In the industrial coating field, thermosetting powder coatings have become the mainstream choice due to their durability and environmental friendliness. They use thermosetting resins as the core of film formation, combined with a curing agent, to form a hard coating upon heating. However, this high efficiency hides many safety hazards, which can threaten health and production safety if not carefully monitored. Below, we break down the safety points of the entire spraying process, from operating procedures to personal protective equipment.
1. Basic Operations at the Spraying Site
The spraying of thermosetting powder coatings requires a dedicated workshop, and "meticulousness" is the core principle here.
If powder leakage occurs during spraying, immediately cutting off the power is crucial—splattered powder not only pollutes the environment but may also cause static electricity or dust risks. When cleaning, it is recommended to use anti-static tools to avoid dry sweeping which raises more dust.
If powder is accidentally inhaled or splashed into the eyes, don't panic! Flush the affected area continuously with plenty of clean water (rinse eyes for at least 10 minutes, ensuring eyelids are fully open). If severe symptoms such as difficulty breathing or severe eye pain occur, immediately stop work and seek medical attention. Do not attempt to treat the condition yourself.
2. Ventilation System
The core of ventilation is a two-pronged approach: reducing solvent vapor and dust concentrations to prevent explosions, and minimizing toxic substances to protect health.
The ventilation layout must be reasonable: At least one air inlet and one air outlet should be installed to allow air convection—especially in enclosed spaces such as shipyards. Ventilation vents should be installed near the ground in the lower part of the compartments, as flammable solvent vapors are heavier than air and tend to accumulate at lower levels.
Ventilation must be continuous: Ventilation must be maintained from the start of painting operations until the paint is completely dry. During this period, the concentration of flammable gases must be monitored regularly, and equipment should only be shut down when the levels are below safety standards.
3. Fire and Explosion Prevention
For industries that frequently use coatings, such as shipbuilding and metal processing, the painting area and its surroundings (including the upper deck and adjacent compartments) are designated as "no-fire zones" for painting. Three ironclad rules apply:
Strictly prevent ignition sources: All open flame operations and sparking are strictly prohibited; even carrying lighters should be avoided.
Equipment must be explosion-proof:Electrical and lighting equipment in the painting area must meet explosion-proof standards. It is recommended to install intelligent fire detection devices for early detection and rapid response to fires.
Confined space testing: Before spraying in enclosed spaces such as ship cabins and storage tanks, the concentration of flammable gases must be tested and only started work if it meets the standards. Sufficient fire extinguishers and fire sand should also be provided, and their effectiveness should be regularly checked.
Post-work safety precautions: Waste solvents and thinners must be centrally recycled and disposed of properly. Empty paint cans must be emptied and promptly moved to a safe area to eliminate any remaining hazards.
4. Static Electricity Prevention
Static electricity is the most insidious risk in powder coating spraying—it can cause electric shock or ignite dust. To effectively mitigate static electricity, follow these guidelines:
Dress and Behavioral Norms:Wear anti-static work clothes and conductive shoes; avoid wearing synthetic fiber clothing. Do not shake clothing during work (to prevent dust generation) and avoid operations that may generate mechanical sparks.
Reliable Equipment Grounding: Spray gun hoses must be made of conductive material, and metal joints must be wrapped with insulating material (to prevent frictional sparks). All coating equipment and workpieces must be grounded to ensure timely discharge of static electricity.
Upgraded Factory Protection: It is recommended to install distributed lightning protection devices (such as antenna-type or mesh-type) in the coating workshop to safely disperse lightning current and prevent accidents caused by static electricity buildup.
5. Dust Prevention
Dust is the most common health threat in coating operations; long-term inhalation may cause respiratory diseases. Try these methods to "lock in" dust: Prioritize low-dust processes: Use chemical rust removal instead of mechanical methods if possible; if mechanical grinding is necessary, use wet methods whenever possible—dry sandblasting dust concentrations can reach over 300mg/m³, while wet operations can reduce it to below 2mg/m³; Double protection with ventilation and safety: When performing large-scale indoor sandblasting operations, in addition to turning on the ventilation and dust removal system, wear dust masks, oxygen-supplied helmets, and protective clothing to isolate dust from both the respiratory system and skin.
6. Personal Protective Equipment (PPE)
Even the most comprehensive environmental protection measures cannot compensate for the "last mile" of personal protective equipment:
Select equipment according to the scenario: Wear an activated carbon mask (to absorb harmful gases) when manually painting; when cleaning surfaces with thinner, wear latex gloves to handle gauze soaked in solvent;
Double protection in confined spaces: When working in enclosed spaces with only an overhead entrance, in addition to standard protective equipment, use a lifeline—in case of an accident, an external supervisor can quickly pull the worker out;
Don't neglect daily care: Avoid exposing skin during work; apply skin-protecting oils to exposed areas; if paint gets on the skin, first wipe it off with gauze soaked in a small amount of thinner, then wash with soap and apply skin-protecting oil;
Long-term health management: Painting workers should have regular medical checkups; if suspected occupational disease symptoms appear, seek timely specialized examination; if necessary, adjust job assignments to prevent small problems from becoming major hazards.
7. Conclusion
Safety in powder coating spraying is never a matter of a single measure working in isolation; rather, it requires a collaborative effort encompassing operational procedures, environmental control, equipment protection, and individual awareness. Ventilation reduces risks, explosion prevention blocks ignition sources, static electricity prevention eliminates hidden dangers, dust protection protects breathing, and personal protective equipment forms the bottom line—every detail is crucial for safeguarding health and production.
Making these measures a daily habit not only makes spraying operations more efficient but also ensures that every worker can start and finish work with peace of mind.
