1.

Health and safety

PPE (Personal Protective Equipment’s)
To keep yourself safe during any residential or commercial painting project, you need the right
personal protective equipment (PPE):
 Gloves: Always wear gloves to protect your hands. Leather or cloth gloves are sufficient
for sanding. Solvent-resistant gloves are required for handling paint thinner and other
solvents. Impermeable gloves are best for
water- and oil-based paint.
 Eye wear: Use protective eye glasses, eye
goggles or a face shield whenever
handling paint or paint thinners. It is
especially important when painting above
your head or spray painting, as well as
when sanding.
 Paint masks: Wear a dust mask
or particulate respirator when sanding. If
you are very sensitive to chemicals, you
should also wear a respiratory mask when
using a brush or roller. Note that if you
are painting outside in an area with lots of
birds, you may need to wear a mask to
protect yourself from the harmful
pathogens in bird droppings. When you are spray painting, you are best advised to use a
paint respirator, as this offers more protection for your airways.
 Coveralls and shoe covers: A disposable or cotton coverall and disposable shoe
covers serve to protect both your clothing and any exposed skin that could become
irritated by contact with paint.
 Hard hat: If you are working at heights, a hard hat is a wise safety precaution, as it can
help protect your head if you fall. Additionally, if you are working on a busy construction
site, it will protect your head if an object falls on you.
 Fall arrest: A fall arrest system can consist of a single carabiner or double carabiner that
can be attached to a railing to prevent you from falling. It often comes with a harness
that straps around the torso and legs for added safety. Scaffolding may also be used in
some situations to prevent injuries from falls.
 Fire extinguisher: It is always important to keep a fire extinguisher on site in case there
are any incidents with flammable materials such as paint thinner.
VOC Compliance
During automotive painting, volatile organic compounds (VOCs) associated with the
paint solvents are emitted to the atmosphere. Most VOC emissions come from spraying
operations via the use of solvent-based paints, as the spray booth air picks up gaseous solvent
compounds and overspray paint materials. The VOCs consist of aromatic and aliphatic
hydrocarbons, ketones, esters, alcohols, and glycol ethers. Most VOCs (some hydrophilic VOCs
are captured and retained in the water.) are captured by an adsorption system and thermally
oxidized. In this paper, the processes involved in automotive painting and in VOC control are
reviewed. The topics include: painting operations (briefly), the nature of VOCs, VOC-control
processes (adsorption, absorption, biological removal, and thermal oxidation) and energy
recovery from VOCs using a fuel reformer and a fuel cell, and the beneficial use of paint sludge.

Current Practices in Painting Operations and VOC Control

 During typical painting operations (Fig. 1), metal vehicle bodies are initially put together,
washed to remove the materials (including oily materials) used to protect body parts against
corrosion and damage during stamping and transport, and treated with phosphating agents to
prepare the surface for coating. The cleaned and surface-treated bodies are then placed in a dip
tank where they are electrolytically coated with paint polymers, followed by a series of spraying
operations starting with primer, basecoat, and finally clear coat. The painted bodies are baked
in an oven to cure the coated paint materials. Most VOC emissions come from the spraying
operations.
The spraying operations take place in spray booths, which consist of a spraying section
and a water scrubber system, as shown in Fig. 2. During painting, overspray paint materials are
captured in the continuously recirculating scrubber water and stored in a sludge pit. The booth
air that comes out of the scrubber system goes through a filter house or wet electrostatic
precipitator to remove paint particulates that survived the scrubber. The VOCs in the exhaust
air may have to be removed, depending on the operating permit issued by the regulatory
agency, for which an adsorption process is most commonly used. The adsorption process
typically consists of two sets of absorbers: a sacrificial activated-carbon adsorber followed by a
fixed-or moving-bed adsorber. By desorbing the adsorbed VOCs, a concentrated stream of VOC-
laden air is produced and sent to a thermal oxidizer (RTO), where they are thermally oxidized.
The second set of the adsorber is typically a moving-bed system made of rotating adsorber
wheels. The exhaust air from the oxidizer, along with that from the adsorber, is emitted to the
atmosphere.
VOC Adsorption
As mentioned earlier (Fig. 2), the VOC-laden air from the scrubber goes through a
sacrificial-carbon adsorber, which is a fixed-bed system containing cartridges of pelletized
activated carbon. The carbon is called “sacrificial” because it is not designed to be regenerated,
but periodically replaced (a few years or longer) once it has become saturated with “heel”
compounds. The sacrificial carbon is used to:
1. Protect the more costly adsorber wheels that follow the trapping heel compounds,
which are relatively high boiling-point, irreversibly-adsorbing vocs, as well as
particulates that escape the preceding scrubber and filter systems,
 2. Moderate the voc concentrations in the incoming booth air by shaving peaks and valleys
of the fluctuating voc concentrations caused by the intermittent nature of painting
operations.
In other words, VOCs are adsorbed during the peaks and desorbed during the valleys.
Consequently, the VOC concentrations in the air from the sacrificial-carbon bed remain
relatively constant during normal operating conditions. The VOCs at this point are relatively
hydrophobic (e.g., hydrocarbons), because most hydrophilic VOCs (e.g., alcohols and glycol
ethers) are captured in the spray booth scrubber water, although some are slowly released by
stripping during non-painting periods.

