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3M Automotive AftermarketManagement Guide to Bodyshop PPE
To Bodyshop PPEGuideManagement
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WelcomeThe 3M Guide to Bodyshop PPE contains straight forward advice to help
employers and employees understand where, when and how to use PPE inthe bodyshop.
It also contains useful background information on legislation, sample HSE
inspector checklists, PPE selection guidelines, and a few other pieces of
information we thought might come in handy.
Section 1:
Legislation:
The Fundamentals
5 Employer Duties
5 Employee Duties
6 Enorcement
Section 2:
Compliance
8 Risk Assessment
9 PPE selection
11 Bodyshop selection guide
14 Fit Testing
15 PPE training
15 Usage
15 Maintenance (includingBreathable Air Quality
Testing)
Section 3:
Bodyshop Applications
in Detail
18 Paint Spraying
19 Health eects
19 PPE selection
20 Clearance time
20 Biological Monitoring
This document is produced by 3M for guidance only. As with any guide it cannot cove r every eventuality and must not, therefore, be seen as an
authoritative interpretation of the law. If you have any questions or concerns about personal protective equipment or hea lth and safety matters, it is
essential that you seek appropriate expert advice. This guide is believed to be accurate as at October 2007 but does not take account of any changes
in legislation, regulations or guidance issued after that date.
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Section 1Legislation: The Fundamentals
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Employer DutiesThe Health and Saety at Work etc Act 1974, also reerred
to as HASAW or HSW, is the primary piece o legislation
covering occupational health and saety in the United
Kingdom. The Health and Saety Executive (HSE) is
responsible or enorcing the Act and a number o other
Acts and Statutory Instruments relevant to the working
environment.
The HASAW places a general duty on employers so ar as
is reasonably practicable, to ensure the health, saety and
welare at work o their employees and others who maybe
aected by their work activities.
Examples of Regulations that the HSEenforce in your type of industry are:The Management of Health and Safety at Work
Regulations 1999 require employers to assess the risks
to employees and other who may be aected by their
undertaking.
The Control of Substances Hazardous to Health
Regulations 20 02 (as amended). Employers are required to
prevent or control exposure to hazardous substances at work.
The Control of Noise at Work Regulations 2005 requires
employers to take action to prevent or reduce risks to health
and saety rom exposure to noise at work.
Summary of Employers Duties:
1. Conduct Risk Assessment
2. Where appropriate, provide PPE which issuitable for purpose
3. Provide training on correct usage and maintenance4. Supervise correct usage
Employee DutiesUnder the HASAW the employees (and sel-employed) are
required to take reasonable care o their own saety and that
o other people who may be aected by their actions. They
are also required to co-operate with their employer to enable
legal obligations to be met. For example employees must:
FollowtrainingoncorrectPPEusage
Adheretocompanyprocedures
Obeyinstructions
ReportanylossordefectwithPPE
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Section 2Compliance
EnforcementThe HSE are responsible or ensuring that Motor Vehicle
RepairpremisescomplywithHealthandSafetyLaw.In
addition to carrying out routine inspection visits the HSE
also responds to accident and illness reports and whistle-
blowers. Notices are issued to bodyshops and individuals
or breaches o health and saety law.
1. Improvement notice: The recipients are required to
make improvements over a given time period.
2. Prohibition notice: The prohibition notice normally
requires the recipient to stop the activity immediately.
The work must not be resumed until action has been
taken to remove or control the risk. Failure to do this
mayleadtoprosecution.Oncethenoticehasbeen
complied with and the inspector is satised then the
notice will be withdrawn.
3. Prosecution: Non-compliance may lead to prosecution
(Inspectors ollow HSEs enorcement policy to decide
on the most appropriate action to take)
There have been increasing numbers o improvement
notices issued to bodyshops or poor health surveillance
andfailuretoprovidesuitablePPE.
These notices cannot be ignored as ailure to make
improvements can lead to prosecution.
