the creation of a dangerous atmosphere (flammable, explosive, toxic or
asphyxiating).

9.7 Flammable Gas Piping Components

Check valves installed downstream of station outlet valves are recommended for oxygen and fuel gas lines.

Quick Disconnects, when utilized with flammable gases or liquids, or oxidizers, are recommended for use only
within the confines of the ventilated thermal spray booth for purposes of connecting to the thermal spray gun.
Quick disconnects are prone to leakage and can contribute to a fire, particularly in a non-ventilated area.
Flashback 3 Arresters affixed to acetylene lines are recommended after the station outlet valve and at the
thermal spray device or gun.

9.8 A rea Classification

Typically, thermal spray equipment provides containment of flammable gases within hoses, regulators, gauges
and other components outside of the thermal spray booth. Regulations, similar in the US and in Europe, require
manufacturers to designate areas around their equipment within which it is inappropriate to mount electrical
devices that might act as ignition sources (see additional information in Section 10.4). Consult the
manufacturer's literature for proper spacing requirements.

9.9 Piping Fabrication

Piping Materials − All materials used during fabrication of thermal Spray piping systems are required to be
compatible with the chemical and physical characteristics, as well as the temperature, flow, and pressure
requirements of the gas/fluid to be conveyed. The external environment (temperature, physical damage
potential, corrosion) must receive consideration when selecting materials.
Branch lines − These are typically are hard plumbed lines bringing supply gases and fluids from main
distribution lines within the facility to a station outlet valve located at the thermal spray booth. Typically such
lines are run overhead before being brought down and attached to the side of the booth. In most installations
line filters and regulating components will be installed immediately after the station’s shut off valves.
Piping Identification – It is recommended that process piping to the thermal spray cell be properly identified in
order to clearly indicate the contents of each pipe. Color coding and labeling requirements differ from country to
country. Consult local regulations for proper identification. As a general rule, paint is applied only over a small
percentage of the pipe. Extensive paint application serves to mask leaks and prevent later identification of the
piping materials used.

3
Individual thermal spray devices may require flashback arresters and/or check valves to be installed in a specific part of
the system plumbing. Such usage is not limited to acetylene. These devices are often found in oxygen and fuel lines
supplying thermal spray guns and gas control panels. Often such devices are installed to address specific safety and
performance issues and should not be removed, modified or substituted without explicit recommendation from the
manufacturer.

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 Designation SG003-03

Piping Protection – It is recommended that Branch piping be routed and mounted in a manner that protects the
piping from external damage or wear. Flexible hoses and lines should be routed and protected from damage
and abrasion.
Grounding (bonding) Requirements − Branch piping for all flammable gases and liquids must be grounded to
avoid static electricity build-up.
Cleaning − Branch and process piping cleaning is recommended during and after construction prior to being
placed in service.
Cleaning for Oxygen Service − Piping and components designed for oxygen service require thorough cleaning
per established practices for such service. Seemingly small quantities of foreign materials, such as oil or grease,
can result in the creation of violently explosive mixtures in the presence of oxygen.
Pipe Joining and Sealing Recommendations − Pipe joining techniques should be per manufacturer's
recommendation. Pipe sealing should be per standard accepted practices. Sealing compounds are required to
be compatible with the gases to be carried.

9.10 Piping System Integrity Monitoring

Leak checking – It is recommended that all branch and process piping be leak checked at least every six
months, or more frequently, per manufacturer's recommendations.

Gas Detectors/Oxygen Monitors – Natural and/or forced and interlocked ventilation is the preferred method for
assuring safe air conditions around and in thermal spray booths. Combustible gas detectors and/or oxygen level
monitors can be considered for use both within and outside the thermal spray booth to help warn of any unsafe
conditions, but should be viewed as secondary protection and not be relied on as the primary safety measure.
Detectors and monitors require assurance of compatibility with dust and contaminants and need regular
maintenance and testing.

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10. ELECTRICAL GUIDELINES

10.1 Scope

The focus of this section is the configuration of control electrics and associated equipment throughout the
thermal spray cell. The section provides information intended to increase safety awareness and the use of safe
practices with regard to the configuration of electrical equipment within thermal spray installations. In addition,
this section will address specific recommended practices regarding critical safety related topics such as
emergency stop circuits, lockout-tag out, electrics/fuel separation, etc.

The scope of this section is not intended to extend to electrical wiring and hardware within manufacturers’
supplied consoles and equipment, nor will it address supply wiring normally considered part of the building
facility.

Ventilation System
Mai n Powe r

Thermal Spray Booth

Boot h Control
Ventilation Contro ls Console
C ontro ls Spray Equipment
M ain
Disconn ect

Figure 10-1. Typical Thermal Spray Booth -─Typical Power Wiring

10.2 General Topics

Manufacturer’s information − The manufacturer’s literature for the specific thermal spray equipment being
installed is the recommended source for proper voltage and current requirements for the specific installation.
Grounding/bonding requirements − Grounding of electrical cabinets, booth walls and other metallic structures
must be provided. Grounding to metallic building structures or metallic plumbing is typically sufficient. Check
local codes.

Adequate Access/Lighting − Electrical cabinets containing electrical equipment for the control of typical thermal
spray installations typically require frontal clearance of 3 ft. (910 mm) for adequate safety during service
activities. Consult local regulations. In addition adequate lighting of all cabinet areas is recommended to
further enhance safety during service work.

Overload protection − Appropriate overload protection is required for the electrical supply in the form of either
circuit breakers or fuses. Consult the National Electrical Code or local codes for appropriate configurations.

Ground Fault Interrupters (GFI) – GFI’s are recommended for all convenience outlets mounted in, on or around
the thermal spray cell. This provides extra safety protection against electric shock hazards considering the fact
that most thermal spray devices use water cooling and leaks and puddling of coolant are common during
maintenance.

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 Designation SG003-03

Dust protection − Electrical components within the thermal spray booth require the type or design
characteristics that afford protection from powder and dust.

Documentation Recommendations − Adequate documentation for each installation should be provided such as
to permit and encourage safe operation, maintenance and service of the thermal spray cell and associated
components.
10.3 Gas and Electrical Interlocking

Gas interlocking Requirement − Process gas flow into the thermal spray booth must be electrically interlocked
through suitably rated solenoids or other automatic shutoff devices such that gases are allowed to flow only
when sufficient ventilation airflow through the booth is confirmed.
Electrical Interlocks − Thermal spray installations typically present numerous hazards to operators and other
personnel. It is common and accepted practice to use electrical interlocks to protect personnel from these
hazards (see: 6.7 Safety Interlocks for descriptions of the hazards addressed by these electrical interlocks).
The following list represents typical recommended interlock applications:
• Booth door
• Robot travel
• Parts manipulating table or other motion devices
• Electrical connections
• Equipment guards
• Pressure and flow of liquids or gases
• Ventilation flow

Interlocks should be designed to discourage any attempt to defeat their function. Consult local codes for
recommendations regarding interlock requirements.
Emergency Stops (E-Stop) − Emergency stop buttons are required at appropriate locations around the thermal
spray cell. Actuating an E-Stop button will remove power (as appropriate) in an emergency, except for functions
that are required for personnel safety such as the ventilation system, fire suppression, hazard alarms, etc.

Typical E-Stop functions include:

• Process Gas flow
• Ignition
• Arc Power sources
• Motion Control
• Hydraulics
• Robotics
• Control Power

E-Stop button location(s) must be selected to afford operator and maintenance people quick access in case of
an emergency. E-Stop buttons are typically of the “push to energize pull to release style”. Emergency stop
circuits must be designed so that when an E-stop button is reset, the system does not automatically re-
energize. A separate reset or start action must be required to avoid unexpected restarts of the equipment after
the source of an emergency stop has been corrected. In addition, for integrated systems, emergency stop
buttons must be interconnected so that all E-Stop buttons in a cell perform the same emergency stop function.
In some locales, the use of dual channel safety circuits is a requirement. Consult local codes for guidance.

Lock-out/Tag-out − System shutoff means are required to allow all energy sources to be disconnected and
isolated from the thermal spray system or cell. Such shutoff devices must be equipped to accept a lockout
device and associated tag to prevent accidental re-energizing of the equipment and subsequent exposure to
hazards.

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 Designation SG003-03

10.4 Area Classification

Typically thermal spray equipment provides complete containment of flammable gases within hoses, regulators,
gauges and other components both outside and within the thermal spray booth. Since leaks can and do occur,
regulations − similar in the US and in Europe − require manufacturers and/or users to designate areas around
their equipment within which it is inappropriate to mount electrical devices that might act as ignition sources for
flammable gases. These areas are referred to as classified or zoned depending on national/local conventions
and rules. Consult the manufacturer's literature for proper spacing requirements.
Often cabinets or enclosures are utilized to protect or contain components that in turn carry or contain
flammable gases. It is always wise to adequately, and preferably naturally, ventilate such enclosures to aid in
the dispersion and dilution of any potential gas leaks. Typically the entire internal area of such enclosures and
suitable surrounding areas external to the cabinet are considered classified or zoned areas.
Electrical cabinets, consoles and other electrical boxes are normally positioned so as to avoid combustible gas
classified areas. When such devices encroach on a classified enclosure area, typically the inside of that
enclosure becomes a classified area. In these cases, appropriate steps are required in order to de-classify the
electrical enclosure. Purging and pressurization, natural and forced ventilation, and other means exist to de-
classify such areas. Consult the National Electrical Code or NFPA 497 for further guidance.
In cases where the extent of hazardous (classified) areas/zones or specific spacing recommendations are not
available from the manufacturer, the following recommendations are offered to help promote safe installations
and operations.
Cabinet Ventilation − A high degree of natural or interlocked artificial ventilation to a cabinet is especially
important and required for cabinets containing both combustible gas carrying components and electrical
components. This is to prevent containment or concentration of potential leaks. Such cabinets should be
designed with a high degree of natural ventilation. Expanded metal grates, extensive louvering, and open
cabinet tops and bottoms are typically used to increase natural ventilation. It is a requirement that when forced
(fan driven) ventilation is used, gas flow to a cabinet is interlocked so that flow is blocked if insufficient
ventilation is sensed.
Cabinet/Component Location − Cabinets containing non-classified or non-rated electrical components that are
4
considered ignition sources , or individually-mounted ignition sources, should be separated from gas carrying
components or cabinets by a minimum of 16 inches (406 mm) for typical thermal spray equipment.
Spray Booth Area Classification – It is recommended that electrical components are separated by 12 in. (305
mm) from flammable gas connections where practicable within the booth. Thermal spray booths are typically
provided with forced ventilation systems designed primarily for the removal and filtration of effluent containing
unused powder and combustion or arc by-products. Such systems typically more than adequately fully dissipate
and dilute any fuel gas leakage. When such systems are interlocked (see: 10.3 Gas and Electrical Interlocking)
to interrupt process gas flows in case of insufficient ventilation most areas within the booth can be considered
non-classified (not requiring rated electrical components). In addition, the interiors of such booths are designed
for combustion to occur during normal operation.
If sufficient separation is not possible, electrical cabinets should be protected either by:
• Using components rated for use in the specific hazardous (classified) area or zone.
• Purging and pressurization of the electrical cabinet.
• Barriers or other protection devices or schemes.

