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Breathing Easy
Ensuring Proper Ventilation of Paint
Mixing Rooms In Auto Refinish Shops
Design for Hie Environment
Aufo Refinish Project
www.epa.gov/dfe/projects/auto
Design for the
Environment
Auto Refinish Project
In its Auto Refinish Project,
U.S. EPA's Design for the
Environment (DfE) Program
works with auto refinishers to
identify and encourage safer,
cleaner, and more efficient
practices and technologies.
EPA's project team has uncov-
ered many examples of health
and safety improvements that
increase efficiency and can
help shops save money.
If you're interested in partici-
pating or would like to learn
more about this project,
please write Mary Cushmac
at cushmac.mary@epa.gov or
David Di Fiore at difiore.david
©epa.gov, or visit the DIE
Web site at .
For a virtual auto body
shop experience, filled with
helpful health, safety, and effi-
ciency information, visit
. The virtual auto
body shop is a joint product
of DfE and the Coordinating
Committee tor Auto Repair
(CCAR).
The Auto Refinlsh Project
Auto refinishers use many potentially
harmful chemicals when painting
vehicles and auto parts. In particular.
shops use solvents, isocyanates, pigments.
and other additives in paints and coatings
that can present serious risks to human
health and the environment. Isocyanates, for
example, are the leading cau^c of occupa-
tional asthma in the United States.
To help protect auto refmish workers and
neighborhoods from these hazardous chemi-
cals, the U.S. Environmental Protection
Agency (EPA) launched the Auto Refinish
Project, part of EPA's Design for the
Environment (DfE) Program. Through this
project, FPA has formed partnerships wiih
Philadelphia-area auto refmish shops to deter-
mine which tasks pose the greatest health
threats and which procedures and equipment
protect workers best. In many cases, these
procedures and equipment also increase shop
efficiency and help save money on shop
materials and waste disposal fees.
Reducing Risks During
Paint Mixing and
Cleanup
Spray painting operations may present
the greatest potential risks to auto
refmishers. Many shops have
addressed this risk through the use of venti-
lated spray booths, respirators, gloves, and
coveralls when spray painting.
Two operations—paint mixing and
cleanup—are often overlooked when shops
are considering safety measures. Many work-
ers perform paint mixing and cleanup in
small, enclosed rooms with little or no venti-
lation or with ventilation that works improp-
erly, often increasing worker exposure.
This fact sheet describes ways shop own-
ers can improve ventilation in paint mixing
and cleanup rooms and discusses other steps
to better protect workers during paint mixing
operations.
Ventilation Systems—
The Basics
Without proper ventilation, paint
mixing and cleanup rooms can be
unhealthy. Paints, solvents, and
reducers all generate hazardous vapors that
can build up and remain in a room.
Ventilation systems are needed to remove
these vapors and provide a healthy working
environment.
There are two basic types of ventila-
tion—general exhaust ventilation and local
exhaust ventilation.
General exhaust ventilation systems
typically consist of an exhaust fan, mounted
in the ceiling or wall, that pulls air out of the
workroom and discharges it outdoors.
Replacement air is brought into the work
area by either natural means, such as win-
dows and vents, or by a more sophisticated
setup that includes a separate make-up air
fan, duct work, and air registers that provide
clean air to the work space. General exhaust
ventilation is also known as "dilution venti-
lation" because it dilutes vapors by mixing
ihem with cleaner room air.
Since they do not immediately remove
the vapors from the work space, general
exhaust systems are not recommended as the
sole source of ventilation when hazardous
vapors are present. (Note, doorways also
provide a path for make-up air to enter the
workroom; however, fire codes typically
require that mixing room doors that open
into other areas of the shop remain closed
when not in use.)
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Paint/solvent vapors
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Common Paint Mixing Room Ventilation Mistakes
Does your ventilation system provide workers with enough pro-
tection? Consider the following situations, which describe venti-
lation scenarios found in many auto refinish shops:
Scenario: An exhaust fan is installed in the ceiling of a small
paint mixing room, directly above the paint mixing
bench.
Issue: The fan is installed too far from the mixing opera-
tions to capture the vapors and, thus, is allowing
them to mix with general room air before being
exhausted. In addition, many of the hazardous
vapors emitted in the paint mixing room are
heavier than air and tend to collect at floor level.
Exhaust fans at the ceiling level do little to capture
and remove these low-lying vapors.
Scenario: An exhaust fan is installed in a paint mixing room at
floor level on the wall just opposite from the work
bench. Make-up air vents are located about 2 feet
above the surface of the work bench, directly in front of the workers' faces. (See Figure 1.)
Issue: While this system provides for the removal of low-lying vapors, it creates a new problem. The air supplied to
the room through the make-up air vents passes over the work bench and mixes with solvent vapors emitted
during the mixing process. Because the exhaust fan is on the opposite wall, behind the workers, the con-
taminated air travels past the workers' faces before being exhausted from the room.
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Figure 1. Poor Ventilation Design
Local exhaust ventilation systems remove chemicals and
other contaminants at their source. These systems arc recom-
mended for controlling hazardous vapors because, if designed
properly, they remove the vapors before workers are exposed
to them. Local exhaust ventilation systems always consists of
three basic components:
• A hood (exhaust vent or special duct end) installed as close
as possible to where work is performed, to capture the
vapors;
• Ductwork to transport the vapors from the hood to outside
the building; and
• A fan located downstream of the hood to draw air away
from the work area, through the hood and ductwork, and
discharge it from the building.
