for fire safety inpaint sprayingprocesses(excludingautomotiverefinishing)
RC32
I ' Fi R h S f di h
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RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
First published byFire Protection AssociationLondon RoadMoreton in MarshGloucestershire GL56 0RH
Tel: +44 (0)1608 812500 Fax: +44 (0)1608 812501E-mail: [email protected] Website: www.thefpa.co.uk
2008 © The Fire Protection Association, on behalf ofInsurers’ Fire Research Strategy
Copies of this document may be obtained from thepublications department of the FPA, at the aboveaddress.
Printed by Alden Press 0.9/07.08
Front cover image © mjl84 - Fotolia.com
LOSS PREVENTION RECOMMENDATIONS
The aim of the FPA series of Recommendations is toprovide loss prevention guidance for industrial andcommercial premises and systems. The series continues along tradition of providing authoritative guidance on lossprevention issues started by the Fire Offices’ Committee(FOC) of the British insurance industry more than ahundred years ago and builds upon earlier publicationsfrom the Loss Prevention Council and the Association ofBritish Insurers.
Lists of other publications on loss control including otherdocuments in the RC series are available atwww.thefpa.co.uk and from the FPA at London Road,Moreton in Marsh, Gloucestershire GL56 0RH. Copies of publications can be downloaded free of charge from www.fpadownloads.co.uk or purchased from the FPA by calling +44 (0)1608 812500 or [email protected].
Technical contact:
Adair Lewis
Email: [email protected]
IMPORTANT NOTICE
Insurers’ Fire Research Strategy scheme (InFiReS) membershipcomprises a group of UK insurers that actively support a number ofexpert working groups developing and promulgating best practice forthe protection of people, property, business and the environmentfrom loss due to fire and other risks. The technical expertise for thisdocument has been provided by the Technical Directorate of the FireProtection Association (FPA), external consultants, and experts fromthe insurance industry who together form the various InFiReSSteering Groups. Although produced with insurer input it does not(and is not intended to) represent a pan-insurer perspective.Individual insurance companies will have their own requirementswhich may be different from or not reflected in the content of thisdocument.
The FPA have made extensive efforts to check the accuracy of theinformation and advice contained in this document and it is believedto be accurate at the time of printing. However, the FPA make noguarantee, representation or warranty (express or implied) as to theaccuracy or completeness of any information or advice contained inthis document. All advice and recommendations are presented ingood faith on the basis of information, knowledge and technology asat the date of publication of this document.
Without prejudice to the generality of the foregoing, the FPA makeno guarantee, representation or warranty (express or implied) thatthis document considers all systems, equipment and procedures orstate of the art technologies current at the date of this document.
Use of, or reliance upon, this document or any part of its content isvoluntary and is at the user’s own risk. Anyone considering using orimplementing any recommendation or advice within this documentshould rely on his or her own personal judgement or, as appropriate,seek the advice of a competent professional and rely on thatprofessional’s advice. Nothing in this document replaces or excludes(nor is intended to replace or exclude) entirely or in part mandatoryand/or legal requirements howsoever arising (including withoutprejudice to the generality of the foregoing any such requirements formaintaining health and safety in the workplace).
Except to the extent that it is unlawful to exclude any liability, theFPA accept no liability whatsoever for any direct, indirect orconsequential loss or damage arising in any way from the publicationof this document or any part of it or any use of or reliance placed onthe content of this document or any part of it.
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CONTENTS
Scope 3
Synopsis 3
Definitions 3
Introduction 4
Recommendations
1. General 5
2. Ventilation 5
3. Ignition 6
4. Containment 8
5. Exchange 8
6. Separation 8
7. Housekeeping 9
8. Maintenance 10
9. Fire protection 10
10. Fire safety management 10
11. Powder coating 10
12. Checklist 12
References 22
Further reading 22
SCOPE
These Recommendations concern the key aspects ofproperty protection in processes involving the sprayingof paint and similar surface treatments using powdersand flammable or highly flammable liquids, withsubsequent stoving and curing. Many of theseRecommendations may apply equally to other coatingprocesses such as dipping, roller or flow coating, andfluidised bed coating. Automotive refinishing processesare excluded; these are addressed in RC31 (ref. 1).