4
Ignition sources are typically defined as devices that, during normal operation, could ignite combustible gas
concentrations. Unprotected and/or non-rated switch and relay contacts, centrifugal switches, open spark gaps, plugs and
sockets that are connected and disconnected during normal operation, devices with hot surfaces with the possibility of
exceeding the auto-ignition temperature of gases are all examples of ignition sources.

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 Designation SG003-03

11. ERGONOMICS

11.1 Scope

This section on ergonomics is intended to provide information to increase safety awareness and use of safe
practices in designing the human-machine interface to prevent ergonomic or musculoskeletal disorder
injury/illness. Additional guidance will be provided that should be considered in the layout, workflow and
movement of parts and material through the thermal spray installation. This should be included in the design of
both the thermal spray booth, tooling/fixture to be utilized in the booth, coating materials and actual work steps.

11.2 Design Considerations

The overall intent is to reduce the potential of ergonomic injuries or illness via the following methods and in the
same order of priority:

1. Engineering Design
2. Administrative Procedures
3. Personal Protective Equipment

Engineering Design − In the engineering of the equipment, ergonomics must be integrated into the design of:
tooling, workstation layout, material movement, process, and maintenance activities. During this engineering
phase, the opportunity exists to reduce and eliminate future injuries/illnesses due to ergonomics. Consideration
must include, among other things, operator size, body position, reaches, ease of operation (force and repetition
of motion) and weight. This list is numerous and it is recommended that an ergonomics checklist be
developed/obtained and utilized. An example of an engineering design may be a new lever-type clamp to hold a
part versus a manual twist clamp where the twisting motion is eliminated, thereby reducing the potential of an
ergonomic injury due to the repetitive motion of the wrist/hand.

Administrative Controls − may be incorporated for existing controls measures where the equipment is already
installed or where the new design may be economically unjustified. These types of controls are operating
procedures that incorporate the same or similar ergonomic considerations into the task at hand. An example is
use of a pneumatic air tool for grinding debris or overspray from a part versus using a file or emery cloth, which
involves extended gripping, may be forceful and repetitive.

Personal Protective Equipment (PPE) − must be utilized throughout the workplace, however, there are specific
tasks whereby PPE may be necessary to eliminate or reduce the potential for ergonomic type injuries/illnesses.
Again consideration must be given to the task at hand and how PPE may be utilized. An example is the use of
padded gloves to reduce vibration in certain power tools. Extended vibration may lead to an ergonomic
injury/illness if not properly addressed.

Ideally, ergonomics should be addressed in the design; however, there are numerous equipment/processes in
existence already. For those existing applications the other two controls are still available resources.

Material Movement

Consideration should be given to the movement of material into the workplace, in the workplace and out of the
workplace. Consideration to include the handling of material so that the operator is not over extending
himself/herself, frequency of motions, as in loading/unloading parts is minimized and lifting/bending and twisting
is controlled to an acceptable practice.

Page 46 of 47
 Designation SG003-03

Weight, Size and Shape of Workpieces

Consideration for the weight, size and shape of the workpiece must be factored into the ergonomic analysis.
Many companies now have weight limits placed on individuals to reduce the injury potential. Those weight limits
range from 30 to 100 pounds (13.6 to 45.4 kg). Remember size, shape and loading needs when performing the
analysis.

Workpiece Preparation Requirements

What are the tasks needed for the preparation of parts and most importantly how are they accomplished? Is the
operator able to face the work in a neutral position whether standing or sitting? Grasping the work with the
hands or fingers, arms, hands, feet and leg placement while working, lighting, body or back position and
repetition are critical in the ergonomics analysis.

Workspace or Workstation Layout

Consider the posture of the individual performing the work. Correct posture is also defined as the ears,
shoulders and hips being in vertical alignment. The work needs to be close at hand, this is true whether the
operator is standing or sitting. Less force is required when the work is within reach (12 to 18 inches (305 to 457
mm) of the body and at an acceptable elevation). Beyond that the work becomes awkward and injury potential
increases.

11.3 Repetitive and Force of Operations

Consideration must include the frequency and force of the task. Performing a minor task over and over or
performing a task with excessive force may lead to a cumulative trauma ergonomic injury/illness. Consider
periodic breaks or job rotation as a means to reduce the stress from these tasks.

In summary, ergonomics simply means designing the workstation so that the task at hand may be accomplished
without stressing the body to a point of injury. With proper forethought this may be accomplished utilizing the
basic concepts mentioned above.

Page 47 of 47
 Designation SG003-03

Guidelines for the Use of Personal Protective Equipment

(PPE) in Thermal Spraying

Prepared by the ASM-TSS Safety Committee

Key Document Authors:

Gregory Wuest, Sulzer Metco (US), Inc.

Aaron Hall, Sandia National Laboratories

Daryl Crawmer, Thermal Spray Technologies, Inc.

TSS Safety Committee Members:

Gregory Wuest Chairman Sulzer Metco (US), Inc.

Richard Neiser Sandia National Laboratories

Aaron Hall Sandia National Laboratories

Lysa Russo SUNY at Stony Brook

Daryl Crawmer Thermal Spray Technologies, Inc.

Douglas J. Gifford Praxair Surface Technologies, Inc.

Donna Guillen Idaho National Engineering and

Environmental Laboratories

Larry Pollard Progressive Technologies, Inc.

Page 1 of 33
Copyright © 2008 ASM International® www.asminternational.org
All rights reserved.
 Designation SG003-03

DISCLAIMER:

This document represents a collective effort involving a substantial number of volunteer specialists. Great
care has been taken in the compilation and production of this document, but it should be made clear that
NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE GIVEN IN CONNECTION
WITH THIS DOCUMENT. Although this information is believed to be accurate by ASM International®,
ASM cannot guarantee that favorable results will be obtained from the use of this document alone. This
document is intended for use by persons having technical skill, at their sole discretion and risk. It is
suggested that you consult your own network of professionals. Since the conditions of product or
material use are outside of ASM’s control, ASM assumes no liability or obligation in connection with any
use of this information. No claim of any kind, whether as to products or information in this document, and
whether or not based on negligence, should be greater in amount than the purchase price of this product
or publication in respect of which damages are claimed. THE REMEDY HEREBY PROVIDED SHOULD
BE THE EXCLUSIVE AND SOLE REMEDY OF BUYER, AND IN NO EVENT SHOULD EITHER PARTY
BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHETHER OR NOT
CAUSED BY OR RESULTING FROM THE NEGLIGENCE OF SUCH PARTY. As with any material,
evaluation of the material under end use conditions prior to specification is essential. Therefore, specific
testing under actual conditions is recommended.
Nothing contained in this document should be construed as a grant of any right of manufacture, sale, use,
or reproduction, in connection with any method, process, apparatus, product, composition, or system,
whether or not covered by letters patent, copyright, or trademark, and nothing contained in this document
should be construed as a defense against any alleged infringement of letters patent, copyright, or
trademark, or as a defense against liability for such infringement.
Comments, criticisms, and suggestions are invited, and should be forwarded to the Thermal Spray
Society of ASM International®.

Page 2 of 33
 Designation SG003-03

CONTENTS

1.
U U SCOPE AND OVERVIEW ..................................................................................................................... 5
U U

2.
U U RELATED STANDARDS AND DOCUMENTS ...................................................................................... 6
U U

3.
U U TERMINOLOGY/DEFINITIONS ............................................................................................................ 9
U U

4. PPE PROGRAM: TYPICAL RESPONSIBILITIES OF EMPLOYERS, SUPERVISORS, AND

U U U

WORKERS .................................................................................................................................................. 12
U

4.1
U U Employers .................................................................................................................................. 12
U U

4.2
U U Supervisors ................................................................................................................................ 12
U U

4.3
U U Employees ................................................................................................................................. 12
U U

5.
U U CLEANING AND MAINTENANCE OF PPE ........................................................................................ 13
U U

6.
U U EYE AND FACE PROTECTION .......................................................................................................... 13
U U

6.1
U U Safety Glasses ........................................................................................................................... 13
U U

6.2
U U Single Lens Goggles.................................................................................................................. 13
U U

6.3
U U Welders/Chippers Goggles ........................................................................................................ 13
U U

6.4
U U Face Shields .............................................................................................................................. 14
U U

6.5
U U Welding Shields ......................................................................................................................... 14
U U

6.6
U U Additional Protection .................................................................................................................. 14
U U

6.7
U U Prescription Safety Eyewear...................................................................................................... 14
U U

6.8
U U Eye Protection Cleaning and Maintenance ............................................................................... 15
U U

6.9
U U Emergency Eyewash & Shower Facilities ................................................................................. 17
U U

7.
U U HEAD PROTECTION .......................................................................................................................... 17
U U

7.1
U U Head Protection Cleaning and Maintenance ............................................................................. 17
U U

7.1.1
U U Damage to shell..................................................................................................................... 18
U U

7.1.2
U U Deterioration in shock absorption or penetration resistance ................................................. 18
U U

7.1.3
U U Other Considerations ............................................................................................................ 18
U U

7.1.4
U U Replacement ......................................................................................................................... 18
U U

8.
U U FOOT PROTECTION .......................................................................................................................... 18
U U

8.1
U U Safety Footwear Cleaning and Maintenance............................................................................. 19
U U

9.
U U HAND PROTECTION .......................................................................................................................... 19
U U

9.1
U U Glove Cleaning and Maintenance ............................................................................................. 21
U U

Page 3 of 33
 Designation SG003-03

10.
U U RESPIRATORY PROTECTION ..................................................................................................... 21
U U

10.1
U U Air purifying respirators .............................................................................................................. 22
U U

10.2
U U Air-supplied respirators .............................................................................................................. 22
U U

10.3
U U Respiratory Protection Summary ............................................................................................... 22
U U

11.
U U HEARING PROTECTION .............................................................................................................. 23
U U

11.1
U U High Noise Areas ....................................................................................................................... 23
U U

12.
U U TRAINING ...................................................................................................................................... 24
U U

13.
U U RECORDKEEPING........................................................................................................................ 24
U U

14.
U U REFERENCES...............................................................................................................................24
U U

15.
U U Appendices .................................................................................................................................... 26
U U

15.1
U U Appendix A: Glove Chart ........................................................................................................... 26
U U

