Put yourself in this worker's shoes: You're given the job of applying chromium- and nickel-based thermal sprays at a temporary worksite. It's a two-day job. The ventilation is inadequate. You don't wear an appropriate respirator.

After the job, you develop a cough. Soon you're experiencing symptoms of fatigue and shortness of breath. A family member later finds you dead in your home. A post-mortem exam reveals that you died of lung damage consistent with toxic exposure.

This is a true story. It happened to an Oregon worker in 2003. The employer was cited for four OSHA violations: lack of an exposure assessment plan, improper respirator provided (worn incorrectly), overexposure to nickel, chromium and carbon monoxide and lack of engineering controls.

Don't let this happen at your jobsite. Here's how to protect workers performing thermal metal spraying operations.

The Hazards of Thermal Metal Spraying

Thermal metal spraying refers to the process of melting metals and spraying them on a surface to form a coating. The process is used for building-up worn parts and applying corrosion-resistant layers in industries such as automotive, marine, aerospace and transportation. Some of the associated hazards include:

• Exposure to toxic dust, gases, fumes and radiation.
• Being hit by the fast, hot spray.
• Exposure to toxic metal fumes and asphyxiating gases and fine metallic dusts, which can also explode.
• Damage to the skin and eyes from the ultraviolet and infrared radiation generated by the spray.
• Exposure to noise levels ranging from 88 to more than 130 decibels.

Take 5 Safety Measures

Before you assign a thermal metal spraying task, consult your spray material suppliers to ensure the equipment is being used according to recommended operating guidelines, and provide appropriate safety training for workers.

You should also assess the hazards and take appropriate precautions. These include:

1. Ensuring Adequate Ventilation

Local exhaust ventilation must be carefully designed to capture contaminants and remove them from the air. Conduct air-sampling tests to monitor workers' exposure to the contaminants.

2. Providing Appropriate Respiratory Protection

Your respiratory protection program should consist of several components, including proper selection, fitting, training and medical screening. Positive, air-supplied respirators are also recommended.

3. Providing Hearing Protection

Noise hazards can be addressed by supplying appropriate hearing protection devices, audiometric testing and monitoring.

4. Guarding Against Carbon Monoxide Poisoning

You can manage the risk of carbon monoxide poisoning by placing power generators outside the building in a well-ventilated area.

5. Protecting Against Exposure to Harmful Radiation

The hazards of radiation are easily dealt with through appropriate eye and skin protection as recommended by the equipment manufacturer.

Conclusion

In addition to these precautions, equip your workers with training that addresses other potential hazards associated with spraying toxic metals, including electric shock, fire and thermal burns.

Recall of Air Purifiers

This air purifier is a fire hazard.

The US Consumer Product Safety Commission has issued a warning about Perfect Air Ultra Air Purifiers, whose overheating capacitor can cause arcing in a connecting wire, posing the risk of a fire.

There have been six reports of incidents where the air purifiers have either melted or caught on fire. Units have also been returned that show evidence of melting or charring. Fortunately, no injuries have been reported.

The air filtration device is 12 inches high, 15 inches wide, 6 inches deep and has an outer casing made of white plastic. Consumers are advised to stop using the air purifier and to contact the retailer, Thane International, for more information.

Thane International can be reached toll-free at (800) 895.0986 anytime or by email at thane@ecustomerresponse.com.

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