NoticesExamples o Notices issued in 2007 include:
Sprayingisocyanatesbasedpaintswithoutsuitableand
sucient control measures (unltered extraction, spraying
outside the booth)
Failuretouseadequateandsuitablerespiratoryprotective
equipment whilst spraying isocyanate based paints
(supplied air breathing apparatus)
Failuretocarryoutadequatehealthsurveillance(lung
unction tests)
A bodyshop was ned 15,000 or ailure
to comply with a prohibition notice on
spraying isocyanates in an uncontrolled
environment. An additional cost o1,203
was awarded to the HSE.
6 7
I am going to fine you 15,000, I hopeyou can repair the damage!
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Selection Guidance:WhenselectingPPEconsiderthefollowing:
Select quality products which are CE marked in accordance
with the PPE regulations (2002)
EmployersarerequiredtoselectPPEthathasbeen
approved to certain standards, demonstrating that the
product has undergone testing and meets the basic saety
requirements or the user.
Select products which provide adequate protection
DifferentclassesofPPEaregenerallyavailableto
matchdifferentseveritiesofhazards.Respirators
havedifferentprotectionfactors,forexampleFFP1
How much of the hazards are the workers exposed to?
Howlongaretheyexposedfor?
Howhighistheconcentration?
2. How can they harm the wearer?
There are several routes o entry which hazards can take
intothebody.ItislikelythatmorethanoneitemofPPEwill
be required when there are dierent hazards present.
disposable respirators have a lower protection actor
thanFFP3products.Therefore,FFP1respirators
are generally selected when the dust hazard is o low
toxicityand/orlowconcentrationandFFP3respirators
are used in more hazardous atmospheres where a higher
level o reduction in exposure is required. Ensure that
the level o protection selected is appropriate to the task.
Select products which are suitable for the job
Formostapplicationsthereareanumberofdifferent
typesofPPEwhicharesuitable.Questionwhetherthe
product selected is suitable given the conditions it will be
used in. In other words will the product deorm, melt or
ail?
Select products which are suitable for the wearer
OnetypeofPPEmaynotbesuitableforeveryone.For
examples workers with acial hair and injuries or wearers
ofprescriptionglassesmayrequiredifferentPPE.
Itisimportanttogetthewearertotrialtheproductrst
tomakesurethatittsandiscomfortable.(Referto
section on Fit Testing)
Ensurethatthewearercanperformtheirjobproperlyin
thePPEselectede.g.cantheycommunicateeffectively
and do they have the dexterity and mobility required.
Select products which are compatible with other PPE
EnsurethatifmorethanoneitemofPPEiswornthat
they can be used together without compromising on
protection levels or increasing discomort
Forexample:Respiratorswornbywelderstoprotect
themselves rom welding umes will need to t
comortably underneath their shield.
Ensure that there are procedures in place to carry out the
maintenance of PPE
Forexample:Maintenancerecordcards,availabilityof
replacement and spare parts
Ensure that adequate provision is made for the cleaning and
storage of reusable PPE after use
Forexamplestoragelockersforsuppliedairrespirators.
AllPPEshouldbestoredinacleanuncontaminated
area.
Excessive noise may
lead to tinnitus, hearing
impairment or other
conditions
Welding/metal
umes can
cause lung
damage and
metal ume
ever
Solvents can enter the
bloodstream through
the skin and cause
organ damage
Particulates can
penetrate into the
lungs and cause
tissue damage
Gases and vapours once
inhaled can be absorbed
into the bloodstream
and cause irreparable
damage to liver, kidney
and central nervous
system
Particulates can irritate
the nose and throat
Inhaling Isocyanates
can cause occupational
athsma
Keep your hands clean
to avoid ingesting
harmul substance,
eg oil.
Impact o fying particles
can damage the eyes
Particulates = dusts, bres and mists
Application
DrySandingandGrinding
Welding
Inhalationofdusts(andother
fineparticles)
Eyedamagefromfl
ying
particles
Noise
Inhalationofweldin
gfumes
andozonegas
EyedamagefromU
V/IRlight
ParticulateRespirator
Impactresistantgoggles
(machineuse)
Spectacles
(handsandingonly)
HearingProtectiveEquipment
ParticulateRespiratorwith
carbonlayer
Weldingshield
FoldableFFP2Disposable
Respirator(06923)
SpeedglasS
LWelding
Shield
BandedEarPlugs(1310)
ReusableEarPlugs(1261)
Cup-shapedFFP2
DisposableRespirator
(0692
2)
DisposableEarPlugs(1100)
HighC
omfortEarMuffs
(1440
)
PremiumLineGoggles
(2790
)Polycarbonatelens
Weldin
gFumeRespirator
(06920)
Acetatelensgoggles
ClassicLinespectacles
(2720
)orComfortLine
specta
cles(2740)
Nuisancedustmask
Nuisancedustmask
Hazard
AdvisoryPPE
SuggestedProd
ucts
UnsuitablePPE
Bodyshop Selection Guide
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Application
Adhesives,
Coatingsand
Sealers
PolishingandCompounding
*
Thisguideisonlyanoutline.