15.2
U U Appendix B: Glove Type and Chemical Use ............................................................................. 27
U U

15.3
U U Appendix C: Job Hazard Analysis Example .............................................................................. 31
U U

15.4
U U Appendix D: Filter Lenses for Protection Against Radiant Energy ............................................ 32
U U

Page 4 of 33
 Designation SG003-03

1. SCOPE AND OVERVIEW

0B

It is the belief of the Thermal Spray Society Safety Committee that every person is entitled to work in a safe and
healthful environment. People are the most important assets in the Thermal Spray Community and their health
and safety is the community’s greatest responsibility.
This document “Guidelines for the Use of Personal Protective Equipment in Thermal Spraying” is intended to
provide information consistent with the Occupational Safety and Health Administration’s (OSHA) Personal
Protective Equipment Standard (29 CFR 1910.132-138). All information is presented in the context of Thermal
Spraying.
Personal Protective Equipment (PPE) is intended to protect individuals from the risk of injury by creating a
barrier against workplace hazards. Personal protective equipment is not a substitute for good engineering
controls, administrative controls, or good work practices. Instead, it should be used in conjunction with these
controls to ensure the safety and health of workers. The thermal spray enclosure (spray booth) is the most
important safety device (PPE not withstanding) used in thermal spray processing. The use of a spray enclosure
is always preferable to the use of PPE. The primary role of a thermal spray enclosure is to contain and/or control
various hazards associated with thermal spray processing of materials. Because the spray operations are
conducted within its confines, all of the energy sources (gas, electricity, and water), the feedstock materials, and
all of the process effluents (heat, dust, fumes, sound, and ultraviolet light) are present and controlled.
Engineering controls, administrative controls, and good work practices are always preferred instead of PPE as
methods to protect workers against workplace hazards. Nevertheless, many situations exist in which a fully
enclosed spray booth cannot be used or where an operator must enter a spray booth while the spray device is
operating. Personal protective equipment should be used when it has been determined that its use will lessen
the likelihood of occupational injury and/or illness and when other protection methods are not available. These
situations demand the use of PPE.
This document provides guidelines for establishing PPE programs, assessing hazards associated with thermal
spray operations, and training workers about PPE, as well as guidelines for selecting, using, and maintaining
PPE. This document also provides an overview of eye, face, head, hand, foot, hearing, fall, and respiratory
protection. Respiratory and hearing protection should be used in conjunction with industrial hygiene monitoring.
These guidelines are written within the context of the prevailing internationally accepted practices and
standards, as well as United States laws and regulations. They are intended to have worldwide application. It is
incumbent upon each individual, company, or institution referencing these guidelines, to ensure compliance with
all relevant local country/community laws, rules and regulations, and to apply generally accepted, good
engineering practice to the selection, use, and maintenance of personal protective equipment.
Thermal Spray activities are complex and involve many different materials and situations. Because of the
diverse nature of thermal spray process requirements, this document alone cannot provide all the information
needed for PPE selection, use, and maintenance. Suppliers/professionals with expertise in specific aspects of
industrial hygiene should be consulted to ensure safety and health of workers.
This guideline is intended for use in conjunction with the other reference publications, local publications, and
applicable standards. An extensive, but not comprehensive, list of these is included in Section 2, RELATED
X X X

STANDARDS AND DOCUMENTS

Page 5 of 33
 Designation SG003-03

2. RELATED STANDARDS AND DOCUMENTS

1B

Where standards and other documents are referenced in this publication, they refer to the latest edition.

U.S. Standards

Publication Title Available from:

ASTM Publications: “Standard specification for performance American Society for Testing
requirements for foot protection”. and Materials
ASTM F2413:
100 Bar Harbor Drive
West Conshohocken, PA
19428-2959
www.astm.org

ANSI Publications: Personnel Protection - Protective Footwear". American National Standards

Institute
ANSI Z41-1991,
1430 Broadway
New York, NY 10018
Practice for Occupational and Educational Eye
ANSI Z87.1- and Face Protection www.ansi.org
1989

ANSI Z89.1- Safety Requirements for Industrial Head

1986 Protection

ASM-TSS Publications: Thermal Spray Booth Design Guidelines ASM International®

9639 Kinsman Road
Safety Guidelines for Performing Risk Materials Park, OH 44073-
Assessments 0002
www.asminternational.org

AWS Publication AWS C2.16 Guide for Thermal Spray Operators American Welding Society
550 NW. LeJeune Road
Miami, Florida 33126
1-800-443-9353
e-mail: [email protected]
HU U

Page 6 of 33
 Designation SG003-03

U.S. Standards

Publication Title Available from:

OSHA Publications Occupational Safety and Health
Occupational Safety and Health Act of
Administration
1970 (29 U.S.C. 653, 655, 657); Secretary
of Labor’s Order No. 12-71 (36 FR 8754), 1-800-321-OSHA for nearest
8-76 (41 FR 25059), 9-83 (48 FR 35736), or location
1-90 (55 FR 9033), Sections 1910.132, and
www.osha.gov
1910.138 also issued under 29 CFR part
HU U

1911; sections 1910.133, 1910.135, and

1910.136 also issued under 29 CFR part
1911 and 5 U.S.C. 553.

OSHA Standard "General Requirements"

29 CFR
1910.132,
"Eye and Face Protection"
OSHA Standard
29 CFR
1910.133

OSHA Standard "Head Protection"

29 CFR
1910.135,

OSHA Standard Occupational Foot Protection

29 CFR
1910.136, "
"Hand Protection"
OSHA Standard
29 CFR
1910.138,

European Directives

Available from:
Publication Title/Contents
Council
of 30 November 1989 on the minimum health and safety requirements
H

Directive
for the use by workers of personal protective equipment at the workplace All of this
89/656/EEC
(third individual directive within the meaning of Article 16 (1) of Directive
H

information, and
89/391/EEC), Official Journal n° L 393 of 30.12.1989, p. 18. more, can be found
Council at:
of 21 December 1989 on the approximation of the laws of the Member
H

Directive
States relating to personal protective equipment. Official journal NO. L http://osha.europa.
89/686/EEC HU

399 , 30/12/1989 P. 0018 - 0038

H

eu/legislation/ U

Page 7 of 33
 Designation SG003-03

European Directives

Available from:
Publication Title/Contents
Council
of 24 June 1992 on the minimum requirements for the provision of safety
H

Directive
and/or health signs at work (ninth individual Directive within the meaning
92/58/EEC
of Article 16 (1) of Directive 89/391/EEC), Official Journal n° L 245 of
H

26.08.1992, p. 23.
Council
of 29 May 1990 on the minimum health and safety requirements for the
H

Directive
manual handling of loads where there is a risk particularly of back injury
90/269/EEC (
to workers (fourth individual Directive within the meaning of Article 16
H

EU )
(1) of Directive 89/391/EEC), Official Journal n° L 156, 21.06.1990, p. 9

Council All of this

of 27 November 1980 on the protection of workers from the risks related
H

Directive information, and

to exposure to chemical, physical and biological agents at work, Official
80/1107/EEC more, can be found
Journal n° L 327 of 03.12.1980, p. 8.
H

at:
http://osha.europa.
HU

Council
H of 7 April 1998 on the protection of the health and safety of workers from eu/legislation/
U

Directive the risks related to chemical agents at work (fourteenth individual

98/24/EC H Directive within the meaning of Article 16(1) of Directive 89/391/EEC)

Council of 30 November 1989 concerning the minimum safety and health

Directive requirements for the use of work equipment by workers at work (second
89/655/EEC individual Directive within the meaning of Article 16 (1) of Directive
89/391/EEC)
Council on the minimum health and safety requirements regarding the exposure
Directive of workers to the risks arising from physical agents (noise)
2003/10/EC

Page 8 of 33
 Designation SG003-03

3. TERMINOLOGY/DEFINITIONS
2B

ACGIH – American Council of Industrial Hygienists.

Administrative Controls – Reducing the risk of injury through management of the processes and workforce.
Action level – under OSHA regulations it is a concentration of a specific substance or hazard calculated as an
eight (8)-hour time-weighted average, which initiates certain required activities such as exposure monitoring and
medical surveillance. Typically, the AL is one-half the PEL level.
ANSI – An abbreviation for American National Standards Institute.
ASTM – An abbreviation for American Society for Testing and Materials.
AWS – An abbreviation for the American Welding Society.
Approved – Acceptable to the authority having jurisdiction.
CGA – An abbreviation for the Compressed Gas Association.
Detonation Gun – A thermal spray device that employs rapid detonation of an oxygen-fuel mixture to heat and
carry coating powders to the surface of a part in order to apply a coating that enhances the part’s surface
performance properties.
Decibel (dB) – A numerical expression of the relative loudness, or intensity, of a sound. The difference in
decibels between two sounds is ten times the logarithm of the ratio of their power levels. The “A” suffix when
used with dB (dBA) signifies a non-linear averaging of noise levels across ten octave bands to compensate for
human ear sensitivity to sound at various frequencies.
Dry Ice (CO2 Snow) – the solid state of carbon dioxide. Usually forms when a sudden pressure release of CO2
occurs such as spraying.
Effluent – A term used to encompass all the gases, particulate, fumes, etc. emitted from a thermal spray gun or
torch.
Enclosure – The cabinet or housing of apparatus or the fence or wall surrounding an installation to prevent
personnel from personal injury hazards or to protect the equipment from physical damage.
Engineering Controls – Reducing the risk or potential for injury by incorporating safety systems, features,
interlocks, etc. into the design of machines, tools, layouts and processes.
EPA – abbreviation used for the Environmental Protection Agency (USA).
Equipment - A general term including materials, fittings, devices, appliances, fixtures, apparatus and the like
used as a part of, or in connection with, a thermal spray installation.
Ergonomics – The process or science of adapting workstations, tools, equipment and work techniques to be
compatible with human anatomy and physiology so as to reduce the risk of injury due to occupational activity or
stresses.
Fuel Gas – Any combustible gas, including hydrogen, propane, propylene, acetylene, MAPP, etc. used in a
thermal spray process.
Fumes – Particulate matter consisting of particles generated by the condensation of gases created by
evaporation of melted substances.
Frequency – The number of cycles-per-second of a device, signal, or parameter. Generally expressed in
Hertz (Hz).

HEPA – An abbreviation used for High Efficiency Particulate Air. In reference to air filters, it specifies that
99.97% of particles larger that 0.3 micron will be removed from the air stream.