Guidance is limited to ways in which the hazards of fireand explosion initiation and spread may be reduced to aminimum. Some liquids, vapours and dusts may betoxic or irritants, when extra precautions to those givenin these Recommendations may be necessary (see, forexample, ref. 2).
For further information relating to life safety issues andfire safety regulations, the Health and Safety Executiveor the local fire authority should be consulted.
SYNOPSIS
These Recommendations provide guidance for thosemanaging and undertaking spraying processes,including powder treatments, in premises other thanthose where automotive refinishing is carried out. Theneed for the DSEAR ‘VICES’ acronym to be appliedand suitable fire protection measures to be provided areemphasised, together with the importance of aneffective fire safety management regime.
DEFINITIONS
Classification of hazardous areas
(BS EN 60079-10: 2003) (ref. 3)
(This classification refers to areas in which openprocesses are carried out. Areas in which closedprocesses are undertaken should be subject to a riskassessment.)
Zone 0: An area in which an explosive gas atmosphereis present continuously or for long periods.
Such zones are uncommon, but include the interior ofextract ductwork (where there may be gassing off fromdeposited solids, particularly just after switching off thefan on completion of work).
Zone 1: An area in which an explosive gas atmosphereis likely to occur in normal operation.
Such zones should include:
(a) the interior of a spray booth; and
(b) within 2m horizontally around any source offlammable vapour and vertically upwards from thefloor to 1m above the source, over the whole 2mhorizontal radius.
In zones where there are many vapour sources, it isrecommended that the whole zone from floor level upto 1m above the highest source be designated Zone 1 toallow flexibility in rearranging plant and simplifying
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INTRODUCTION
The dusts and vapours that are evolved during thespraying process and the flammable nature of the solidresidues may present serious fire and explosion hazards.Deposits of material used in the processes may besusceptible to spontaneous heating, particularly if severallayers of deposits are allowed to build up over time.
Drying, baking and curing processes often involve theuse of heaters and ovens, which present additional fireand explosion hazards.
Flammable liquids fall within the definition of a‘dangerous substance’ as defined in the DangerousSubstances and Explosive Atmospheres Regulations2002 (DSEAR) (ref. 4). Therefore, if flammable solventsor paints are used, this legislation will apply and asuitable and sufficient assessment of the hazardsassociated with these materials has to be undertaken.
Where an explosive atmosphere may occur, theworkplace must be classified into zones based on thefrequency and duration of the explosive atmosphere (seeBS EN 60079-10: 2003, ref. 3) and the zones checkedby a competent person.
It is a legal requirement for employers to carry out anassessment of the risk from fire to their employees,visitors and other ‘relevant persons’ in compliance withthe Regulatory Reform (Fire Safety) Order 2005 and theequivalent legislation in Scotland and Northern Ireland(refs 6 to 9). As a result, the ‘responsible person’ for firesafety in the premises for the purposes of the Ordermust make a suitable and sufficient assessment of therisks to which relevant persons are exposed for thepurpose of identifying the general fire precautions toensure the safety of both employees and non-employeesin and about the premises.
The assessment process must be reviewed if it issuspected that it is no longer valid or when changes havebeen made to the layout of the premises, the processescarried out, the amounts or types of hazardoussubstances present or the number and character of thepeople who may be present. The insurers of the businesswill often be able to offer assistance with this process.
As fire safety legislation is only concerned with life safetyissues, it is recommended that when the fire riskassessment process is carried out, consideration mustalso be given to an assessment of the risks to thebuilding, its contents and the continuing smoothrunning of business operations.
The fire risk assessment should thus identify plant thatis essential to the business but may be unique or difficultto replace. Equipment of high intrinsic value should alsobe identified. An action plan should be prepared toreduce the risk of damage from fire to such equipmentor installations and a suitable contingency plan shouldbe prepared. Further guidance on the preparation ofsuch a plan can be found in Business resilience. A guide toprotecting your business and its people (ref. 10).
maintenance. This would include paint kitchens/mixingareas and paint shops containing several booths.
