Direct answer: Do not start spray painting or powder coating until product hazards, airborne contaminants, ventilation, ignition and static controls, equipment condition, access, PPE and emergency arrangements are sorted. Plan preparation, mixing, application, curing, cleaning, maintenance and waste together, because exposure can occur outside the spraying step.
Information current: 5 August 2026.
Main hazards
Spray painting atomises liquid coating. Powder coating commonly uses an electrostatic charge to apply powder to an earthed item. Both can put contaminants into the breathing zone and spread them beyond the operator.
Common hazards include:
- aerosols, solvent vapours, powder and sanding dust contacting the lungs, skin or eyes
- sensitising substances such as isocyanates, and hazardous powder ingredients such as TGIC
- fire or explosion involving flammable vapours, combustible powder, sparks, hot work or static
- high-pressure injection from airless spray equipment
- electric shock, poor earthing and unsuitable electrical equipment in a hazardous area
- noise, heat, manual handling, repetitive work, falls and confined spaces
- exposure during mixing, hopper filling, filter changes, spill response and clean-up.
A high-pressure injection injury can look small but needs immediate medical treatment.
What to sort before work starts
Walk through the whole job with the workers and other businesses sharing the site. Agree who controls the work area, ventilation, isolations, emergency response and access by other trades.
Before starting:
- identify each coating, thinner, cleaner and preparation product; obtain current labels and safety data sheets (SDS)
- check the substrate and old coating for hazards created by sanding, grinding, stripping or heating
- consider whether a safer product or application method can remove or reduce the hazard
- choose a suitable booth, effective local exhaust ventilation or a controlled outdoor spray zone
- inspect hoses, couplings, gun guards, trigger locks, earth connections, extraction, filters and alarms
- remove or control ignition sources and coordinate hot work, electrical work and mobile plant
- plan spill, fire, first aid, decontamination, waste and cleaning arrangements
- confirm workers understand the equipment, controls, PPE, RPE and emergency steps.
For outdoor work, assess wind, temperature, openings, neighbouring work and where overspray may travel. Base the exclusion zone on the actual task and products.
What good controls and documents usually cover
Use the hierarchy of control: eliminate the spray task where reasonably practicable, or substitute a lower-risk product or process. For powder coating, check whether a TGIC-free product is readily available.
Engineering controls normally do the heavy lifting. Depending on the task, these may include a suitable booth, local exhaust ventilation, enclosed powder transfer, automated application, effective earthing, interlocks, guarding and mechanical handling. PPE and RPE support these controls and should be properly selected, fitted, maintained and stored.
A practical work pack commonly brings together the SDS set, chemical register where required, task risk assessment, operating procedure, plant checks, maintenance records, training evidence, emergency arrangements and any exposure or health-monitoring actions. Check controls during the job and review them after changes, faults, symptoms, spills or near misses.
Ongoing work with isocyanates may require health monitoring where there is a significant exposure risk. Confirm current local requirements and use the appropriate occupational health process.
When a SWMS or site-specific document commonly applies
Coating work does not by itself decide whether a SWMS is needed. On a construction project, check whether the wider activity falls within a high risk construction work category under the local rules. Where it does, prepare the SWMS before that work starts, coordinate it with project controls, communicate it to workers and follow it on site.
Where a SWMS is not triggered, a site-specific risk assessment, JSA or task procedure may still record the agreed controls. It should match the products, location, equipment, people and work interfaces.
Warning signs
Pause, isolate the area and review the controls if there is:
- mist, vapour or powder escaping the work zone, or an extraction alarm
- powder build-up, static shocks, damaged earth leads or unsuitable electrical equipment
- a leaking hose, blocked tip, missing guard or faulty trigger lock
- wind carrying overspray towards workers, the public, vehicles or openings
- wheezing, chest tightness, dizziness, headache, eye irritation or dermatitis
- a missing SDS, unknown decanted product, incorrect cartridges or poorly sealing RPE
- hot work, vehicles, tools or other trades entering the exclusion zone.
Do not restart until the cause is understood and effective controls are restored.
How Blue Safe helps
Blue Safe provides compliant WHS documents tailored to the client's activities, applicable Australian WHS/OHS requirements, jurisdiction and industry. Blue Safe guarantees the document compliance of the WHS documents it provides, including eligible customer documents after Blue Safe has reviewed and upgraded them.
Blue Safe can prepare or upgrade practical SWMS, risk assessments, procedures, hazardous chemical documents, registers and supporting site records. Customers actively put the compliant documents into practice through controls, consultation, training, actions, records and evidence.
Official sources
The Safe Work Australia Model Code is useful national orientation; it does not automatically apply as law in every jurisdiction. Local requirements vary, so check current regulator material and project rules for the place where work occurs.