What are the Risks of Powder Coating?

An alternative to spray paint, powder coating protects metal surfaces from corrosion and provides a flawless finish. Most metals like steel and aluminum can be powder coated, but wood, glass, and plastic components can also be powder coated when heated above a certain temperature. While powder coating has several benefits over spray paint, uncured powder poses health risks and safety hazards. 

Though powder coating is widely used in various applications, the process is risky and requires Personal Protection Equipment (PPE) at all times. 

In this blog, we will explore the potential health and safety risks of powder coating and the common regulations governing it.

What Makes Powder Coating Potentially Hazardous?

Powder coating is classified as respirable hazardous dust. The dust particles are very fine and cannot be seen but reach deep into the lungs if inhaled. Significant exposure to the powders may result in skin irritation, respiratory irritation, asthma, and skin sensitivity issues. 

In addition, some powder pigments and curing agents are also highly toxic. It is critical to exact caution if you find the following chemicals in the powder:

• Trimellitic Anhydride
• Triglycidyl Isocyanurate
• Pigments with Lead Chromate

Read the safety data sheet before powder coating objects with the chemicals mentioned above. Machine or manual operators must wear PPE at all times to avoid potential health risks of powder coating. 

Health Risks of Powder Coating

• Physical Injury

  A physical injury may occur to the operator due to improper handling of powder coating machines. 

• Lung Damage

  Inhalation of powder particles and other chemicals may cause damage to the air tract and lungs.

• Burns

  Possible burns due to accidental combustion of powder coating materials

• Chemical Exposure

  Possible exposure to chemicals in spray systems during chemical cleaning of substrates.

• Eye Damage

  Potential eye damage due to the chemicals, vapors, and powder coating dust. 

Powder Coating Applications that Require Careful Handling

There are certain high-risk activities during the powder coating process, including:

• Application of powder containing Trimellitic Anhydride, Triglycidyl Isocyanurate, or Lead Chromate pigments
• Improper ventilation in the powder coating booth and
• Improper cleaning resulting in involuntary powder transfer

Safety Measures for Powder Coating

With great risks comes the greater responsibility of ensuring your operators and other personnel stay safe. While you cannot eliminate the risks of powder coating, you can take the following steps to reduce the possibility of an accident:

• Properly covering spray booths and other designated areas to prevent dust leakage
• Adhering to guidelines for proper storage and disposal of toxic materials
• Providing appropriate PPE kits to all employees
• Maintaining adequate ventilation in your facility
• Lowering the temperature to control vapor release
• Ensuring precise powder gun settings to limit powder required for the desired finish
• Training staff rigorously to prevent amateur accidents
• Eliminating manual powder coating by investing in an automatic coating booth

As a precaution, always examine your floor for any powder dust. This would indicate your powder coating booth isn't functioning at full efficiency.

Powder Coating Regulations in the US

Many powder coating regulations in the US govern the process. Here are some statutes that you must comply with:

• Clean Air Act
• Clean Water Act
• Effluent Guidelines and Standards for Metal Finishing
• National Pollutant Discharge Elimination System
• Resource Conservation & Recovery Act

As a powder coating shop, pay attention to the following common guidelines:

• Size

  The powder coating must be at least 1" x 3". The maximum size can be 60" in any direction.

• Weight

  Powder-coated parts must weigh at least 50 lbs.

• Quality

  Each powder coating should comply with the American Architectural Manufacturers Association (AAMA) guidelines for flexibility, chip resistance, impact resistance, hardening, weathering, and edge coverage.

• Air Pollutants

  Powder coating surface operations flagged as 'major' are regulated by National Emission Standards for Hazardous Air Pollutants (NESHAP).

• Human Safety

  Conduct a proper risk assessment of the necessary PPE kits needed to protect employees. These may include protective glasses, masks, coveralls, or a suit.

• Deburring

  Large parts that may develop burrs must be deburred before powder coating.

What PPE is Needed for Employee Safety?

As a powder coating facility owner, your employees must have the right PPE and equipment. A risk assessment must be conducted to identify the necessary safety gear. Depending on the part and application technique, spray operators and other powder coating personnel are required to wear:

• A respirator
• Suit to protect the applicator from hazardous particles
• Protective glasses to shield eyes from powder particles
• Hand gloves for safe material handling
• Hard hats (in areas with moving parts)
• Coveralls to protect the operator from chemical splashes in automated booths

Safe & Precise Powder Coating in NJ

In a world of high industrial demand and environmental concerns, the balance of performance and safety is paramount. At Rusty Lions, our professional powder coaters follow safety checks before and after coating to ensure they comply with safety and quality guidelines. Our seasoned experts will identify risks early on and prevent any accidents or defects in the finishing.

When you trust Rusty Lions for the job, you get strategic certainty that your manufacturing needs will be duly, safely, and efficiently met. Contact our team to discuss your powder coating specifications or other metal finishing requirements.