Product Overview

Summary: This Paint Spraying Safe Operating Procedure sets out clear, practical steps for carrying out paint spraying tasks safely and efficiently in Australian workplaces. It helps businesses control overspray, fumes, fire and health risks while maintaining consistent finish quality and meeting WHS obligations.

Paint spraying is a high‑risk activity that combines flammable substances, airborne contaminants and pressurised equipment. Without a clear procedure, businesses are exposed to serious hazards including fire and explosion, solvent exposure, respiratory illness, environmental contamination and poor-quality finishes that require costly rework. This Paint Spraying Safe Operating Procedure provides a structured, step‑by‑step framework for planning, preparing and carrying out spraying tasks in compliance with Australian WHS requirements.

The SOP guides workers and supervisors through pre‑start checks, ventilation requirements, safe mixing and handling of coatings, correct use of spray guns and hoses, and effective housekeeping to control overspray and waste. It addresses both health risks (such as isocyanate and solvent vapours) and physical hazards (such as ignition sources, slips in overspray areas and equipment failures). By implementing this procedure, organisations can standardise training, demonstrate due diligence, and significantly reduce the likelihood of incidents, worker illness and regulatory non‑compliance across workshops, construction sites, automotive repair shops and manufacturing environments.

Key Benefits

• Ensure consistent compliance with Australian WHS laws and relevant Codes of Practice for hazardous chemicals and spray painting.
• Reduce worker exposure to hazardous vapours, mists and isocyanates through defined ventilation, PPE and handling controls.
• Minimise the risk of fire, explosion and ignition events associated with flammable paints and solvents.
• Standardise paint spraying techniques to improve finish quality and reduce rework, waste and downtime.
• Support effective induction and refresher training with a clear, documented procedure for all spray painting tasks.

Who is this for?

• Spray Painters
• Workshop Supervisors
• Site Supervisors
• WHS Managers
• Maintenance Managers
• Automotive Refinishing Managers
• Manufacturing and Production Managers
• Facilities Managers
• Small Business Owners in Painting and Coating Services

Hazards Addressed

• Inhalation of hazardous vapours, mists and isocyanates from paints and hardeners
• Skin and eye contact with solvents and coatings causing irritation or sensitisation
• Fire and explosion risks from flammable and combustible liquids and vapours
• Static electricity build‑up and ignition during spraying operations
• High‑pressure injection or impact injuries from spray equipment and hoses
• Noise exposure from spray booths, compressors and extraction systems
• Slips, trips and falls due to overspray, spills and obstructed work areas
• Manual handling strains from moving spray equipment, paint containers and workpieces
• Environmental contamination from improper disposal of waste paint, thinners and filters

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Applicable Work Areas
• 3.0 Roles and Responsibilities
• 4.0 Required Competencies and Training
• 5.0 Equipment, Materials and Spray Booth Requirements
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Pre‑Start Checks and Work Area Preparation
• 8.0 Paint Mixing, Thinning and Transfer Procedures
• 9.0 Safe Operating Procedure for Paint Spraying
• 10.0 Ventilation, Extraction and Overspray Control
• 11.0 Hazard Identification and Risk Control Measures
• 12.0 Housekeeping, Clean‑up and Waste Management
• 13.0 Maintenance, Inspection and Tag‑out of Spray Equipment
• 14.0 Health Monitoring and Exposure Controls (including isocyanates)
• 15.0 Emergency Procedures and Incident Response
• 16.0 Recordkeeping, Review and Continuous Improvement

Legislation & References

• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• Safe Work Australia – Model Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 2161: Occupational protective gloves
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 4114: Spray painting booths, designated spray painting areas and paint mixing rooms
• Work Health and Safety Act and Work Health and Safety Regulations (as adopted in relevant State or Territory)