Thermal Oxidation of VOCs

Regenerative RTOs are the most commonly used type in the automotive industry ,
which has two heat-storage sections, with a ceramic heat-transfer medium for recovering and
storing the heat liberated in the combustion chamber situated between the two heat-storage
sections. The desorbed VOC-laden air from an adsorber enters one of the two sections, is
heated via the heated medium, and sent to the combustion chamber, where the VOCs are
thermally oxidized with natural gas. The hot exhaust gas from the chamber enters the other
heat-storage section, where it heats the medium. Once the medium in the first heat-storage
section cools to a preset design temperature, the flow of air is reversed so that the VOC-laden
air enters the other section, section to become subsequently heated there this process
continues. The temperature in the combustion chamber is typically >650°C.

Booth air Recirculation

Recirculation of VOC-laden spray booth air has been used as an alternative to carbon
adsorption for increasing the VOC concentration in the air and; thus, reduce the air volume
requiring subsequent treatment via thermal oxidation or carbon adsorption. The recirculation
can only be used in automatic spraying sections, not in manual spraying sections, because of
the potential adverse health hazards associated with elevated VOC concentrations in the spray
booths of automatic sections, as well as the generally low VOC concentrations in spray booths
of the manual sections.

VOC Absorption
As mentioned earlier, the spray booth air first passes through a water scrubber, where
some of the VOCs are captured by absorption. However, the scrubber is typically designed to
capture overspray paint materials, but not VOCs. Therefore, the captured VOCs are eventually
stripped during non-painting periods, which is dependent on the Henry’s law constants of the
VOCs. The Henry’s law constants of paint solvents typically ranges from 6,000 atm cm3 /mol,
for toluene, to approximately 0.003 atm cm3 /mol for n-methyl-2-pyrrolidinone [7].
Hydrocarbons, such as toluene, can be stripped in a few minutes; whereas, glycol ethers, such
as butyl cello solve and butyl carbitol, and amino ketones, such as n-methyl-2-pyrrolidinone,
can remain with water for a sustained period of time, even with vigorous mixing.
 2. Chemical Safety
Introduction to Paints
Paint is used to decorate, protect and prolong the life of natural and synthetic materials,
and acts as a barrier against environmental conditions.
Paints may be broadly classified into Decorative paints, applied on site to decorate and
protect buildings and other objects, and Industrial coatings which are applied in factories to
finish manufactured goods such as cars.