Itisdesignedtohelpfocus
onthemostappropriateproductsinthe3M
rangeforvariousapplicationsandhazards.
Itshouldnotbeusedastheonlymeans
ofselectingaproduct.Detailsofperformanceandlimitationsaresetoutintheproductpackaginganduserinstructions.
Itisultimatelytheresponsibilityoftheemployertoselectthe
mostappropriatePPEbasedonafullriskassessment.
**
Nuisancelevel=belowWorkplaceExposureLimit
Inhalationofmists(low
concentration)and
nuisance
level**vapour
Inhalationofvapoursand
mists(higherconce
ntrations)
Eyeirritationfromv
apours
andchemicalsplas
h
Inhalationofdust
(Wherevapour/odouris
presentrefertosolutions
foradhesives,
coatingsand
sealersabove)
ParticulateRespirator
withnuisancelevelvapour
protection
Particulate,
GasandVapour
Respirator
Chemicalresistantgoggles
ParticulateRespirator
Mainte
nanceFree
Respirator
(06941FFA1P2D)or
(06942FFA2P3D)
Hazard
AdvisoryPPE
SuggestedProd
ucts
UnsuitablePPE
Disposableparticulate
respirator(06923)
PremiumLineGoggles
(2790
A)Acetatelens
DisposableSpeciality
Respirator(9914Valved)
DisposableSpeciality
Respir
ator(06998
Unvalv
ed)
FoldableFFP2Disposable
Respirator(06923)
Cup-shapedFFP2
DisposableRespirator
(0692
2)
Application
PaintSpraying
Degreasing
Mixingpaint(wherethereis
insufficientventilation
Inhalationofisocya
nates
foundin2-packpaints
Inhalationofsolven
tvapours
Inhalationofsolven
tvapours
Eyeirritationfromv
apours
andchemicalsplas
h
SuppliedAirBreathing
Apparatus
GasandVapourRespirator
GasandVapourRespirator
Chemicalresistantgoggles
Mainte
nanceFree
Respirator
(06941FFA1P2D)or
(06942FFA2P3D)
Mainte
nanceFree
Respirator
(06941FFA1P2D)or
(06942FFA2P3D)
Hazard
AdvisoryPPE
SuggestedProd
ucts
UnsuitablePPE
SuppliedAirVisorSystem
(3MV
isionAir)
7500SeriesHalfFace
Maskwith06971Supplied
AirSystem(mustbeused
witheyeprotection,
e.g.
gogglesasshown)
6000SeriesFullFaceMask
with06971SuppliedAir
System
PremiumLineGoggles
(2790
A)
Particulaterespirator
(e.g
6922)
Maskwithfilters(e.g
6000SeriesFullFace
withcartridgefilters)
Gasandvapour
respirator(e.g.
6941)
PremiumLineGoggles
(2790
A)Acetatelens
Bodyshop Selection GuideBodyshop Selection Guide
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3. PPE TrainingSuitablePPEmayhavebeenselectedbuttoensurethatthe
desired level o protection is provided it is important that the
wearer uses the product as intended.
Awareness
ToencourageoperativestowearPPEitisimportantthat
they ully understand the reasons why they are required to
wear protection. Wearers should be provided inormation on
the ollowing:
Whatthehazardsare
Whattheassociatedrisksarewitheachapplication
Whatthehealtheffectsare
Using PPE CorrectlyInorm wearers o how to
Inspectproductsbeforeusetoensurethattheywill
provide protection.