Zone 2: An area in which an explosive gas atmosphere isnot likely to occur in normal operation. If it does occur,is likely to do so only infrequently and will exist for ashort period only.
Such zones include:
(a) a further horizontal zone extending 2m beyondthe Zone 1 above, and from floor level up to theheight of the Zone 1 or 3m minimum; and
(b) store rooms containing sealed tins of paint (anystore room containing open tins, or wherecontainers are opened, should be Zone 1).
Zone 20: A place in which an explosive atmosphere inthe form of a cloud of combustible dust in air is presentcontinuously, for long periods or frequently.
Zone 21: A place in which an explosive atmosphere inthe form of a cloud of combustible dust in air is likely tooccur in normal operation occasionally.
Zone 22: A place in which an explosive atmosphere inthe form of a cloud of combustible dust in air is notlikely to occur in normal operation but, if it does occur,will persist for a short period only.
Explosive Limits
(BS EN 60079-10: 2003) (ref. 3)
Lower explosive limit (LEL): The concentration offlammable gas or vapour in air, below which the gasatmosphere is not explosive.
Upper explosive limit (UEL): The concentration offlammable gas or vapour in air, above which the gasatmosphere is not explosive.
Fire resistance
In this document, fire resistance refers to the materialproperties of both insulation and integrity.
Flammable liquid
A liquid (etc) as defined below for highly flammableliquid but with a flashpoint up to 55°C.
Highly flammable liquid
The definition of ‘highly flammable liquid’ in DSEAR2002 (ref. 4) is as follows:
‘Highly flammable liquid’ means any liquid, liquidsolution, emulsion or suspension, other than aqueousammonia, liquefied flammable gas, and liquefiedpetroleum gas which:
(a) when tested in accordance with Part A.9 of theAnnex to the Directive has a flashpoint ofless than 32°C; and
(b) when tested at 50°C using the procedure referredto in Appendix B to the ‘Approvedrequirements and test methods for theclassification and packaging of dangerousgoods for carriage’ (ref. 5) with a heatingtime of 60 seconds supports combustion.
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Other legislation may impose additional requirementsto the provisions contained within this document (seerefs 11 and 12). Due regard should also be given toenvironmental protection, particularly the disposal ofwaste solvents and solid residues.
To reduce the fire hazards on the premises, attentionshould always be given to the possibility of replacingflammable liquids with non-flammable liquids or, atleast, with those having a flashpoint above 55°C.
RECOMMENDATIONS
1. General
1.1 Wherever potentially hazardous materials arestored or used, a list of the substances presentshould be maintained, along with details of theirquantities and locations, as required in theCOSHH Regulations (ref. 12). These detailsshould be readily available for use by the firebrigade.
1.2 The HSE guidance in booklet HS (G) 51 (ref. 13)suggests the use of the acronym VICES to helpapply five basic principles which ensure that anyflammable or highly flammable liquid is used andstored with appropriate care.
The acronym may be explained as follows:
V Ventilation (see section 2)
• Is there sufficient ventilation to keep theconcentration of the liquid’s vapour below itslower explosive limit?
I Ignition (see section 3)
• Have all possible ignition sources beenremoved?
• Is the electrical and heating equipment usedin this area suited to the risk category?
C Containment (see section 4)
• Are the liquids stored in suitable containers?
• Is only the minimum quantity for the workperiod kept in the workplace?
• Is explosion relief provided?
E Exchange (see section 5)
• Can flammable substances be eliminated?
• Can the substance be replaced by a lessflammable one?
S Separation (see section 6)
• Is the storage of liquids separated from otherstored materials?
• Is the area where the liquids are usedadequately separated from those used forother purposes?
• Are physical barriers (examples might bewalls, doors, cabinets and bins) present asrequired?
1.3 Suitable staff training should be in place to ensureall personnel are aware of the hazards in theworkplace and apply VICES to ensure a saferworking environment for all.