The constituents of paint

Paints contain:

 Pigment(s) - prime pigments to impart

colour and opacity
 Binder (resin) - a polymer, often referred
to as resin, forming a matrix to hold the
pigment in place
 Extender - larger pigment particles added
to improve adhesion, strengthen the film
and save binder
 Solvent (sometimes called a thinner) -
either an organic solvent or water is used
to reduce the viscosity of the paint for
better application. Water-borne paints
are replacing some paints that use
volatile organic compounds such as the
hydrocarbons which are harmful to the
atmosphere.
 Additives - used to modify the properties
of the liquid paint or dry film

The binder (resin) and solvent together

are sometimes known as the vehicle. The
binder may be dissolved as a solution or
carried as a dispersion of microscopically small
particles in a liquid.
Depending on the type of paint and intended
use, additives may include:

 Dispersants - to separate and stabilize

pigment particles
 Silicones - to improve weather resistance
  Thixotropic agents - to give paints a jelly-like consistency that breaks down to a liquid
when stirred or when a brush is dipped into it
 Driers - to accelerate drying time
 Anti-settling agents - to prevent pigment settling
 Bactericides - to preserve water based paints in the can
 Fungicides and algaecides - to protect exterior paint films against disfigurement from
moulds, algae and lichen

Paints are formulated according to their proposed use - primer, undercoat, special
finishes (matt, gloss, heat resistance, anti-corrosion, abrasion resistance). The pigment powder
is broken down into individual particles which are coated by and dispersed in the binder (resin)
- known as 'wetting out'. Solvent is then added to give the required consistency. Each batch of
ingredients is thoroughly mixed in large, stirred containers with the required additives (Fig.).
Amounts ranging up to 40 000 dm3 of paint may be made in a single batch.

Binders in paints

The three most important binders (resins) used in modern paints are:

 acrylic polymers (resins)

 alkyd polymers (resins)
 epoxy polymers (resins)

Health and safety hazards for painters include:

 Exposure to paint products, solvents, lead, and other toxic chemicals.

 Toxic effects to multiple organ systems, including neuropathy and cardiac/kidney injury.
 Lung cancer, leukemia, lymphoma, multiple myeloma, and others cancers.
 The International Agency for Research on Cancer (IARC) classifies painting as a carcinogenic
occupation.
 Exposure to toxic molds, fungi and bacteria with resultant risks of infectious disease.
 Flammability hazards from paints and solvents.
 Working at heights and on ladders, platforms and scaffolds, with attendant risks of falls.
 Working in confined spaces.
 Risks of eye injury.
 Slips, trips and falls, and risk of injury from falling objects.
 Working in awkward positions or performing repetitive physical tasks.
 Standing for long periods of time.
 Lifting heavy or awkward objects.
 Exposure to heat and ultraviolet radiation from work outdoors.
 Exposure to noise with risk of resultant hearing loss and impairment.
 Stress and increased risk of injury and disease from shift work or extended work days.
The main routes of entry of the chemicals into the human body are:

 Inhalation into lungs.

 Absorption through skin membrane/cuts in the skin.
 Ingestion via mouth into the gastrointestinal system.

Corrosives
• Corrosive substances causes destructive burns on the tissue by chemical action at the site of
contact. • Corrosive effect can also occur in the respiratory tract in case of inhalation and in the
gastrointestinal tract in case of ingestion. • Typical examples are sulfuric acid, nitric acid,
potassium hydroxide (caustic potash), sodium hydroxide (caustic soda), bromine and phenol.

Oxidisers
• Oxidisers are chemicals which decompose readily under certain conditions to yield oxygen.
• They can cause a fire to burn violently.
• Oxidisers must not be stored with flammables.
• Typical examples include hydrogen peroxide, nitric acid, perchloric acid , sulphuric acid,
chlorates, chromates, nitrates, peroxides, permanganates and picrate’s .

Flammables
• The vapours released from a flammable liquid are a common fire hazard in a laboratory.
• The degree of hazard associated with a flammable liquid depends on its flash point,
flammability limit and ignition temperature.
• Flammable substances are those that readily catch fire and burn in air.