FitPPEcorrectlyandrefertothemanufacturerstting
instructions
MaintainPPEandkeeprecordsofusage.
Store,cleananddisposeofPPE
Complywiththeirlegalresponsibilities.
Rememberthatregulationdoesntjustgovernwhat
employers do it also eects the actions o employees
improving health and saety in the workplace is a joint
responsibility.
MaintenanceMaintenanceisrequiredtoensurethatPPEcontinuesto
provide the level o protection or which it was designed.
COSHHrequiresthatequipmentisinspected,tested
and maintained in accordance with the manuacturers
instructions or use and HSE guidance.
Maintenance procedures Typical requirements
Pre-shiftcheck Visual inspection
Post-shif t check Cleanandinspect
Store
Monthly check Maintenance records must
be kept
Typical Inspection o Respirators
Checkthefacepieceforcracks,tearsanddirt.Becertain
that the ace piece, especially the ace seal area is not
distorted.
Examinethevalvesforsignsofdirt,distortion,cracking
or tearing.
Ensurethatanyheadstrapsareintactandundamaged
Examineallplasticpartsforsignsofcrackingorfatigue
Makesureallgasketsareproperlyseated
Forsuppliedairequipmenttheinputpressureand
condition o supply tube a couplings should be check.
Visors should be checked or damage and changed i
necessary.
Cleaning
Cleananddisinfectthefacepieceaftereachuseorat
theendofeachshift.Cleanwitheitheradampclothora
ace seal wipe.
Fit Testing
What is t testing?
Fit testing checks that a respirator provides an adequate seal
to the wearers ace.
Why is it necessary?
Fit testing is an important step in the process o deciding
whether a respirator with a tight tting acepiece is suitable
forpurpose.FittestingisrequiredbytheApprovedCode
ofPracticeoftheCOSHHregulationsandisindustrywide
requirement.
What products need to be t tested?
Fit testing needs to be carried out on all wearers o
respirators with tight tting acepieces where testing has
not been carried out beore.
Examples o respirators or which t testing are required:
When is t testing required?
Oninitialselectionofrespiratoryprotection
Itshouldberepeatedatappropriatetimesforexample
i the wearers ace shape changes due to weight loss or
gain, or acial surgery
How is t testing carried out?
There are two types o t testing generally used
Qualitativetestusingatastetestmethod
Quantitativetestusingaparticlecountingdevice
Qualitative
What is this type o testing suitable or?
Disposablerespirators
Halffacemasks
Not suitable or
Fullfacemasks
3M Fit Test Kits
3MoffertwottestkitsFT10(Sweet)andFT30(Bitter).
Each kit contains a hood and collar assembly, two
nebulisers, sensitivity solution, test solution and detailed user
instructions.AtrainingCDisalsoincludedwhichfeatures
a step-by-step video demonstration o how to use the kit.
The test relies on the wearers response to the taste o a testagent. The quality o the seal to the ace is assessed while
the wearer perorms a series o head movements, talking
and breathing exercises.
All o the respirators listed as requiring t testing must only
be used by clean shaven wearers
.
These kits are generally purchased and used by employers
wishingtocarryoutttestingin-house.
Quantitative
What is this type o testing suitable or?
Alltypesofrespirators
incorporating a tight tting
acepiece including ull ace masks
Quantitativettestingusingaparticlecountingdeviceis
generally undertaken by a consultant visiting the workplace.
TheTSIPortacountdeviceisusedtoassessthequalityof
the respirators seal to the ace while the wearer perorms a
series o head movements, talking and breathing exercises.
ThePortacountreportsanumericalresultcalledatfactor.
The HSE speciy the minimum t actor required depending
on the type o respirator used.
6941
3MMaintenance Free
Reusable Respirator
6922
3M Disposable Respirator
6923
3M Disposable Respirator
7500
3M 7500 Reusable Hal Mask
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Breathable Air Quality Testing
Why is testing necessary?
Legislation:
COSHHrequiresthatairsuppliedtoabreathingapparatus
should be tested at least every three months to ensure that it
meets the standard or air purity as laid out in EN 12021.
