Safety Patrol - The EPA hopes to boost environmental and employee protection measures with a new education project.

A 42-year-old automotive refinisher suffered an asthmatic attack while on the job in May 1996. The painter--who was not wearing a supplied-air respirator even though the Material Safety and Data Sheets (MSDS) called for one--died at the Sinking Spring, Pa. dealership where he was employed. The Occupational Safety and Health Administration (OSHA) reports that the painter had previously complained to his employer about clogged spraybooth filters and a lack of personal protection training.

To help prevent such tragedies in the future, the U.S. Environmental Protection Agency's (EPA) Design for the Environment (DfE) branch has launched an educational initiative to help collision repairers integrate safer, cleaner, more efficient work procedures and equipment into their refinishing departments. The DfE has already analyzed work habits in eight, Philadelphia area collision repair facilities, and it's now evaluating a second group of shops in that region. The challenge will then be to share its findings and advice with shops nationwide.

By improving shop safety and efficiency levels, the DfE also hopes to save repair facilities time and money, minimize waste generation and reduce the amount of chemicals released into the environment.

Concerns for refinishing technicians primarily stem from their exposure to isocyanates, found in urethane topcoats and primer surfacers. Isocyanates can cause a range of health problems, including skin irritation, allergic reactions, lung toxicity, and respiratory irritation and sensitization. "We're looking for practical solutions and are working with shop owners and painters who have made some changes, seeing what they recommend as the best type of protection and deciding the best way to get that message out to other shops," says Mary Cushmac, a DfE project manager.

On-Site Analysis

The first phase of the program consisted of evaluating refinishing procedures in body shops that are considered to be "level one" facilities because they have already made safety a priority: They have downdraft spraybooths; they use high-volume, low-pressure (HVLP) sprayguns; they regularly change booth filters; one individual is responsible for health and safety information; and employees have access to personal protective equipment.

Industrial hygienist Kevin Sikora, a senior safety engineer with Eastern Research Group (ERG) Inc. in Chantilly, Va., conducted the shop evaluations. He spent six to eight hours analyzing the refinishing processes. In addition to applauding each shop's effective practices, he recommended ways to eliminate shop hazards.

Alan's Collision Center has implemented each of the changes Sikora suggested, shop owner Dennis Winokur says. These included improving paint and solvent storage and handling and ensuring that technicians use the protective gear the shop provides. "There's less waste now, and [the technicians are] more efficient in what they're doing and handling," Winokur says. "There's also less down time because the employees are here. They're not sick from not protecting themselves." Arthur Kulis, owner of A.O.K. Auto Body Inc., says Sikora gave his shop high ratings but suggested improved ventilation for gun cleaning.

Among the health and safety routines the eight shops received praise for which were: maximum use of spraybooths; some use of downdraft prep stations; consistent use of personal protective gear, such as respirators and gloves; continuous improvement in regards to using a supplied-air system and HVLP sprayguns; some utilization of an environmental consultant; routine communication of chemical hazards; and some efforts to develop a ventilation system for paint mixing.

Shop Limitations

Sikora understands that budget constraints dictate the extent to which many shops can formalize their health and safety efforts. For example, some facilities may not be able to afford an environmental consultant or a downdraft spraybooth--the type the DfE recommends.

Many facilities also face challenges from employees who find safety gear and equipment bulky, uncomfortable and difficult to work with. "A lot of the things that seem simple for us aren't," says Dave DiFiore, project manager for the DfE. "That's the important part of being in the shop and understanding the realities there."

The solution to these problems often means taking time to adjust to the equipment, learning to use it properly or purchasing a style that is more user-friendly.

Sharing the Findings

The DfE team is now launching a second wave of evaluations in five Philadelphia shops. These are viewed as "level two" shops because they are not as likely as the first group to have in place all environmental controls and equipment. While the DfE will base its evaluations on its original criteria as well as the best-practices examples set by the first shops, it will take into account how practical certain upgrades are.

The DfE also wants to establish a peer support network for the shops it evaluated. At the same time, the DfE is developing educational materials and planning to distribute them to shops in Philadelphia. They will solicit feedback and, if the materials are deemed effective, will circulate them nationwide. The project team also hopes to work with the entire industry to communicate the project's findings and to receive any additional suggestions. "The key," Cushmac says, "is to reduce exposure and to have a program set up where the painter can wear proper protective equipment and still paint the car and get a good product to the customer."

Step By Step

When conducting shop evaluations for the EPA's project, industrial hygienist Kevin Sikora identifies proper and improper work habits and equipment usage. He assesses the technicians' work habits by dividing the entire refinishing process into smaller, separate tasks, which are:

* Preparatory Work--This includes dry and wet sanding and an overall solvent wipedown before the vehicle is sprayed. This is one of the more dangerous steps because many painters believe that the solvent is weak and relatively harmless. Because of this, they tend not to wear gloves or ensure proper ventilation.

* Paint Mixing--The emphasis on this step is whether the painters wear gloves and respirators and whether the paint mixing area is properly ventilated. One of the concerns is whether the exhaust ducts are placed in a location where they remove vapors before they enter the work area. In one repair facility, the duct was located behind the repairer, and vapors were pulled across the technician before they were removed from the area.

* Priming Operations--The type of respiratory protection technicians use is evaluated. Many painters believe the primer is less harmful than other coatings, even though many primers require hardener. Because of their perception, technicians often perform this procedure in an open bay and with less protective equipment than the procedure requires. Ideally, technicians should prime vehicles in a downdraft spraybooth or in a downdraft prep station.

* Color or Topcoat Application--The important part of this step is the type of respiratory protection technicians utilize. Although they are advised to use supplied-air respirators, many find the equipment uncomfortable, and they complain that it's difficult to wear and still turn out a quality paint job. There are also visibility problems associated with the equipment. Some shops have purchased more user-friendly respirators, while others have found that technicians gradually adjust to the protective gear.

* Spraygun Cleaning--This is usually performed in the paint-mixing room, so the focus is again on proper ventilation. Although gun washers are closed, solvent and paint containers that are left open increase vapor levels.

* Recycling Operations--Ventilation is again a concern and so is ensuring that the recycling equipment is operating properly. In one shop, a loose connection allowed a mist of solvent to leak into the air.