Potentially explosive chemicals

• Chemicals when subjected to heat, impact, or friction, undergoes rapid chemical change,
evolving large volumes of gases which cause sudden increase in pressure.
• Heat, light, mechanical shock and certain catalysts can initiate explosive reactions.
• Shock sensitive substances include acetylides, azides, nitrogen triiodide, organic nitrates,
nitro compounds, perchlorate salts and organic peroxides.
•Perchloric acid, if allowed to dry on wood or other combustibles, will explode and cause a fire
on impact or friction.
• Picric acid and picrate’s are detonated by heat and impact.
• Ethers that have aged and dried to crystals are extremely unstable and potentially explosive.
Toxic chemicals
• Toxic chemicals produce injurious or lethal effects upon contact with body cells due to their
chemical properties.
• The toxic effects depend upon the extent of exposure and the inherent toxicity of a chemical.
• The extent of exposure is determined by the dose, duration and frequency of exposure and
the route of exposure.
•Toxic effects of a chemical may occur after a single (acute) exposure or long term repeated (chronic)
exposure.

• Examples of acute toxins are sodium cyanide, sodium azide and dimethyl mercury.

• Benzene is an example of a chronic toxin which can cause damage after repeated or long term
exposure.

Safe handling
Establish the procedure to receipt, storage, handle the chemicals, paint and thinner used at various
processes safely and avoid spillage & dispose without polluting the Environment.

SCOPE: Applicable for all the activities relating to handling & storage of chemicals.

RESPONSIBILITY: All departments

INSTRUCTIONS / PROCEDURE:

 Before using the chemicals check for the supply of MSDS from the supplier for all the chemicals
purchased.

 In case of any spillage of chemicals apply sand and clean. Contaminated sand disposed to
hazardous waste.

 Keep the leaked / spilled / damaged chemical in isolated area with the provision of secondary
containment to avoid land contamination.
  Do not handle the chemical by bare hands. Use appropriate PPE’s during handling the chemicals.

 The chemical consumption should be monitor in regular basis and the record should be
maintained & updated

 Do not keep empty chemicals cans, containers & drums outside the department and in open
condition.

 All the empty chemicals cans, drums & containers should be disposed off to the waste storage
yard.

 In case of any spillage the same should be cleaned as per the MSDS procedures, the generated
waste should be disposed to the hazardous waste storage.

 Check the use of gloves, masks, safety shoes, caps, aprons & spectacles wherever necessary.

 Check the chemicals are stored in area free from potential source of ignition or fire to avoid fire
accident.

 Ensure the chemical storage area is always well ventilated.

 Check all the key hazardous chemicals MSDS is displayed in chemical storage.

PERSONAL PROTECTIVE EQUIPMENTS:

 Gloves, masks, safety shoes, Eyewash, Apron, Goggles.

IMPACT IN CASE OF DEVIATION:

 Land Contamination.

CORRECTIVE ACTION IN CASE OF DEVIATION:

 In case of minor spillage, clean up the area and dispose the waste in safe manner immediately.

 In case of accidental contact, refer MSDS, provide first aid and seek medical advice.
3. Cleaning
 4. Pre-Treatment
Chemical Pretreatment also known as bond rising on sheet metal or conversion coating.
Pretreatment is required to ensure bonding between metal and paint.
Zinc phosphate pretreatment coating is commonly used for sheet metal component
Pretreatment required for three purposes.
1. Provide corrosion protection.
2. Bonding or adhesion between sheet metal and paint.
3. Improve the life of paint.
3Types of Chemical pretreatment on sheet metals
1. Wiping sheet metal with 3 in 1 solution to remove dust, oil, grease and flash rust.
2. 7 stage dipping PT process, to remove dust, oil, grease, rust and with zinc phosphate
conversion coating.
3. 11 stage spray pretreatment process to remove dust, oil, rust and with uniform zinc
phosphate coating.
Mechanical pretreatment
3 types of Mechanical pretreatment on sheet metals (blasting)