Health Conseqiences:
Air delivered through a compressor system to outlets in the
booth can be aected by a number o contaminants:
Oil
Water
Carbonmonoxide
Carbondioxide
Othercontaminantsspecictothebodyshop
How is Air Quality Testing Carried Out?
3MofferaBreathableAirQualityServicewhichprovides:
Abriengwhererequired,onthetestprocedure
Testingofthebreathableairforoxygenlevelsand
contaminants e.g. water, oil, carbon monoxide and carbon
dioxide
Flowteststoensurethattheairissuppliedatthe required
pressure and fow rates
Adviceonsuggestedactionsintheresultofafailure
Writtensetoftestresults
Automaticnoticationforre-testasperyourrequirement.
For urther inormation about this service please contact
ourSafetyServiceCo-ordinatoron01612376278.
Maintenance and Servicing
Changeparticleltersassoonasincreasedbreathing
resistance occurs, that is when it becomes harder to inhale
and exhale.
Ifitemsneedtobereplacedonlyusethesparepartsas
recommended by the manuacturer.
Thevolumeowandqualityofair(refertosectionon
breathable air quality testing) should be tested at least
every 3 months (supplied-air only).
Record Keeping
TocomplywithCoSHHregulationsmaintenancerecords
should include details o:
Detailsofemployerresponsibleforprovisionofequipment(e.g.Bodyshopmanager)
Detailsofpersoncarryingouttheinspection
Equipmentdetailsincludingmanufacturerandproduct
numbers
Conditionoftheequipmentanddetailsofanydefects
Storage
Storeequipmentsomewherewhichisclean,safeanddry
and away rom sources o contamination. For example in
a storage container such as a locker or sealed bag.
Filters have a limited shel lie. It is important to note the
expiry dates.
Section 3Bodyshop Applications
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Health Effects
Isocyanates (commonly ound in two-pack paints) are the
most common cause o occupational asthma. HSE statistics
showthatvehiclepaintsprayersareapproximately80times
more likely o contracting occupational asthma than the
average or the UK working population.
Occupational Athsma
ResearchconductedbytheBritishOccupationalHealth
ResearchFoundation(BOHRF)foundthatapproximately
onethirdofpatientsareunemployedupto6yearsafter
diagnosis. There is good evidence that early detection and
removal rom exposure improves prognosis (re 1).
Symptoms Include:
Recurringsorenessorwateringofeyes
Recurringblockedorrunningnose
Boutsofcoughing
Chesttightness,wheezingorbreathlessness
Anyotherpersistenthistoryofchestproblems
Symptomsimproveatweekendsorduringholidays
Individuals diagnosed with occupational asthma may have
no choice but to leave employment which may lead to a
substantial loss o income.
PPE SelectionA supplied air ull ace mask or visor is the preerred choice
o protection or paint spraying as it provides complete
acial protection. However where direct vision is considered
essential a supplied air hal mask with suitable goggles
may also be used. Note however that i a hal mask is used
biological monitoring must be undertaken to ensure that the
system is providing adequate levels o protection.
What is not suitable protection?Any type o ltering device (see right). Isocyanate Myths
Many paint sprayers believe that a signifcant or even the
main route o isocyanate paint spray is through the skin,
with the thin skin around the eyes being a particular
concern. These views are conusing and wrong.
The overwhelming route o entry or isocyanate mist in
bodyshops is through inhalation o fne airborne paint mist.
Getting mixed paint onto the hands can cause dermatitis
but this is a dierent issue
SourceHSEReducingIllHealthintheMotorVehicleRepairIndustrySeep21
PPE typically used whenpaint spraying:
Items unsuitable orpaint spraying:
Full ace mask(6000 series)+Supplied airsystem
Any fltering device such as:
Acetate lensgoggles+Hal Face mask(7500 series)+Supplied
air system
Supplied Air VisorSystem (3M
VisionAir)
All systems require approvedCompressed Air Supply Tube(CAST) and couplings.
Gas andVapourRespirator
FFP2ParticulateRespirator
Dont lit thevisor to inspectthe paint job
oror
Paint SprayingThis is a copy o the checklist used by HSE sta on visiting
premises spraying isocyanate-based paints. Ensure that you are
prepared or an unexpected visit:
Questions you need to ask Yes No AdditionalComments
Are the sprayers aware that they use isocyanate based paints?(Note alternative terms such as 2-pack, 2K, aliphatic,
polyisocyanate, blocked isocyanate, polyurethane, etc)
Do they know that isocyanates can cause severe occupational
asthma and what the warning signs and symptoms are?