Page 9 of 33
 Designation SG003-03

HVOF – High Velocity Oxygen Fuel. This type of high velocity coating process uses a liquid or gaseous fuel
combusted with oxygen to heat and carry coating material to the surface of a part in order to enhance the part’s
surface performance properties.
HVAF – High Velocity Air Fuel. This type of high velocity coating process uses a gaseous fuel with air to heat
and carry coating material to the surface of a part to enhance its surface features.
LPPS – Low Pressure Plasma Spray. See preferred term Vacuum Plasma Spray Deposition.
Lock-out/Tag-out – The process of locking and tagging any energy source (typically a valve or electrical
shutoff) to isolate sources of energy during maintenance/repair and prevent inadvertent operation – or release of
energy or hazardous material.
MSDS – An abbreviation used for Material Safety Data Sheets.
NFPA (National Fire Protection Association) – A U.S. based organization providing advisory standards
offered for use in law and for regulatory purposes in the interest of life and property protection.
NIOSH – National Institute for Safety and Health
Noise - Unwanted sound which may be hazardous to health, interferes with communications, or is disturbing.
OSHA – Occupational Safety and Health Administration (USA).
Permissible Exposure Limit (PEL) – is the maximum amount or concentration of a chemical that a worker may
be exposed to under OSHA regulations.
Process Equipment – The mechanical and/or electrical devices and associated control systems that are used
to produce coatings or produce surface enhancements, and whose operation directly affects the chemistry, or
the physical properties, of the final product. Typically, this includes gas consoles, regulator panels, hose
bundles, powder feeders, gases and gas supplies, and the thermal spray gun or torch.
REL (Recommended Exposure Limit) – An 8 or 10-hour time-weighted average (TWA) or ceiling (C) exposure
concentration recommended by NIOSH that is based on an evaluation of health effects data.
Sound – A vibrational disturbance, exciting hearing mechanisms, transmitted in a predictable manner
determined by the medium through which it propagates.
Sound Pressure – Fluctuations in air pressure caused by the presence of sound waves.
Sound Pressure Level - The intensity of a sound, expressed in decibels (dB).
Spray Booth – An enclosure for thermal spray processes that is specifically designed to mitigate process
hazards. A spray booth is NOT designed for human occupancy during routine spray operations; however, it is
routinely occupied for maintenance and process setup.
Spray (Coating) Box – A spray (coating) box is an enclosure for thermal spray processes that is specifically
designed to mitigate process hazards. These boxes are NOT designed for human occupancy during routine
spray operations, process setup and routine maintenance.
Spray Enclosure – A term used in this document whenever a statement is equally applicable to either a spray
booth or a spray (coating) box.
Threshold Limit Value (TLV) – are guidelines prepared by the American Conference of Governmental
Industrial Hygienists, Inc (ACGIH) to assist in making decisions regarding safe levels of exposure to various
hazards found in the workplace. A TLV reflects the level of exposure that the typical worker can experience
without an unreasonable risk of disease or injury.
Vacuum Plasma Deposition (VPD) – A thermal spraying process variation utilizing a plasma gun confined to a
solid enclosure. The enclosure is evacuated and the spraying performed under low pressure, also known as
Vacuum Plasma Spray (VPS), Low Pressure Plasma Spray (LPPS®).

Page 10 of 33
 Designation SG003-03

Ventilation System – A complete air handling and filtration system for a thermal spray booth from the intake of
air into the process to the exhaust of the air back into the atmosphere. In this document, the spray booth is
considered as part of the exhaust system in regard to air flow.

Page 11 of 33
 Designation SG003-03

4. PPE PROGRAM: TYPICAL RESPONSIBILITIES OF EMPLOYERS, SUPERVISORS,

AND WORKERS
This section sets forth minimum personal protective equipment (PPE) requirements. It also provides an
overview of PPE program responsibilities for employers, supervisors, and employees. It includes workplace
assessments, supplying PPE, care, maintenance, and training.

4.1 Employers
14B

The ultimate responsibility for implementing a PPE program resides with the company/employer. It is
recommended that every company/employer performing thermal spray operations establish a formal PPE
program. This program should:
• Document and explain the companies PPE policies and the PPE procedures to be followed by
supervisors and employees.
• Identify a person as the PPE program leader
• Explain the methods for performing hazard assessments
• Explain the requirements for documenting hazard assessments, training, and PPE records

4.2 Supervisors
15B

Supervisors typically have the primary responsibility for implementation of PPE Programs in their work area.
This involves:
• Conducting workplace hazard assessments to determine the presence of hazards which necessitate the
use of PPE.
• Providing appropriate PPE and making it available to all workers.
• Ensuring workers are trained on the proper use, care, and cleaning of PPE.
• Maintaining records on PPE assignments and training.
• Supervising workers to ensure that the PPE Program elements are followed and that employees
properly use and care for their PPE.
• Posting instructional signs relative to the requirement for PPE (e.g., “All persons entering this area must
wear safety glasses.”)
• Seeking assistance from industrial hygienists to evaluate hazards.
• Ensuring defective or damaged PPE is immediately replaced.
• Conducting periodic workplace reassessments when new hazards are introduced or when processes
are added or changed.
• Maintaining records on hazard assessments.
• Providing guidance for the selection and purchase of approved PPE.
• Periodically reevaluating the suitability of previously selected PPE.
• Reviewing, updating, and evaluating the overall effectiveness of their specific PPE Program.

4.3 Employees
16B

Employees are typically the PPE user and therefore are responsible for following the requirements of their
companies individual PPE Program. This involves:

Page 12 of 33
 Designation SG003-03

• Wearing PPE as required and when required.

• Performing required training.
• Caring for, cleaning, and maintaining PPE as required.
• Informing the supervisor of the need to repair or replace PPE.
• Observing and coaching other employees to encourage safe behaviors.
• Utilizing individual “Stop Work” authority if unsafe conditions exist. Note: It is important to recognize that
PPE will not save you if conditions are inherently unsafe. PPE is just a line of defense.

5. CLEANING AND MAINTENANCE OF PPE

4B

It is important that all PPE be kept clean and properly maintained. Cleaning is particularly important for eye and
face protection where dirty or fogged lenses could impair vision. A contaminant could be ingested, inhaled, or
absorbed through exposed skin or mucus membranes. PPE should be inspected, cleaned, and maintained at
regular intervals so that the PPE provides the requisite protection. Personal protective equipment should not be
shared between employees until it has been properly cleaned and sanitized. PPE should be distributed for
individual use whenever possible.
It is also important to ensure that contaminated PPE, which cannot be decontaminated, is disposed of in a
manner that protects employees from exposure to hazards.

6. EYE AND FACE PROTECTION

5B

Prevention of eye injuries requires that all persons who may be in eye hazard areas wear protective eyewear.
This includes employees, visitors, researchers, contractors, or others passing through an identified eye hazard
area. Note: any place where thermal spray is conducted is an eye hazard area. To provide protection for these
personnel, a sufficient quantity of goggles and/or plastic eye protectors should be available. If personnel wear
personal glasses, eye protectors suitable to wear over them should be provided. Five common categories of
protective eyewear are defined below. Signs indicating that an area requires use of eye protection should be
posted. Safety glasses should be made available at all access points to the eye protection area.

6.1 Safety Glasses

Protective eyeglasses are made with safety frames, tempered glass or plastic lenses, temples and side shields
which provide eye protection from moderate impact and particles encountered in job tasks such as carpentry,
woodworking, grinding, scaling, etc. Safety glasses are also available in prescription form for those persons
who need corrective lenses. Personnel requiring prescription safety glasses should follow their corporate
procedures obtaining PPE to obtain their prescription safety glasses.

6.2 Single Lens Goggles

Vinyl framed goggles of soft pliable body design provide adequate eye protection from many hazards. These
goggles are available with clear or tinted lenses, perforated, port vented, or non-vented frames. Single lens
goggles provide similar protection to spectacles and may be worn in combination with spectacles or corrective
lenses to insure protection along with proper vision.

6.3 Welders/Chippers Goggles

17B

These goggles are available in rigid and soft frames to accommodate single or two eyepiece lenses.
Welder’s goggles provide protection from sparking, scaling, or splashing metals and harmful light rays. Lenses
are impact resistant and are available in incremental shades of filtration.

Page 13 of 33
 Designation SG003-03

Chippers/Grinders goggles provide eye protection from flying particles. The dual protective eye cups house
impact resistant clear lenses with individual cover plates.

6.4 Face Shields

18B

These normally consist of an adjustable headgear and face shield of tinted/transparent acetate or polycarbonate
materials, or wire screen. Face shields are available in various sizes, tensile strength, impact/heat resistance
and light ray filtering capacity. Face shields will be used in operations when the entire face needs protection
and should be worn to protect eyes and face against flying particles, metal sparks, and chemical/biological
splash.

6.5 Welding Shields

19B

These shield assemblies consist of vulcanized fiber or glass fiber body, a ratchet/button type adjustable
headgear or cap attachment and a filter and cover plate holder. These shields will be provided to protect
workers’ eyes and face from ultraviolet, infrared, or radiant light burns, flying sparks, metal spatter and slag
chips encountered during welding, brazing, soldering, resistance welding, bare or shielded electric arc welding
and oxyacetylene welding, oxyacetylene cutting operations, flame spray operations, electric arc spray
operations, and plasma spray operations.

6.6 Additional Protection

20B

Additional protection is needed when employees are exposed to hazards from flying particles, molten metal,
acids or caustic liquids, chemical liquids, gases, or vapors, bio-aerosols, or potentially injurious light radiation
such as that produced by some lasers.

• Wearers of contact lenses must also wear appropriate eye and face protection devices in a
hazardous environment.

• The nature of the working environment should be considered before contact lenses are used.
Contact lenses should not be used in an environment that could react with the contact lenses
(e.g. working around chemical vapors that could react with the lens material)

• Side protectors are needed when there is a hazard from flying objects.

• Goggles and face shields are needed when there is a hazard from chemical splash.

• Face shields should always be worn over primary eye protection (safety glasses or goggles).

• For employees who wear prescription lenses, eye protectors need to either incorporate the
prescription in the design or fit properly over the prescription lenses.

• Protectors shall be marked to identify the manufacturer.

• Equipment fitted with appropriate filter lenses need to be used to protect against light radiation
(e.g. from an air plasma spray torch). Tinted and shaded lenses are not filter lenses unless
they are marked or identified as such. Specifically, sunglasses do not adequately filter out the
intense light from thermal spray processes and should not be considered protective filtering
eyewear.

6.7 Prescription Safety Eyewear

21B

OSHA regulations require that each affected employee who wears prescription lenses while engaged in
operations that involve eye hazards shall wear eye protection that incorporates the prescription in its design, or

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shall wear eye protection that can be worn over the prescription lenses (goggles, face shields) without disturbing
the proper position of the prescription lenses or the protective lenses.