1. Sa2(metal grit size) thorough blast cleaning( surface shall be free from visible oils, grease
and dirt)
2. Sand blasting (surface shall be free from visible oil, grease and dirt)
3. Sa3(metal grit size) Blast cleaning to visually clean steel(it shall have a uniform metallic
colour)

Stage wise dipping pt. process

1. Pre degreasing 50 degrees 60 sec alkaline with surfactants
2. Degreasing 50 degrees 180 sec alkaline with surfactants.
3. Water rise RT 60 sec raw water
4. De rusting RT 60sec Strong acids
5. water rinse RT 60Sec Raw water
6. Zn Phosphating 50 degrees 180sec Acids
7. water rinse RT 60 sec Raw water
 5. Coatings
PURPOSE: Coating is required to avoid corrosion on sheet metals and to ensure long lasting.
After ensuring chemical conversion coating on sheet metals by way of chemical
pretreatment/mechanical way of pretreatment, we have to give paint coating to protect sheet
metal for long lasting from corrosion. (Corrosion due to environment)
Fallowing Parameters influence the corrosion,
Humidity, temperatures, concentration of salts, air pollution, dust and acid rain.
To avoid influence of corrosion on pretreated sheet metal we have to give protective coating.
Types of coatings
1. Powder coating
2. Wet paint process
Initially we will go through powder coating on sheet metal components.
PERSONAL PROTECTIVE EQUIPMENTS:

 Safety shoes, PVC hand gloves and safety goggles.

IMPACT IN CASE OF DEVIATION:

 Injuries
CORRECTIVE ACTION IN CASE OF DEVIATION:

 Effective training and advice should be given

 6. Powder coating process
Powder coating is a type of coating that is applied as a free-flowing, dry powder. The
main difference between a conventional liquid paint and a powder coating is that the powder
coating does not require a solvent to keep the binder and filler parts in a liquid suspension
form. The coating is typically applied electrostatically and is then cured under heat to allow it to
flow and form a "skin". The powder may be a thermoplastic or a thermoset polymer. It is
usually used to create a hard finish that is tougher than conventional paint. Powder coating is
mainly used for coating of metals, such as household appliances, aluminium extrusions,
and automobile and bicycle parts.
Powder Coating Process

 Maintain a clean & dust free atmosphere and work area. Ensure that the gun and booth
are clean before commencing work.
 Inspect work area; eliminate possibilities of accumulated dirt on roofing structures and
other equipment from blowing or falling on work place.
 Do not mix powders from two different suppliers / manufacturers.
Careful attention should be given to having clean, dry, oil free compressed air supply, at
the recommended pressure. Periodically drain off water from the compressor tank and
flush the airline dry.
 Clean sieved reclaimed powder should be mixed in small proportionate quantities, as the
work progresses, and not allowed to accumulate and collect the dirt and moisture.
 Always store powder in a closed sealed container and in a cool and dry place. The
powder should not be left in the equipment for long periods when not being used.
5Good earthing of job and equipment are very essential.
Check that the pre-treatment chemicals are in good condition and of the correct
strength. Remove the sludge accumulated at the bottom of the tanks.
 Give due attention to surface pre-treatment of piece.
Characteristics of Powder Coating
Powder coating are finely divided particle of pigment, resin and additives.
1. Application is done electrostatically sprayed on metallic surfaces.
2. On baking they melt into a continuous film and cured in to thin film.
3. Uniform coating.
4. Higher mechanical and chemical resistance.
5. Low energy requirement.
6. One coat application.
7. High efficiency.
8. Minimum wastage of powder during application.
Types of Powder
There are two main categories of powder coatings:
1. Thermosets.
2. Thermoplastics.
The thermosetting variety incorporates a cross-linker into the formulation. When the powder is
baked, it reacts with other chemical groups in the powder to polymerize, improving the
performance properties. The thermoplastic variety does not undergo any addition actions
during the baking process, but rather only flows out into the final coating.
The most common polymers used are----
1. Polyester,
2. Polyurethane,
3. Polyester-epoxy (known as hybrid),
4. Straight epoxy (fusion bonded epoxy)
5. Acrylics.
Formulation and Production:
The polymer granules are mixed with hardener, pigments and other powder ingredients in a
mixer
The mixture is heated in an extruder
The extruded mixture is rolled flat, cooled and broken into small chips
The chips are milled and sieved to make a fine powder