Is spraying isocyanate-based paints limited to an extracted
room or spray booth?
Has the booth or room extraction system been thoroughly
examined and tested in the last 14 months? (Check paperwork)
Does the booth/room have a pressure gauge to show it is
under negative pressure?
Is the paint mist ltered and discharged saely outside?
Are lters blocked or missing?
Is the clearance time o the booth or room known and
on display?
Is airline breathing apparatus (BA) always used whenever
spraying Isocyanate-based paints?
Is the BA maintained adequately?
(Inspect the equipment)
Is gun cleaning carried out using extracted or enclosed
gun-washing equipment in open workshop (or in booth/ventilated
mixing room with normal controls and BA)
Are the sprayers having annual health checks or breathing?
Has a responsible person been appointed to carry
out skin checks?
Is the isocyanate exposure o the sprayers measured annually
using urine tests?
18 19
3M oers a range o supplied
air breathing apparatus,
including the traditional style
visor as well as ull-ace and
hal-ace masks.
Reer to page 20
or guidance on
measuring clearance
times
Isocyanates do not cause
cancer... they cause
occupational asthma.
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Information Sources
3M
www.3m.com/uk/ohes
www.3mbodyshop.co.uk
Health and Saety Executive (HSE)
HealthandSafetyintheMotorVehicleRepairIndustry www.HSE.gov.uk/mvr
Health and Saety Laboratory (HSL)
www.hsl.gov.uk
COSHH
Steps to control health risk rom chemicals
www.coshh-essentials.org.uk
Re 1
Article rom www.occupationalasthma.com
NewmanTaylorAJ,NicholsonPJ(2004)Guidelinesforthe
prevention, identication and management o occupational
asthma:Evidencereviewandrecommendations.British
OccupationalHealthResearchFoundation,London.
Clearance Time
Why is clearance time important?
It is important that sprayers appreciate that ne paint mist
remains in the booth or some time ater the painter has
nished spraying. This mist may not be visible to the eye
however it contains high concentrations o isocyanate. The
sprayer must not lie his visor until the booth has had time to
clear; hence its important to measure clearance time.
Measuring booth clearance time:
A party og or smoke machine can be used to measure the
time it takes or the booth to clear. This should be tested
regularly and included as part o the booth maintenance
checks.
AsummaryoftheguidancepublishedbytheHSL
1. Test in an empty booth and ensure that the extraction
system is turned o
2. Fill the room with smoke, making sure to distribute
smoke evenly throughout the room
3. Switch on the ventilation system and start a timer
4. Checkforanyleakingairaroundtheboothexterior
5. Note the time at which the room is judged to be clear o
smoke
6 . Displaytimeonanoticeonthedoororentranceofthe
booth and inorm all employees
Note:AppropriateRPEshouldbewornduringtheclearance
time measurement to provide protection rom the smoke.
Biological Monitoring
Are the control measures providing adequate protection?
Biologicalmonitoringinvolvesmeasuringforisocyanate
breakdown products in a sample o workers urine. This
will indicate i they have been exposed to isocyanate. I they
have, the controls (e.g. spray booth, respiratory protective
equipment) are not working properly, or are not being used
correctly.
What specialist help do I need?
LaboratoriessuchastheHealthandSafetyLaboratory
(HSL)offeracommercial,condentialservicetomeasure
isocyanate breakdown products in urine. Typically
laboratories charge an amount per sample, including a kit
or collection the sample, packing and instructions.
I visibility is an issue and the
sprayer insists on inspecting his
paintwork ater spraying then
a supplied air hal mask can be
used.
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Please recycle.Printed in the United Kingdom 3M 2007. All rights reserved.70-0000-0000-0
Automotive
Atermarket Division3M United Kingdom PLC3M House28 Great Jackson StreetManchester M15 4PAPhone: 0161 236 8500Fax: 0161 237 6260www.3mbodyshop.co.uk
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