6.8 Eye Protection Cleaning and Maintenance

2B

The lenses of eye protectors must be kept clean as dirty lenses restrict vision, which can cause eye fatigue and
lead to accidents. Scratched or uncleanable eye protectors should be disposed of. There are two methods for
cleaning eye protectors. Glass, polycarbonate and other plastic lenses can be cleaned by thoroughly wetting
both sides of the lenses and drying them with a wet strength absorbent paper. Anti-static and anti-fog lens
cleaning fluids may be used, daily if necessary, if static or misting is a problem. Alternatively lenses can be 'dry'
cleaned by removing grit with a brush and using a silicone treated non-woven cloth. However plastic or
polycarbonate lenses should not be 'dry' cleaned as the cloth used in this method can scratch them.
Eye protectors should be issued on a personal basis and used only by the person they are issued to. If eye
protectors are re-issued they should be thoroughly cleaned and disinfected. Being placed in suitable cases
when not in use should protect eye protectors.
Eye protector headbands should be replaced when worn out or damaged. Lenses that are scratched or pitted
must be replaced as they may impair vision and their resistance to impact may be impaired. Transparent face
shields must be replaced when warped, scratched or have become brittle with age.

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Eye and Face Protection Selection Chart

Source Assessment of Hazard Eye and Face Protection
IMPACT - Chipping, Flying fragments, flying Spectacles with side protection, goggles, face
grinding, machining, objects, large chips, shields.
drilling, chiseling, riveting, particles, sand, dirt, grit, For severe exposure (e.g. grit blasting), use face
sanding, grit blasting, etc. dust etc… shield over primary eye protection.

Note: Grit blasting operations may require

respiratory protection to mitigate lung hazards from
respiratory dust, See Section 10
X X

CHEMICALS - Acid and Splash, Irritating vapors, Goggles, eyecup and cover types.
chemicals handling, hazardous vapors For severe exposure, use face shield over primary
substrate cleaning, and eye protection
rinsing Special-purpose goggles
DUST – Grit Blasting, Nuisance dust Goggles, eyecup and cover types.
buffing, spray hood clean-
up, general dusty
conditions Note: Respiratory protection may also be required
to mitigate lung hazards from respiratory dust. See
Section 10
X X

LIGHT and/or UV
RADIATION – Electric Arc, Optical radiation Welding helmets or welding shields. Typical
Plasma Spray, and shades: 10-14, Auto-dimming shades as suitable.
Welding - electric arc
Note: Skin protection to prevent UV burns (severe
sunburn) is needed in addition to eye & face
protection when working around Wire Arc, Plasma,
and Welding process.

Welding goggles or welding face shield. Typical

Flame Spray, HVOF, and
shades: gas welding 4-8, cutting 3-6, brazing 3-4
gas flame welding Optical radiation

Cutting, torch brazing,

Spectacles or welding face shield. Typical shades:
torch soldering,
Optical radiation 1.5-3 Auto-dimming shades as suitable.

Spectacles with shaded or special-purpose lenses,

Glare
Poor vision as suitable. Auto-dimming shades as suitable.

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6.9 Emergency Eyewash & Shower Facilities

23B

Emergency eyewash facilities meeting the requirements of ANSI Z358.1 need to be provided in all areas where
the eyes of any employee may be exposed to corrosive materials. Eye wash facilities need to be located where
they are easily accessible in an emergency. Permanently plumbed eyewashes are preferred, however portable
eyewash stations are available for areas where plumbing isn’t available. Periodic tests and inspections should
be conducted for all eyewash systems. Plumbed systems can be tested monthly. Mobile systems require
periodic replacement of the eye wash fluid. A record should be kept documenting eyewash inspection/refill.
Emergency shower facilities should also be considered when employees may be exposed to corrosive
materials.

7. HEAD PROTECTION
6B

Head injuries are caused by falling or flying objects, or by bumping the head against a fixed object. Head
protectors, in the form or protective hats, must resist penetration and absorb the shock of a blow. The shell of
the protective hat is hard enough to resist the blow and the headband and crown straps keep the shell away
from the wearer’s skull. Protective hats can also protect against electrical shock.
Head protection needs to be furnished to, and used by, all personnel engaged in construction type work.
Especially when spraying the interior surfaces of a large space, applying coatings overhead, or working with
cranes and forklifts. Head protection should also be worn by engineers, inspectors, and visitors at construction
sites when hazards from falling or fixed objects, or electrical shock are present. Bump caps/skull guards may be
issued and worn for protection against scalp lacerations from contact with sharp objects. However, they must
not be worn as substitutes for safety caps/hats because they do not afford protection from high impact forces or
penetration by falling objects. Hard hat areas should always be clearly posted. Protective hats are made in the
following types and classes:

• Type I - Helmets with a full brim.

• Type 2 - Brimless helmets with a peak extending forward from the crown.

• Class A - General service, limited voltage. Intended for protection against impact hazards.
Used in mining, construction, and manufacturing.

• Class B - Utility service, high voltage. Used by electrical workers.

• Class C - Special service, no voltage protection. Designed for lightweight comfort and
impact protection. Used in certain construction, manufacturing, refineries, and where there
is a possibility of bumping the head against a fixed object.
All head protection (helmets) is designed to provide protection from impact and penetration hazards caused by
falling objects. Head protection is also available which provides protection from electric shock and burn. When
selecting head protection, knowledge of potential electrical hazards is important. Class A helmets, in addition to
impact and penetration resistance, provide electrical protection from low-voltage conductors (they are proof
tested to 2,200 volts). Class B helmets, in addition to impact and penetration resistance, provide electrical
protection from high-voltage conductors (they are proof tested to 20,000 volts). Class C helmets provide impact
and penetration resistance (they are usually made of aluminum which conducts electricity), and should not be
used around electrical hazards.

7.1 Head Protection Cleaning and Maintenance

24B

Head protection must be maintained in good condition. It should:

y Be stored, when not in use, in a safe place, for example, on a peg or in a cupboard. It should
not be stored in direct sunlight or in excessively hot, humid conditions;

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y Be visually inspected regularly for signs of damage or deterioration;

a. Have defective harness components replaced (if the design or model allows this).
Harnesses from one design or model of helmet cannot normally be interchanged with those
from another;

b. Have the sweatband regularly cleaned or replaced.

7.1.1 Damage to shell

34B

Damage to the shell of a helmet can occur when:

• Objects fall onto it;

• It strikes against a fixed object.

• It is dropped or thrown.

7.1.2 Deterioration in shock absorption or penetration resistance

35B

Deterioration in shock absorption or penetration resistance of the shell can occur from:

• Exposure to certain chemical agents.

• Exposure to heat or sunlight.

• Aging due to heat, humidity, sunlight and rain.

7.1.3 Other Considerations

36B

Before head protection is reissued to another person, it should be inspected to ensure it is serviceable and
thoroughly cleaned in accordance with the manufacturer's instructions, e.g. using soap and water. The
sweatband should always be cleaned or replaced.
Chemical agents that should be avoided include paint, adhesives or chemical cleaning agents. Where names or
other markings need to be applied using adhesives, advice on how to do this safely should be sought from the
helmet manufacturer.
Exposure to heat or sunlight can make the shell become brittle. Head protection should therefore never be
stored near a window, e.g. the rear window of a motor vehicle, because excessive heat may build up.

7.1.4 Replacement
37B

The head protection should normally be replaced at intervals recommended by the manufacturer. It will also
need replacing when the harness is damaged and cannot be replaced, or when the shell is damaged or it is
suspected that its shock absorption or penetration resistance has deteriorated - for example when:

• The shell has received a severe impact.

• Deep scratches occur.

• The shell has any cracks visible to the naked eye.

8. FOOT PROTECTION
7B

Safety shoes need to be worn in areas where heavy materials could fall or roll on the feet or where puncture
protection is required. All safety footwear needs to comply with ANSI Z41-1991, "American National Standard

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for Personal Protection - Protective Footwear." And ASTM F2413: “Standard specification for performance
requirements for foot protection”.
Safety shoes or boots with impact protection need to be worn in work areas where carrying or handling
materials such as packages, objects, parts or heavy tools, which could be dropped; and for other activities
where objects might fall onto the feet. Safety shoes or boots with compression protection are typically required
for work activities involving skid trucks (manual materials handling cars) or other activities in which materials or
equipment could potentially roll over an employee’s feet. Safety shoes or boots with puncture protection are
required where sharp objects such as nails, wire, tacks, screws, large staples, scrap metal etc., could be
stepped on by employees causing a foot injury.

8.1 Safety Footwear Cleaning and Maintenance

25B

Safety footwear should be maintained in good condition, checked regularly and discarded if worn or
deteriorated. Laces should be checked and replaced if necessary. Materials lodged into the tread should be
removed. The stitching should be checked for loose, worn or cut seams. Spraying the upper layers of new
footwear with a silicone spray or applying a protective wax will give extra protection against wet conditions.
There are many types and styles of protective footwear and it’s important to realize that a particular job may
require additional protection other than listed here. Footwear that meets established safety standards will have
an American National Standards Institute (ANSI) label inside each shoe.

1. Steel-Reinforced Safety Shoes. These shoes are designed to protect feet from common
machinery hazards such as falling or rolling objects, cuts, and punctures. The entire toe box and
insole are reinforced with steel, and steel, aluminum, or plastic materials protect the instep. Safety
shoes are also designed to insulate against temperature extremes and may be equipped with
special soles to guard against slip, chemicals, and/or electrical hazards.

2. Safety Boots. Safety boots offer more protection when splash or spark hazards (chemicals, molten
materials) are present:

3. When working with corrosives, caustics, cutting oils, and petroleum products, neoprene or nitrile
boots are often required to prevent penetration.

4. Foundry or "Gaiter" style boots feature quick-release fasteners or elasticized insets to allow speedy
removal should any hazardous substances get into the boot itself.

5. When working with electricity, special electrical hazard boots are available and are designed with
no conductive materials other than the steel toe (which is properly insulated).
Safety shoes and boots which meet the ANSI Z41-1991 Standard provide both impact and compression
protection. Where necessary, safety shoes can be obtained which provide puncture protection. In some work
situations, metatarsal protection should be provided, and in other special situations electrical conductive or
insulating safety shoes would be appropriate.

9. HAND PROTECTION
8B

Suitable gloves need be worn when hazards from chemicals, cuts, lacerations, abrasions, punctures, burns,
biological agents, and harmful temperature extremes are present. Glove selection shall be based on
performance characteristics of the gloves, conditions, duration of use, and hazards present. Any one type of
glove will not work in all situations. Skin contact is a potential source of exposure with toxic materials; it is
important that the proper steps be taken to prevent such contact. Most accidents involving hands and arms can
be classified under four main hazard categories: chemicals, abrasions, cutting, and heat. There are gloves
available that can protect workers from any of these individual hazards or any combination thereof.

