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lural-component proportioning spray systems are usedthroughout the coatings industry for efficient, precise,and safe spray application of coating materials. These

systems come in many different configurations with variouscapabilities, but they all help a coating contractor save timeand materials while providing a quality application with min-imal environmental impact.The development of plur-

al-component spray systemsevolved with the emergenceof specialty multi-compo-nent coatings that requiredprecise proportioning com-bined with high applicationrates. Additionally, themovement toward high-solids and 100% solids coat-ing materials contributed tothe development of high-pressure systems capable ofpumping and spraying highly filled, viscous materials.Specifiers often call for these relatively new high and

100% solids high-performance coatings in structuresexposed to very corrosive environments. In many instances,the structures, such as chemical tanks,ballast tanks, pipelines, tunnels, man-holes, pumping stations, and sewers,can be confined spaces, which maypose unique hazards and require addi-tional protective measures for theworkers.While the use of plural-component

systems for applications in confinedspaces can reduce safety hazards,many variables can still have deadlyconsequences. Contractors using plur-al-component spray in permit-required confined spaces should focuson mitigating the hazards associatedwith confined spaces, equipment, coat-ing materials, and chemicals well before the work begins.Definitions of confined spaces and basic tips on safe use ofplural-component equipment and coatings follow. The article

P

Tips on Using Plural-Component Spray TechnologySafely in Confined Spaces

Maintenance Tip

does not replace the need for contractors to read and under-stand all regulations applicable to working in confinedspaces, nor does the article take the place of consulting coat-ing and equipment manufacturers about risks their productsmight pose.

Definitions: Confined SpacesThe definitions below come directly from theCode of Federal Regulations (CFR). Confinedspace work is regulated by 29 CFR 1910.146,which was promulgated by the OccupationalSafety and Health Administration (OSHA). Thestandard1 defines a confined space as one that islarge enough and so configured that an employeecan bodily enter and perform assigned work; haslimited or restricted means for entry or exit (forexample, tanks, vessels, silos, storage bins, hop-pers, vaults, and pits are spaces that may havelimited means of entry); and is not designed forcontinuous employee occupancy.

A permit-required confined space is a confined space thathas one or more of the following additional characteristics.• Contains or has a potential to contain a hazardous atmos-phere

• Contains a material thathas the potential forengulfing an entrant• Has an internal configu-ration such that anentrant could be trappedor asphyxiated byinwardly convergingwalls or by a floor whichslopes downward andtapers to a smaller cross-section• Contains any other rec-ognized serious safety orhealth hazardThus, regardless of the

project, working in confined spaces involves many healthand safety issues, none of which should be taken lightly. In

Continued

By Stephen Wierzchowski, RLS

Potable water tanks like this one can be confinedspaces and require special procedures, evenwith plural-component spray-applied epoxy.

All photos courtesy of RLS

Confined space procedures must be followedto rehabilitate this sanitary sewer manhole.

fact, according to a study from theNational Institute for OccupationalSafety and Health (NIOSH), confinedspace fatalities typically occur as aresult of encountering the followinghazards.2

• Lack of ventilation• Oxygen deficiency• Flammable or explosive atmosphere• Unexpected release of hazardousenergy• Limited entry and exit• Dangerous concentrations of air con-taminants• Physical barriers• Instability of stored productThe NIOSH report also suggests that

such incidents could have been prevent-ed by proper recognition of confinedspaces, atmospheric testing, evaluationand monitoring, and development of anappropriate emergency response plan.While the NIOSH report was written21 years ago, it is still relevant. Forexample, between September 2006 andOctober 2007, 13 citations were issuedto painting contractors for violating theconfined space standard, 1910.146.(See p. 65 of this issue.)29 CFR 1910.146 requires any con-

tractor or employer that owns or worksin confined spaces in general industryto appropriately designate and securethe confined spaces in the work place.This regulation also requires theemployer of the workers who will be ina confined space to prepare a writtenconfined space program that ensuresthe proper training and equipping ofpersonnel. Such a safety program needsto address many issues and should bedeveloped specifically for the opera-tions that may be encountered.

Working Safely with Plural-Component:Why and How

Working with plural-component spraysystems also poses several hazardsrelated to equipment, such as• electric distribution devices,• compressed air/hydraulic power

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Maintenance Tip

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systems,• high-pressure fluids and hoses,• pinch points (places where bodyparts can be pinched or severed) inmoving machinery, and• heating devices.

As with recognizing the hazards asso-ciated with confined spaces, the con-tractor’s safety personnel must recog-nize and appropriately mitigate the haz-ards associated with plural-componentspray equipment so that workers canthen conduct safe coating operations.Tell your equipment manufacturer howyou’ll be using the equipment, and askabout all potential hazardsit may pose.Equipment should be

designed and constructedto operate in the environ-ment in which it is to beused. Incorporation ofequipment rated for opera-tion in hazardous atmos-pheres should be a keyconsideration. Some per-mit-required confinedspaces may require equip-ment rated for use in ClassI, Division 1 or 2 environments.Utilizing extended lengths of hose toreach inside confined spaces can miti-gate some of the hazards related to plur-al-component equipment. This hose set-up reduces the likelihood of an equip-ment-related accident inside the workarea by keeping the equipment outside

