SWMS template · Asbestos & Hazardous Materials

Two-Pack (Isocyanate) Spray Painting — Safe Work Method Statement

Safe Work Method Statement for spray applying two-pack polyurethane and other isocyanate-containing paints and clear coats, covering spray booths, supplied-air respirators, skin protection, health monitoring and flammable atmospheres.

Category: Asbestos & Hazardous Materials
HRCW: 1 category
Job steps: 6
Hazards rated: 14
PPE items: 6

Two-pack polyurethane paints, clear coats and some coatings for steel, floors and architectural metal contain isocyanates in the hardener. Isocyanates are a leading cause of occupational asthma. Once a worker is sensitised, even very small later exposures can trigger a severe asthma attack, so the aim is to prevent sensitisation in the first place. Exposure happens by breathing in spray mist and vapour and through skin contact.

Spray painting in a workshop booth is not usually construction work. When two-pack spraying is done on a construction site, especially indoors or in a partly enclosed space, solvent vapour and spray mist can create a contaminated or flammable atmosphere, which is High Risk Construction Work and requires a SWMS. If the spraying is also done at height or in a confined space, add those HRCW categories and controls.

The main control is to spray in a properly designed and maintained spray booth with mechanical extraction. Where that is not possible, enclose and ventilate the work area and keep other people out. Spray painters should wear supplied-air respiratory protection (air-line or powered air with a clean breathing air supply), selected and fitted under a respiratory protection program in line with AS/NZS 1715. Filter cartridge respirators give poor warning of breakthrough and are not suitable as the main protection when spraying isocyanates. The breathing air supply must come from a clean source with its intake away from exhaust and spray.

Isocyanates are listed in the model WHS Regulations as a hazardous chemical that needs health monitoring. Workers spraying them need health monitoring under the supervision of a registered medical practitioner with experience in health monitoring, including a baseline before starting and ongoing checks. Anyone who develops chest tightness, wheeze or breathlessness must stop spraying and be assessed. Check the SDS for each product, as it sets out the hazards, the exposure standard and the glove material to use.

Customise this template with the products and SDS references, the spray booth or enclosure details and maintenance records, the supplied-air respirator type and breathing air source, health monitoring arrangements, ignition source controls, the exclusion zone and re-entry time after spraying, and mixing, clean-up and waste disposal procedures.

High Risk Construction Work Types

Work in an area that may have a contaminated or flammable atmosphere

Personal Protective Equipment

Supplied-air respirator (air-line hood or full face) with clean breathing air (AS/NZS 1715 program)
Chemical-resistant gloves of the material listed in the SDS
Disposable paint suit with hood
Eye protection where not provided by the respirator
Anti-static safety footwear
Hearing protection near compressors and booth fans

Risk Assessment

RatingsCatastrophicHighModerateLow

Step 1Planning, SDS review and health monitoring

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Workers sensitised to isocyanates	Catastrophic	Read the SDS for every component. Use a lower-hazard product, such as a non-isocyanate or water-based coating, where it meets the specification. Baseline health monitoring before a worker starts spraying, then ongoing monitoring as directed by the registered medical practitioner. Workers already sensitised do not do this work.	Moderate	Employer / Supervisor
Untrained workers spraying or mixing	High	Only trained spray painters mix and spray. Training covers isocyanate hazards, respirator use and checks, and symptoms to report. Records kept.	Low	Supervisor

Step 2Setting up the spray booth or work enclosure

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Spray mist and vapour reaching other workers	High	Spray inside a booth with mechanical extraction, or enclose and ventilate the area on site. Check extraction is running and filters are in date before spraying. Exclusion zone and signs. No other workers in the area without the same respiratory protection.	Low	Supervisor
Fire or explosion from ignition of solvent vapour	Catastrophic	Remove ignition sources: no hot work, smoking or naked flames nearby. Electrical equipment in the spray zone suitable for hazardous areas. Earth and bond equipment and containers. Fire extinguishers at the exit.	Low	Supervisor

Step 3Respirator and breathing air checks

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Contaminated or insufficient breathing air	High	Breathing air from a dedicated supply or a compressor fitted with breathing air filtration, with the intake away from exhausts and spray. Check air flow and filters before each use. Air quality tested at the interval the supplier specifies.	Low	Supervisor
Respirator not sealing or not suitable	High	Supplied-air respirators selected under the AS/NZS 1715 program. Tight-fitting facepieces fit tested and worn clean-shaven; use a loose-fitting hood where facial hair cannot be removed. Inspect the respirator before each use.	Low	Spray Painter

Step 4Mixing paint and hardener

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Skin contact and splashes when decanting hardener	High	Mix in a ventilated area. Gloves of the material listed in the SDS, paint suit and eye protection. Close containers straight after use. Clean spills immediately with the absorbent listed in the SDS.	Low	Spray Painter
Vapour exposure during mixing	Moderate	Mix under extraction or in the booth mixing room. Wear respiratory protection while mixing if extraction is not available.	Low	Spray Painter

Step 5Spray application

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Inhaling isocyanate spray mist	Catastrophic	Supplied-air respirator worn for the whole spray cycle. Spray with the extraction drawing mist away from the painter. Keep the booth door closed. Do not remove the respirator inside the booth until the purge time has passed.	Low	Spray Painter
Injection injury from airless spray equipment	High	Tip guard and trigger lock in use. Release pressure before cleaning or changing tips. Never point the gun at a person or wipe the tip with a hand. Any injection injury is treated as a medical emergency.	Low	Spray Painter
Others entering the area during or after spraying	High	Keep the exclusion zone in place during spraying and for the re-entry time set by the booth design or SDS. Signs on all entries.	Low	Supervisor

Step 6Clean-up, waste and decontamination

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Solvent and isocyanate exposure when cleaning guns	Moderate	Clean guns in an enclosed gun washer or under extraction. Gloves and eye protection. Keep wearing respiratory protection if extraction is not available.	Low	Spray Painter
Fire from solvent-soaked rags and waste	High	Put rags and waste in a closed metal bin. Dispose of waste paint and solvent through a licensed waste contractor. Never pour waste down drains.	Low	Spray Painter / Supervisor
Symptoms of sensitisation not reported	High	Workers report chest tightness, coughing, wheezing or breathlessness, including symptoms that start hours after work. Stop spraying and arrange medical assessment. Review controls.	Moderate	Spray Painter / Supervisor

Relevant Codes of Practice

Worker Acknowledgement

By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.

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