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Gloves should also be worn whenever it is necessary to handle rough or sharp-edged objects, and very hot or
very cold materials. The types of glove materials to be used in these situations include leather, welder’s gloves,
aluminum-backed gloves, and other types of insulated glove materials.
The first consideration in the selection of gloves for use against chemicals is to determine, if possible, the exact
nature of the substances to be encountered. Read instructions and warnings on chemical container labels and
MSDS's before working with any chemical. Recommended glove types are often listed in the section for
personal protective equipment.
Chemicals eventually permeate all glove materials. However, they can be used safely for limited time
periods if specific use and other characteristics (i.e., thickness and permeation rate and time) are known.
Careful attention must be given to hand protection when working with tools and machinery. Power tools
and machinery must have guards installed or incorporated into their design that prevent the hands and
gloves from contacting the point of operation, power train, or other moving parts. To protect hands from
injury due to contact with moving parts, it is important to:

• Ensure that guards are always in place and used.

• Always lockout machines or tools and disconnect the power before making repairs.

• Treat a machine without a guard as inoperative; and

• Do not wear gloves around moving machinery, such as drill presses, mills, lathes, and grinders.
The following is a guide to the most common types of protective work gloves and the types of hazards they can
guard against:

• Disposable Gloves. Disposable gloves, usually made of lightweight plastic, can help guard against
mild irritants. Disposable gloves are often used for powder handling and for general hand
protection when working with dusty equipment in a spray booth because they prevent nusance
dusts and powders from contacting the skin.

• Fabric Gloves. Made of cotton or fabric blends are generally used to improve grip when handling
slippery objects. They also help insulate hands from mild heat or cold.

• Leather Gloves. These gloves are used to guard against injuries from sparks or scraping against
rough surfaces. They are also used in combination with an insulated liner when working with
electricity. Leather gloves should be used when hand spraying and may be sometimes be used
when handling hot parts.

• Metal Mesh Gloves. These gloves are used to protect hands form accidental cuts and scratches.
Persons working with cutting tools or other sharp instruments use them most commonly.

• Aluminized Gloves. Gloves made of aluminized fabric are designed to insulate hands from intense
heat. Persons working molten materials most commonly use these gloves. Aluminized gloves can
be used as an alternative to leather gloves when handling hot parts.

• Chemical Resistance Gloves. These gloves may be made of rubber, neoprene, polyvinyl alcohol
or vinyl, etc. The gloves protect hands from corrosives, oils, and solvents. The table in Appendix
A is provided as a guide to the different types of glove materials and the chemicals they can be
used against. When selecting chemical resistance gloves, be sure to consult the manufacturers’
recommendations, especially if the gloved hand will be immersed in the chemical.

• Electrical Gloves. These gloves are made of natural rubber and are designed to protect the
wearer against electrical current. Leather protectors must be worn over gloves when voltage

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exceeds 250 volts. Leather protectors provide puncture, abrasion, and moisture resistance. Note:
If electrical gloves are used as PPE for working on a live electrical circuit it is important to consult
NFPA 70E to determine the Hazard Risk Category and the type of glove required.

9.1 Glove Cleaning and Maintenance

26B

Care should be taken in the donning, use, removal and storage of protective gloves. They should be maintained
in good condition, checked regularly and discarded if worn or deteriorated. Gloves should be free of holes or
cuts and foreign materials and their shape should not be distorted. They should fit the wearer properly leaving
no gap between the glove and the wearer's sleeve.
Gloves should be replaced periodically, depending on frequency of use and permeability to the substance(s)
handled. Overtly contaminated gloves should be rinsed and then carefully removed after use. For the purposes
of compliance with 1910.132 (a) and (b), PPE should be inspected, cleaned, and maintained at regular intervals
so that the PPE provides the requisite protection. It is also important to ensure that contaminated PPE which
cannot be decontaminated is disposed of in a manner that protects employees from exposure to hazards. [59
FR 16362, April 6, 1994]
Gloves should always be cleaned according to the manufacturer's instructions as they may have particular
finishes that may make the following general guidance inappropriate. For example, repeated washing may
remove fungal and bacterial inhibitors from the lining of the glove that may ultimately lead to skin irritation. And
there is also the risk of cross contamination as chemical residues can remain on the gloves even after washing.
Contact between the gloves and chemicals should be kept to a minimum as some chemicals can alter the
physical characteristics of a glove and impair its protective properties. Gloves contaminated by chemicals
should be washed as soon as possible and before their removal from the hands.
Grossly contaminated gloves should be discarded. Gloves contaminated on the inside can be dangerous, as
the skin will absorb the chemical contamination. Wear armlets if there is a danger of chemicals entering the
glove at the cuff.
When wearing protective gloves do not touch other exposed parts of the body, equipment or furniture as
contamination can be transferred to them. Cotton liners can be worn if hands sweat profusely.

10. RESPIRATORY PROTECTION

9B

Respirators are devices that protect the wearer from inhaling dangerous substances such as particulates,
fumes, vapors, and gases. There are a wide variety of respiratory protection devices available. The two main
categories are air-purifying and air-supplied respirators. It is critical to select the proper type of respiratory
protective equipment, to supply it to workers, and to train workers to use it correctly. It is strongly
recommended that a formal respiratory protection program be set up for workers and that an industrial hygiene
professional be consulted as part of the process.
Respiratory protection must be considered for several thermal spray activities. The most common respiratory
hazards associated with thermal spray are particulates and fumes. Surface preparation techniques, for example
grit blasting, can generate fine particulates of the grit medium and of the substrate. These particles can be
inhaled by the worker and do present a respiratory hazard. Sand blasting creates a cloud of silicon dioxide
particles that should not be breathed. Loading and emptying grit blast cabinets should be done while wearing
the proper respirator. Powder handling activities such as loading, unloading, and cleaning hoppers should
similarly be performed with respirators. The thermal spray operation itself potentially exposes the worker to the
feedstock particulate as well as to fumes produced by the vaporization and condensation of the feedstock.
Appropriate respiratory protection should always be used when hand spraying or working around an operating
spray device. Cleaning operations within the thermal spray enclosure should always be performed with the
awareness that fine particulates will be stirred up and inhaled by unprotected workers. Vapors from solvents
can also be of concern since they are often used during the part-cleaning process. The respiratory threats
posed by thermal spray activities can introduce either acute or chronic risks to the worker that have to be
mitigated.

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In general, it is recommended that engineering and administrative controls be introduced to minimize worker
exposure to respiratory hazards. For example, not entering a spray booth after a part has been coated until
several air exchanges have been completed is a method that can be used to reduce exposure. A respiratory
protection program should train workers as to what type of protection to wear, when to wear it, and how to
properly wear and care for the equipment.

10.1 Air purifying respirators

27B

Air-purifying respirators are typically negative pressure units in which the user’s inhalation draws contaminated
air in through a filtration medium and exhalation pushes air out through one-way valves back into the
atmosphere. Straps are used to hold the respirator in place on the wearer’s head. A half-face mask that covers
the nose and mouth is the most commonly used style for thermal spray operations. Full-face masks are used
whenever the contaminant in the air can harm the eyes or rest of the face. Cloth or paper nuisance dust masks,
similar in style to surgical masks, are tempting to use because they are inexpensive; however, they do not
provide adequate protection for thermal spray operations and should not be used.
Air-purifying respirators typically use a pair of replaceable filter cartridges. There are several different types of
cartridges to choose from, depending on the contaminant in the air. Some cartridges remove particles from the
air, others remove organic vapors given off by solvents, while still others can handle chemical vapors such as
acid fumes. Combination filters that remove both organic vapors and suspended particles are also available, if
they are needed. It is essential that the correct cartridge type is chosen for the worker to wear. It should also
be recognized that all cartridges have to be replaced periodically.
Particulate filtering is the most common need in thermal spray operations. Particles in the size range of ~0.3
microns are the most difficult to filter out of the air. Coarser particles get embedded in the filter medium as air is
drawn through it. Finer particles get trapped by Brownian motion in the filter material. Particles that are a few
tenths of a micron in diameter penetrate most deeply through the filter and are of the greatest concern. The
lower end of powder size distributions often contain quantities of submicron-sized particles. Fumes from
partially vaporized powders and atomized wire droplets also contain particles in this size range. In order to
ensure that optimal protection is provided to the worker, it is important that the mask fits properly and is well
maintained. It is also important that the correct cartridges are chosen and that they are replaced as needed.

10.2 Air-supplied respirators

28B

In an air-supplied respirator the worker typically wears a half- or full-face mask and breathable air is supplied via
a pressurized air line. The air can come from a tank with a regulator and pressure gauge that is carried by the
operator, in which case the unit is considered to be a self-contained breathing apparatus. Alternatively, the air is
provided by a specially designed compressor that filters the air and supplies it to the worker via a long hose or
through a specially designated piping system with a manifold that the hose is connected to. Conventional
“house air” available at all thermal spray facilities to run grit blasters, and so on, should never by used to supply
breathing air to workers, because of lubricant and particulate that are suspended in the air stream.

10.3 Respiratory Protection Summary

29B

Respiratory PPE must be considered for all thermal spray facilities. Particulates of many kinds and sources are
the most significant hazard, but solvents and chemical vapors and fumes should also be evaluated when setting
up a respiratory protection program. It should be recognized that respirators do not eliminate operator exposure
to contaminated air; rather they reduce it by some factor that depends on the properness of the respirator’s fit,
the concentration of the contaminant in the air, the type of respirator being used, and so on. Operational
procedures in the form of engineering and administrative controls should be put in place to reduce or eliminate
the need for respiratory PPE and to limit the concentration of contaminants that workers are exposed to. It is
highly recommended that an industrial hygienist be consulted when addressing respiratory protection issues.

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11. HEARING PROTECTION

10B

In accordance with OSHA 1910.95, it is required that employees are protected from noise levels above 85 dBA,
time weighted average, during a normal eight hour workday.
Thermal spray processes generally exceed 85 dBA and can exceed 125 dBA. Because of the nature of most
thermal spray businesses, operators, supervisors, quality inspectors, maintenance, and occasionally office
workers are exposed to these levels of noise. Therefore, we recommend that all persons working in spray shop
areas required to wear either earplugs or earmuffs with the highest Noise Reduction Rating (NRR) available.
These persons include operators, supervisors, outside contractors, and inspection personnel. Persons who
may not be included would be visitors who are taking short tours, delivery personnel, and office personnel who
are passing through the area.
Every employee, who is required to wear hearing protection, in the performance of his or her duties, must
participate in a hearing conservation program that includes yearly auditory testing to insure the effectiveness of
the Hearing Protection Program.
Ear plugs and earmuffs should be provided by the employer to all who require them at no cost. The employer
should also bear the cost of the annual auditory testing.