the hazardous environment. However,it is not always possible to keep theequipment out of the confined space.Coating materials applied by plural-

component spray and ancillary chemi-cals such as reducing or cleaning sol-

vents may also pose hazards,especially when used in confinedspaces. Some coatings may havecomponents such as isocyanates,which require the use of special-ized respiratory protection equip-ment in addition to standard pro-tection from particulates.Solvent-borne coatings, includinghigh-solids coatings, contain flam-mable components that can behazardous during and after appli-cation.One additional concern not

commonly encountered is the haz-ardous polymerization of chemicals. Insome cases, the chemical reaction ofcoatings can create high exothermicheat, especially when the coating ismixed in mass (such as in waste pails) oris applied in thick layers. The heat itselffrom an exothermic reaction can be ahazard, can create toxic fumes, or can

displace oxygen from the atmosphere inthe confined space. The heat of the reac-tion can exceed 300 F, hot enough tomelt plastic waste pails. The exothermicreaction is associated more with high or100% solids coatings than with conven-tional coatings.

Continued

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Maintenance Tip

Plural-component spray system being lowered into shaftleading to water transmission tunnel. Safe practice is needed

even before work begins.

Plural-component spray equipment inside watertreatment structure prior to spray application.

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High-pressure plural-componentspray systems make it possible toreduce or totally remove solvents fromcoating systems, making application inconfined spaces safer and more efficientthan with conventional coatings.However, solvents may still be used to

purge and clean various components ofthe plural-component spray system,requiring applicators to take specialsafety precautions. Non-flammable syn-thetic solvents or plasticizers such asDOP (Dioctyl Phthalate) can be used topurge mixed coating materials fromequipment. Unfortunately, high cost orunder-performance may make non-flammable solvents less desirable thancommon and dangerous solvents suchas MEK or acetone. Regardless of thecleaning solvent selected, strict confor-mance with the equipment manufactur-er’s instructions for safe cleaning isessential.If flammable or combustible materi-

als are to be used in any confined space,the following precautions are amongthose that should be taken.• Hot work must not be performed inthe space or adjacent spaces.• Coatings, thinners, solvents, and usedsolvent rags must be properly stored.• Smoking and open flames must beprohibited.• Equipment that may generate staticelectricity must be grounded/bonded.• Ensure only properly rated equip-ment is utilized if hazardous atmos-pheres exist.• Adequate ventilation must be main-tained in storage, mixing, transfer, andapplication areas.• Frequently conducted atmospherictests may be required.• Suitable fire fighting equipment must

be immediately available.• Power and lighting cables must beinspected to evaluate electrical hazards.• Spills of solvents should be cleanedup immediately.Any of the above-mentioned hazards

can be dangerous at a regular job site,and they can be especial-ly dangerous in combina-tion with confinedspaces. Be sure to checkwith your manufacturerand safety personnelabout additional precau-

tions needed with the materials youhave purchased for a job.Well-written and properly imple-

mented safety programs address thehazards that personnel may encounterand should include reporting require-ments and disciplinary action for non-conformance. Programs should enablepersonnel to be capable of• recognizing and mitigating hazards,• testing and evaluating atmospheres,• monitoring the work space and sur-rounding environment, and• understanding and executing theemergency response plan.Implementing a plan that encompass-

es these objectives will greatly reducethe likelihood of accidents during coat-ing operations in confined spaces.

Always Havean Emergency Response Plan

However, even the best of programs can-not foresee every circumstance.Therefore, an emergency response plan iscritical and cannot be overvalued. Theability of workers to safely evacuate ahazardous environment and for rescuersto respond quickly when workers cannotescape on their own is directly propor-tional to the planning and communicationexecuted in preparation for a job.Emergency response plans should be

developed for each individual workarea and be specific to the existing andpotential hazards therein. Personnelshould have the means to evacuateCl

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Maintenance Tip

While plural-component coatingsmay contain no solvents, solvents

may still be needed to cleanthe spray equipment.

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Maintenance Tip

quickly and safely in more than onedirection. Properly trained andequipped rescue personnel should benotified of the operations before workbegins and be afforded the opportunityto be involved in developing the plan.Emergency plans should also be prac-ticed to familiarize personnel and toexpose any weakness in the plan.

Closing ThoughtsAlthough plural-component sprayequipment can improve efficiency andsafety in coating operations, it does noteliminate all hazards, especially in con-fined spaces. The hazards of confinedspaces increase the danger of any workenvironment and should not be under-estimated. Through careful planning,evaluation of hazards, development ofsound safety plans and communicationwith personnel and emergency servicesmany accidents can be prevented.Finally, before you use any coatingmaterials or equipment in a confinedspace, consult the manufacturers, safetypersonnel, and OSHA.Disclaimer: This article is not intend-

ed to be complete or to take the place oftraining in safe practice for plural-com-ponent spray in confined spaces.

References1. www.osha.gov2. Preventing Occupational Fatalities in

Confined Spaces, NIOSH ALERT:January 1986, DHHS (NIOSH)Publication No. 86-110

Stephen Wierzchowskiis the operations man-ager for RLS. RLS sellsRaven-branded 100%solids epoxies for theprotection and renewal

of municipal infrastructure, and man-ages the Raven Certified Applicator net-work. RLS also represents theAquataPoxy and CuraFlo Spincastbrands in the municipal market.

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