Combination Systems: An
Effective Solution
The most effective way to ventilate your paint mixing
rooms is to use both local and general exhaust ventila-
tion systems in combination. A local exhaust system
installed at the work bench as close to the mixing operation as
possible will capture most hazardous vapors before they can
escape into the room air and be inhaled by workers. A general
ventilation system for the room with floor level exhaust vents
will remove low-lying vapors that are not captured by the
local exhaust system or are generated from other sources of
vapor in the room, including trash cans containing solvent-
laden rags; gun cleaners or other equipment; and open solvent,
paint, and waste containers.
With a combined system, it is only necessary to turn on the
local exhaust ventilation during actual mixing or cleaning
operations. The general exhaust ventilation, however, should
remain on throughout the workday to maintain constant air
circulation in the room. A combined system actually can help
reduce energy costs because the local exhaust ventilation sys-
tem, which operates for only a small portion of the work day,
can remove the majority of the vapors from the room while
only exhausting a small amount of air. This lowers the concen-
tration of vapors in the room and allows you to operate the
general ventilation system at a lower flow rate, thus reducing
the amount of heated (or air-conditioned) air exhausted from
the building throughout the day.
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Figure 2. Top view of room—
Locate exhaust vent near vapor sources
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Exhaust
vent
Make-up
air inlet
Painl/solvenl vapors
drawn away from
worker's breathing zone
Figure 3. Draw vapors away
from workers breathing zone
Make Informed Decisions
A properly designed ventilation system can make the
mixing room and shop operations cleaner, safer, and
more efficient. An improperly designed system, how-
ever, will do little to improve current workplace conditions or
protect workers. For this reason, it is important to make sure
that the system is designed and installed by properly trained
individuals, such as a qualified ventilation contractor or an
industrial hygienist. As an alternative, prefabricated paint mix-
ing rooms are currently on the market and typically provide
spill protection, explosion-proof electrical installation, and
general ventilation.
Tips to Consider
General Ventilation
When considering general exhaust ventilation systems for
your paint mixing room, it is important to:
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make-up
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Mixing
Bench
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Make-up
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re 4. Top view of room — Locate
air inlet opposite from exhaust vent
Position exhaust vents as close to the source of haz-
ardous vapors as possible to reduce the spread of
vapors in the room (see Figure 2).
Situate exhaust vents and sources of make-up air so that
hazardous vapors are not drawn past the worker on the
way to the exhaust vent (see Figure 3).
Ensure continual movement of air within the paint mixing
room to prevent hazardous vapors from accumulating.
Conserve energy by installing a fan that operates at two
speeds: a higher speed for greater air movement when
workers are in the area, and a lower speed for reduced air
flow when workers are not present.
Place exhaust vents at or near floor level to remove low-
lying vapors.
Locate exhaust vents and sources of make-up air on oppo-
site sides of the room to ensure that air flows through the
entire room (sec Figure 4).
Figure 5. Local exhaust ventilation
Local Ventilation
Local exhaust systems can be more expensive to install initial-
ly, but they offer greater worker protection. In addition, oper-
ating costs are generally reduced by allowing for a reduced
general exhaust flow rate. The following considerations should
be taken into account when installing a local exhaust system
in your paint mixing room:
• The fan must be sized correctly to move the required
amount ol air.
• The exhaust hood or vent should be loeaied within 1 to 2
feet of the mixing operation to effectively capture vapors.
• Air velocity at the exhaust hood or vent must be strong
enough to overcome potential cross drafts.
• A series of slot exhausts located at the rear of the paint
mixing table at about the level that work occurs will most
effectively capture vapors generated during paint mixing
operations (sec Figure 5).
• The use of baffles or other types of enclosures at the sides of
the mixing table will help reduce cross drafts and improve
the system's ability to capture vapors (see Figure 5).
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Special Design Considerations
No matter what type of ventilation system you
choose, keep in mind that the vapors produced in
paint mixing rooms are extremely flammable and
can produce explosive environments. For this reason, all
electrical equipment that you place or install in this room,
including ventilation fans, wiring, and switches, must be
specifically designed and approved for use in explosive
atmospheres. Ventilation equipment manufacturers should
be able to tell you what types of environments their equip-
ment can be used in. In addition, electrical equipment
approved for use in flammable or explosive environments
should bear appropriate labels. For more information about
applicable electrical requirements, contact your local Fire
Marshall.
Other Safety Considerations
Proper ventilation systems are a vital part of ensuring a
safe work environment. Nevertheless, workers should
take additional precautions when mixing paint and
cleaning up. Here are some steps workers can take every
day to further reduce risks to their health when they perform
these operations:
Use air-purifying respirators and create a respiratory pro-
tection program, including fit testing and cartridge
change-out schedules. This is especially important when
ventilation does not adequately reduce harmful vapors.
Always wear chemical-protective gloves during paint
mixing and gun cleaning activities. Note: latex gloves
typically do not hold up well against solvents and iso-
cyanates and can cause allergic reactions. Nitrite gloves
would be a more protective choice. Talk to your paint
distributor or equipment supplier to determine the most
appropriate types of gloves for your operations.
Close all containers of solvents, paints, and reducers
immediately after use to minimize vapor emissions. This
not only prevents workers from breathing hazardous
vapors, but also saves money by reducing the amount of
refmishing and cleaning products lost through evaporation.
Fit all waste drums with funnel lids. Keep the lids closed
when you are not using them. Most safety product dis-
tributors sell funnel lids that allow for easy drum access
when transferring solvent wastes.
Keep tight-fitting lids on all trash containers.
Clean up all spills immediately. Allowing spilled materials
to simply evaporate from the work surface can greatly
increase the amount of hazardous vapors present in the air.
cxEPA
United States
Environmental Protection
Agency
Draft
744-F-02-008
May 2002
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