11.1 High Noise Areas

30B

There are areas and circumstances associated with many thermal spray operations where noise levels are
higher than those associated with conventional thermal spray processes. These include the High Velocity Oxy-
Fuel (HVOF) spray operations, high-energy plasma-arc spraying, and high-energy electric arc spray (EAS). In
these areas and with these processes, noise levels meet and can exceed 125 dBA. In these areas and with
these processes, both earplugs AND earmuffs are required. The NRR for hearing protection devices is not
additive and neither OSHA nor NIOSH recognize the full NRR given by manufacturers of these devices,
because of variances in fitting.
The following are examples of situations where both earplugs AND earmuffs must be worn.
• When either hand spraying, entering a booth during spraying, or working around a spray booth that has
open doors or frequently opened doors or access panels while spraying with:
o HVOF,
o Argon-helium plasma-arc where gas flow and current are equal to or higher than [Ar 130-150
psi (234-267 scfh), He 150-200 psi (74-99 scfh), 900 Adc],
o Using Argon-hydrogen plasmas
o Using nitrogen as a primary plasma-arc gas, or
o EAS with air pressures above 80 psi with current levels above 200 Adc and any operating
current above 100 psi air pressure.

As mentioned above, the NRR value for plugs and muffs cannot be applied directly to the noise field and the
NRR’s of plugs and muffs are NOT additive, when used together. For example, if hearing protection has an
NRR of 25, and is used in a noise field of 125 dBA, the exposure is NOT reduced to 100 dBA. Likewise, if plugs
and muffs are used, each with an NRR of 25 the combined NRR is NOT 50.
MSHA, NIOSH, and OSHA do not treat the effectiveness the same way. The following is the guideline that the
Thermal Spray Safety Committee recommends based on our best understanding of the issues at hand. The
effectiveness of either plugs or muffs should be calculated using the following formula, using earplugs as an
example.

(NRR-7) / 2 = effective NRR

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Example:
(NRR 29-7) / 2 = 11 dBA reduction

The addition of earmuffs with an NRR of 29 would increase the effectiveness by 3 dBA as follows:

11 dBA (plugs) + 3 dBA (muffs) = 14 dBA

In accordance with OSHA, there can be no unprotected exposure above 90 dBA TWA. Using the above
calculation, the operator could be exposed to 90 + 14 = 104 dBA TWA for 8 hours.
Continuous exposure to HVOF at 125 dBA would follow this calculation.

125 dBA – 14 dBA = 111 dBA

In accordance with OSHA noise exposure tables, under these conditions, an operator would be limited to
between 15-30 minutes in an eight-hour period.

12. TRAINING
1B

Any worker required to wear PPE shall receive training in the proper use and care of PPE. Periodic retraining
shall be offered by EH&S to both the employees and the supervisors, as needed. The training shall include, but
not necessarily be limited to, the following subjects:

• When and where PPE is necessary to be worn.

• What PPE is necessary

• How to properly don, doff, adjust, and wear PPE.

• The limitations of the PPE.

• The proper care, maintenance, useful life and disposal of the PPE.
After the training, the employees shall demonstrate that they understand the components of the PPE Program
and how to use PPE properly, or they shall be retrained.

13. RECORDKEEPING
12B

Written records shall be kept of the names of persons trained, the type of training provided, and the dates when
training occurred. The Supervisor should maintain their employees’ training records for at least 3 years. The
company should maintain the Hazard Assessment Certification Form for each work site evaluated for at least 3
years.

14. REFERENCES
American National Standards Institute, American National Standard ANSI Z41-1991, "Personnel
Protection - Protective Footwear".

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American National Standards Institute, American National Standard ANSI Z87.1-1989, "Practice for
Occupational and Educational Eye and Face Protection".

American National Standards Institute, American National Standard ANSI Z89.1-1986, "Safety
Requirements for Industrial Head Protection".

OSHA Standard 29 CFR 1910.132, "General Requirements"

OSHA Standard 29 CFR 1910.133, "Eye and Face Protection"

OSHA Standard 29 CFR 1910.135, "Head Protection"

OSHA Standard 29 CFR 1910.136, "Occupational Foot Protection"

OSHA Standard 29 CFR 1910.138, "Hand Protection"

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15 Appendices
13B

15.1 Appendix A: Glove Chart

Type Advantages Disadvantages Use Against
Natural Low cost, good Poor vs. oils, greases, Bases, alcohol, dilute water solutions; fair vs.
rubber physical properties, organics. Frequently aldehydes, ketones.
dexterity imported; may be poor
quality
Natural Low cost, dexterity, Physical properties Same as natural rubber
rubber better chemical frequently inferior to
blends resistance than natural natural rubber
rubber vs. some
chemicals
Polyvinyl Low cost, very good Plasticizers can be Strong acids and bases, salts, other water
chloride physical properties, stripped; frequently solutions, alcohol
(PVC) medium cost, medium imported may be poor
chemical resistance quality
Neoprene Medium cost, medium NA Oxidizing acids, anilines, phenol, glycol
chemical resistance, ethers
medium physical
properties
Nitrile Low cost, excellent Poor vs. benzene, Oils, greases, aliphatic chemicals, xylene,
physical properties, methylene chloride, perchloroethylene, trichloroethane; fair vs.
dexterity trichloroethylene, many toluene
ketones
Butyl Specialty glove, polar Expensive, poor vs. Glycol ethers, ketones, esters
organics hydrocarbons,
chlorinated solvents
Polyvinyl Specialty glove, resists Very expensive, water Aliphatics, aromatics, chlorinated solvents,
alcohol a very broad range of sensitive, poor vs. light ketones (except acetone), esters, ethers
(PVA) organics, good physical alcohol
properties
Fluoro- Specialty glove, Extremely expensive, Aromatics, chlorinated solvents, also
elastomer organic solvents poor physical properties, aliphatics and alcohols
(Viton) poor vs. some ketones,
esters, amines
Norfoil Excellent chemical Poor fit, easily Use for Hazmat work
(Silver resistance punctures, poor grip, stiff
Shield)

Page 26 of 33
 Designation SG003-03

15.2 Appendix B: Glove Type and Chemical Use

31B

*Limited service VG= Very Good G= Good F=Fair P=Poor (not recommended)

Chemical Neoprene Natural Latex Butyl Nitrile Latex

or Rubber
*Acetaldehyde VG G VG G
Acetic acid VG VG VG VG
*Acetone G VG VG P
Ammonium hydroxide VG VG VG VG
*Amyl acetate F P F P
Aniline G F F P
*Benzaldehyde F F G G
*Benzene F F F P
Butyl acetate G F F P
Butyl alcohol VG VG VG VG
Carbon disulfide F F F F
*Carbon tetrachloride F P P G
Castor oil F P F VG
*Chlorobenzene F P F P
*Chloroform G P P E
Chloronaphthalene F P F F
Chromic Acid (50%) F P F F
Citric acid (10%) VG VG VG VG
Cyclohexanol G F G VG
*Dibutyl phthalate G P G G
Diesel fuel G P P VG
Diisobutyl ketone P F G P
Dimethylformamide F F G G
Dioctyl phthalate G P F VG
Natural Latex
Chemical Neoprene or Rubber Butyl Nitrile

Dioxane VG G G G

Page 27 of 33
 Designation SG003-03

Epoxy resins, dry VG VG VG VG

*Ethyl acetate G F G F
Ethyl alcohol VG VG VG VG
Ethyl ether VG G VG G
*Ethylene dichloride F P F P
Ethylene glycol VG VG VG VG
Formaldehyde VG VG VG VG
Formic acid VG VG VG VG
Freon 11 G P F G
Freon 12 G P F G
Freon 21 G P F G
Freon 22 G P F G
*Furfural G G G G
Gasoline, leaded G P F VG
Gasoline, unleaded G P F VG
Glycerine VG VG VG VG
Hexane F P P G
Hydrochloric acid VG G G G
Hydrofluoric acid (48%) VG G G G
Hydrogen peroxide (30%) G G G G
Hydroquinone G G G F
Isooctane F P P VG
Isopropyl alcohol VG VG VG VG
Kerosene VG F F VG
Ketones G VG VG P
Lacquer thinners G F F P
Lactic acid (85%) VG VG VG VG
Lauric acid (36%) VG F VG VG
Lineoleic acid VG P F G
Linseed oil VG P F VG
Maleic acid VG VG VG VG
Natural Latex

Page 28 of 33
 Designation SG003-03

Chemical Neoprene or Rubber Butyl Nitrile

Methyl alcohol VG VG VG VG
Methylamine F F G G
Methyl bromide G F G F
*Methyl chloride P P P P
*Methyl ethyl ketone G G VG P
*Methyl isobutyl ketone F F VG P
Methyl methacrylate G G VG F
Monoethanolamine VG G VG VG
Morpholine VG VG VG G
Naphthalene G F F G
Naphthas, aromatic G P P G
*Nitric acid G F F F
Nitromethane (95.5%) F P F F
Nitropropane (95.5%) F P F F
Octyl alcohol VG VG VG VG
Oleic acid VG F G VG
Oxalic acid VG VG VG VG
Palmitic acid VG VG VG VG
Perchloric acid (60%) VG F G G
Perchloroethylene F P P G
Petroleum distillates (naphtha) G P P VG
Phenol VG F G F
Phosphoric acid VG G VG VG
Potassium hydroxide VG VG VG VG
Propyl acetate G F G F
Propyl alcohol VG VG VG VG
Propyl alcohol (iso) VG VG VG VG
Sodium hydroxide VG VG VG VG
Styrene P P P F
Stryene (100%) P P P F
Sulfuric acid G G G G

Page 29 of 33
 Designation SG003-03

Tannic acid (65%) VG VG VG VG

Tetrahydrofuran P F F F
Natural Latex
Chemical Neoprene or Rubber Butyl Nitrile

*Toluene F P P F
Toluene diisocyanate F G G F
*Trichloroethylene F F P G
Triethanolamine VG G G VG
Tung oil VG P F VG
Turpentine G F F VG
*Xylene P P P F

*Limited service VG= Very Good G= Good F=Fair P=Poor (not recommended)

Page 30 of 33
 Designation SG003-03

15.3 Appendix C: Job Hazard Analysis Example

32B

This job hazard analysis is part of a written Hazard Communication Program designed to comply with OSHA’s
Hazard Communication Standard (29 CFR 1910.1200)

Job or Area Title: Al2O3 Plasma Spray Coating

U Location: S&P Coatings Inc.
U

Anytown, USA

Date of Analysis: 06-12-07

U

Step Hazard Required PPE or Procedure

Hopper Cleaning Eyes: Nusance Dust Safety glasses

Lungs: Nusance Dust Respirator
Hands: Nusance Dust Latex/Nitrile Gloves

Plasma Spray Eyes: Bright Light and Bright UV Face Shield w/ 10-12 Shade Lense
Lungs: Respirable Dust and Fumes Respirator
Skin: Bright Light and Bright UV Leather apron
Hands: Thermal Burns / Bright UV Leather gloves
Hearing: Noise above 80db Ear plugs or muffs