Formulation of Powder
The basic formula of any powder
1. Pigment –
• inorganic pigment
• Organic pigment.
• Extender
• Metallic pigment.
2. Solid resin-
• Epoxy
• Pure polyester
• Hybrid
• acrylic
3. Additives –
• Anti-cissing
• Anti-caking agent
• Matting agent
Epoxy Powders
These are general purpose coatings where a limited amount of exposure to sunlight is
experienced. They have all round generally good properties. The coating has slight orange peel.
Most glossy finishes are based on this.
Epoxy-polyester powder coatings are based on a combination of polyester and epoxy resins.
Formula of epoxy powder.
Titanium oxide - 12 %
Barium sulfate - 22%
Violet pigment - 01 %
Epoxy resin - 30%
Polyester resin - 30%
Anti-cissing agent - 01%
Anti-caking agent - 02%
Wetting &dispersing agent -1%
Plasticizer -1%
Epoxy Polyester Powder
These are general purpose coatings where a limited amount of exposure to sunlight is
experienced. They have all round generally good properties. The coating has slight orange peel.
Most glossy finishes are based on this.
Epoxy-polyester powder coatings are based on a combination of polyester and epoxy resins.
Formula of epoxy powder.
Titanium oxide - 12 %
Barium sulfate - 22%
Violet pigment - 01 %
Epoxy resin - 30%
Polyester resin - 30%
Anti-cissing agent - 01%
Anti-caking agent - 02%
Wetting &dispersing agent - 1%
Plasticizer - 1%
Pure Polyester Powder
Pure Polyester powders are good for outdoor use where considerable amount of
sunlight is present. They have good weathering and mechanical properties and resistance to
over baking. The surface finish has higher orange peel. TGIC is used as a hardener. It is used for
glossy and semi glossy finishes.
Formula of powder.
Titanium oxide - 08%
Barium sulfate - 20%
Yellow pigment - 07 %
Polyester resin - 60%
Anti-cissing agent - 01%
Anti-caking agent - 02%
Wetting &dispersing agent -1%
Plasticizer -1%

Process Flow
Coveyorised spray pretreatment process introduced to achieve following
advantages
 To enhance the production as per time and conveyor speed.

 To achieve uniform phosphate coating in all areas.

 To reach quality parameters after painting.

 To get strong bonding between sheet metal and paint film.

 To achieve less sludge.

 Systematic way to achieve production.

 Less carry over from stage wise.

 No spillage of chemicals.

 Operator friendly process.

 Close circuit process to avoid gases in working area.

 It is continuous process.

 Less water required.

Disadvantages of Coveyorised spray pretreatment process

 Conveyor oil dripping.
 Conveyor should not stop during process.
 Water quality important to achieve uniform coating.
 Phosphate bath circulation continuously through filter press.
 Heavy oils on sheet metal cannot dissolve.
 Rust patches not allowed.
 Hard water not allowed.
 Collection of phosphate sludge from filter press in time bound process.
 Ensure no spillage of Phosphate bath sludge.
7. Wet Paint Process
8. Test Procedure
9. Chemicals and Paints
10.Abrasives and Spray Guns
11.Mechanical Processes
12.Practical
13.Defect Analysis
14.Paint Spraying Techniques
15.Light and Quality
16.Practical
17.Automotive Coating Process
18.Preparation for painting
19.Application of primers
20.Base & Ground coat application
21.Clear coat application
22.Colour Evaluation and Adjustment
23.Painting non-metal parts
24.Advanced & Futuristic Painting Techniques
25.Tinkering and Painting
26.Coating Defects and Coating Quality