Approvals
____________________________________________________________________________________

Environment, Health & Safety: ___________________________________ Date: _____________

Department Manager: _________________________________________ Date: _____________

Department Supervisor: ________________________________________ Date: _____________

Page 31 of 33
 Designation SG003-03

15.4 Appendix D: Filter Lenses for Protection Against Radiant Energy

3B

Minimum(*) Operations

Electrode Size 1/32 in. Arc Current Protective Shade

Shielded metal arc welding

Less than 3 Less than 60 7

3-5 60-160 8

5-8 160-250 10

More than 8 250-550 11

Gas metal arc welding and flux

cored arc welding

less than 60 7

60-160 10

160-250 10

250-500 10

Gas Tungsten arc welding

less than 50 8

50-150 8

150-500 10

Air carbon Arc cutting

(Light) less than 500 10

(Heavy) 500-1000 11

Plasma arc welding

less than 20 6

20-100 8

100-400 10

400-800 11

Page 32 of 33
 Designation SG003-03

Plasma arc cutting

(light)(**) less than 300 8

(medium)(**) 300-400 9

(heavy)(**) 400-800 10

Torch brazing 3

Torch soldering 2

Carbon arc welding 14

Gas Welding:

Light (Under 1/8) Under 3.2 4

Medium (1/8 to ½) 3.2 to 12.7 5

Heavy (Over ½) Over 12.7 6

Oxygen cutting:

Light (Under 1) Under 25 3

Medium (1 to 6) 25 to 150 4

Heavy (Over 6) Over 150 5

Footnote(*) As a rule of thumb, start with a shade that is too dark to see the weld zone. Then use a
lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxy-fuel
gas welding or cutting where the torch produces a high yellow light, it is desirable to use a filter lens
that absorbs the yellow or sodium line in the visible light of the (spectrum) operation.

Footnote(**) These values apply where the actual arc is clearly seen. Experience has shown that
lighter filters may be used when the arc is hidden by the workpiece.

Footnote(**) These values apply where the actual arc is clearly seen. Experience has shown that
lighter filters may be used when the arc is hidden by the workpiece.

Page 33 of 33
 Thermal Spray Society
An Affiliate Society of ASM International

A Health and Safety Alert from the TSS Safety Committee: 14-May-2006

National News Release: 06-342-NAT

Date: February. 27, 2006
Contact: Sharon Worthy, Al Belsky
Phone: (202) 693-4676

OSHA Issues Final Standard on Hexavalent Chromium

WASHINGTON -- The Occupational Safety and Health Administration (OSHA) will publish a final standard for
occupational exposure to hexavalent chromium in the Feb. 28, 2006, Federal Register. The standard covers
occupational exposure to hexavalent chromium (Cr(VI)) in general industry, construction and shipyards.
"OSHA has worked hard to produce a final standard that substantially reduces the significant health risks for employees
exposed to hexavalent chromium. Our new standard protects workers to the extent feasible, while providing employers,
especially small employers, adequate time to transition to the new requirements," said Jonathan L. Snare, acting
assistant secretary for occupational safety and health.
The standard will be published in accord with the timetable established by the U.S. Court of Appeals for the Third Circuit
which in April 2003 ordered OSHA to promulgate a standard governing workplace exposure to hexavalent chromium.
The new standard lowers OSHA's permissible exposure limit (PEL) for hexavalent chromium, and for all Cr(VI)
compounds, from 52 to 5 micrograms of Cr(VI) per cubic meter of air as an 8-hour time- weighted average. The
standard also includes provisions relating to preferred methods for controlling exposure, respiratory protection,
protective work clothing and equipment, hygiene areas and practices, medical surveillance, hazard communication and
recordkeeping.
Hexavalent chromium compounds are widely used in the chemical industry as ingredients and catalysts in pigments,
metal plating and chemical synthesis. Cr(VI) can also be produced when welding on stainless steel or Cr(VI)-painted
surfaces. The major health effects associated with exposure to Cr(VI) include lung cancer, nasal septum ulcerations and
perforations, skin ulcerations, and allergic and irritant contact dermatitis.
Employers are responsible for providing a safe and healthful workplace for their employees. OSHA's role is to assure
the safety and health of America's workers by setting and enforcing standards; providing training, outreach, and
education; establishing partnerships; and encouraging continual process improvement in workplace safety and health.
For more information, visit www.osha.gov.

The Final Standard on Hexavalent Chromium

Effective and Practical Protection for Workers

Summary

ƒ On February 28, 2006, pursuant to a 2003 court order, the Department of Labor issued a final standard
addressing occupational exposure to hexavalent chromium, also known as Cr(VI), a natural metal used in a
wide variety of industrial activities, including the manufacture of stainless steel, welding, painting and pigment
application, electroplating, and other surface coating processes.

ƒ OSHA determined that the new standard is necessary to reduce significant health risks posed by occupational
exposure to Cr(VI). The new standard is based on a careful, extensive analysis of all facts and evidence
gathered during the Occupational Safety and Health Administration's (OSHA) rulemaking process, which

Copyright © 2008 ASM International® www.asminternational.org

All rights reserved.
 included two weeks of public hearings and comment periods totaling more than five months. OSHA relied upon
the best available, peer-reviewed science.

ƒ The new standard covers the general industry, construction, and shipyards sectors and will protect workers
against exposure to hexavalent chromium, while providing employers with adequate time to transition to the
new requirements.

ƒ Approximately 558,000 workers are covered by the provisions of the new standard.
What Does the Standard Do?

ƒ Reduces Worker Exposure to Cr(VI). The new standard provides greater protection against significant health
effects, such as lung cancer, nasal septum ulcerations and perforations, and dermatitis by lowering the
permissible exposure limit (PEL) from 52 micrograms of Cr(VI) per cubic meter of air (52 µg/m³) to 5 µg/m³ for
all sectors.

ƒ Practical and Effective Requirements. The new standard requires covered industries to achieve the PEL
through engineering and work practice controls to the extent that is technologically feasible. Additional
provisions cover exposure determinations, respiratory protection, protective work clothing and equipment,
medical surveillance and communication of hazards.

ƒ Supplemental Provision for Aerospace Painting. The new standard recognizes that, given available
technology, the lowest level employers involved in aerospace painting operations of whole aircraft or large
aircraft parts can reach through feasible engineering and work practice controls is 25 µg/m³. For these types of
aerospace painting, OSHA requires the use of engineering and work practice controls to reduce exposures to
25 µg/m³, and allows the supplemental use of respirators to be used to achieve the PEL.

ƒ Protecting Workers Most at Risk. The new standard will focus protections on workers facing heightened
health risks from airborne exposures. An exemption is provided for employers who can demonstrate that Cr(VI)
exposures under any anticipated working conditions will not exceed 0.5 µg/m³.

ƒ Reasonable Transition Time. Given the significant PEL reduction required by the new standard, OSHA is
providing a reasonable transition period for employers to implement the technologies and practices needed for
compliance.

ƒ Effective date of the standard: 90 days from publication.

ƒ This period is intended to allow affected employers the opportunity to familiarize themselves with the
standard.

ƒ Start-up date for all provisions, except engineering controls: 180 days from the effective date (one year for
employers with fewer than 20 employees).

ƒ This period is designed to allow employers sufficient time to complete initial exposure assessments,
obtain appropriate work clothing and equipment, and comply with other provisions of the standard.

ƒ Start-up date for engineering controls: four years from the effective date for all employers.

ƒ This period allows affected employers sufficient time to design, obtain, and install the necessary control
equipment.
What Are the Major Differences Between the Proposed and Final Standards?

ƒ Permissible Exposure Limit

Proposed: A PEL of 1 µg/m³ was proposed.
Occupational Safety & Health Administration
200 Constitution Avenue, NW
Washington, DC 20210
 ƒ Final: Based on the rulemaking record, OSHA determined that a PEL of 5 µg/m³ is the lowest level that is
technologically and economically feasible for industries impacted by this standard.

ƒ Portland Cement Exclusion

Proposed: OSHA proposed to exclude exposures to portland cement in the construction industry because of
data indicating that airborne exposures to Cr(VI) in construction activities involving portland cement were very
low and posed little lung cancer risk. Risks from dermal exposure could be addressed through existing OSHA
standards.

Final: OSHA expanded the exclusion for portland cement to general industry and shipyards, as well, because
new data submitted during the public comment period indicated that airborne exposures to Cr(IV) from portland
cement in these industries are comparable to exposures in construction.

ƒ Scope Exemption
Proposed: No proposed exemption.

Final: OSHA determined that there are certain work operations that may have low airborne Cr(VI) exposure
levels comparable to those generated by portland cement and added an exemption for employers who can
demonstrate that under no expected conditions will concentrations be above 0.5 µg/m³.

ƒ Special Provision for Aerospace Painting

Proposed: OSHA proposed that all industries covered by the standard achieve the PEL through the use of
engineering and work practice controls to the extent feasible.

Final: OSHA determined that it would not be technologically feasible to reduce exposures to the PEL through
engineering and work practice controls when whole aircraft or large aircraft parts are being painted. Therefore,
employers are only required to use engineering and work practice controls to reduce exposures to 25 µg/m³ and
must then use respiratory protection to meet the PEL.

ƒ Exposure Determination
Proposed: In the proposal, OSHA did not include exposure determination provisions for construction or
shipyards because of the practical difficulties in characterizing exposures in these work settings.

Final: The final standard covering general industry, construction, and shipyards all have identical provisions for
exposure determination. The standard also adds a performance-oriented option in all industry sectors to
increase employers' flexibility in making exposure determinations.

ƒ Medical Surveillance
Proposed: OSHA proposed that medical surveillance be offered to employees with signs and symptoms of
Cr(VI)-related health effects, exposures in emergencies, or exposures for 30 or more days above the PEL.

Final: The standard takes into account the new PEL and changed the exposure-based trigger to 30 or more
days above the action level (one-half the PEL). In addition, the standard adds this trigger to the construction and
shipyard standards.

U.S. Labor Department releases are accessible on the Internet at www.dol.gov. The information in this news release
will be made available in alternate format upon request (large print, Braille, audio tape or disc) from the COAST office.
Please specify which news release when placing your request at (202) 693-7765 or TTY (202) 693-7755. The U.S.
Department of Labor is committed to providing America's employers and employees with easy access to
understandable information on how to comply with its laws and regulations. For more information, please visit
www.dol.gov/compliance.

Occupational Safety & Health Administration

200 Constitution Avenue, NW
Washington, DC 20210