1.4 Additional guidance on the application of VICESto the storage and use of flammable liquids is setout in RC20: Parts 1 and 2 (refs 14 and 15)
2. Ventilation
2.1 Flammable vapours and paint overspray should beremoved from the process area by means ofadequate mechanical ventilation at low level,preferably having free discharge direct to the openair. Only clean air should be used to replenish airsupplies and sufficient inlets should be provided ata high level. Inlets should be positioned so as toprovide a cross flow.
2.2 Exhaust ducts should not have sharp bends orledges and should preferably be taken directly tothe open air through an external wall or the roof.Any ducts that pass through other parts ofbuildings should have a minimum fire resistanceof 30 minutes, or other appropriate level tomaintain the fire integrity of the buildingcompartment.
2.3 The points of discharge of vapours should be sitedwell clear of both potential ignition sources andentry points to buildings. Controls on dust andvapour emissions may be required by theprovisions of various environmental protectionlegislation (refs 16 to 21).
2.4 There should be a separate ventilation fan andduct for each booth. Motors should not be locatedwithin the ductwork.
2.5 Fans and ducts should be accessible for cleaning,with access hatches provided at ductwork bends.Cleaning should be carried out regularly,following an assessment of the build-up ofdeposits. The deposits will be readily combustibleand care is necessary in removal and storage. Non-metallic scrapers should be used. The build-up ofdeposits in filters has been known to cause firesand thus filters should be regularly cleaned and/orreplaced, as appropriate.
Deposits should be collected and disposed of inaccordance with environmental regulations. See‘Waste Materials’ below (sections 6.12 to 6.16).
2.6 Fans should be started at least two minutes beforethe process commences and should continue for atleast five minutes after the process has ceased.
2.7 If an automatic timer is used, means of immediateshutdown should be provided for emergency use.
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2.8 An airflow or differential pressure switch whichmonitors the flow of air should be provided in theinlet or exhaust duct and maintained at the settingdetermined by the COSHH assessment (see ref.12). The switch should be interlocked with theelectrical supply if the unit is electrically heated,or otherwise with the fuel supply to the burnerand to an audible alarm. The interlock shouldhave manual reset facilities.
2.9 Adequate ventilation should be provided bymechanical means to prevent concentrations ofvapour or dust approaching the lower flammablelimit. The degree of ventilation required willdepend on the properties of the materials, thequantities used, the location of the work and thetype of process in use. The ventilation willnormally be designed taking into account theresults of the COSHH assessment (see ref. 12). Itis normally deemed sufficient if the vapourconcentration does not exceed 25% of the lowerexplosive/flammable limit (LEL).
2.10 The use of water-wash or water-backed booths is recommended for removing airborne residuesand vapours.
2.11 When spraying is performed outside a booth,flammable liquids are exposed during transfer, or coated objects are air dried, sufficientventilation should be provided to ensure theflammable vapour concentrations do not exceed25% of the lower explosion limit (LEL) in anypart of the room.
3. Ignition
3.1 All sources of ignition such as naked flames, hotsurfaces and unprotected electrical equipmentshould be excluded. In particular, welding andother forms of hot work must not be undertakenin or in the immediate vicinity of the sprayingfacilities.
Heating
3.2 The spraying or storage area may be heated by:
3.2.1 A heating system providing ducted warm air orsupplying hot water or steam to pipes andradiators. The system should incorporate a heatexchanger, so as to prevent flammable vapoursfrom coming into contact with an ignition source.
Any furnace or heat exchanger should besegregated and located outside the process area, inthe open, or in a separate building of brick orconcrete construction with a fire-resisting self-closing door to each opening. Combustionproducts should be exhausted to the open, clear ofwindows or other openings.
Hot water or steam should circulate at atemperature not exceeding 120°C.
3.2.2 Electrical heaters of the low temperatureflameproof type, certificated for the use. Thetemperature of the external surface of such heatersshould not exceed 120°C and they should belocated where they are unlikely to receive paintdeposits from overspray etc.
3.2.3 Electric under-floor or ceiling heating withheating elements totally embedded in concrete.
Booth temperatures
3.3 Operating temperatures should be controlled bythermostats, interlocked with the heating source,to prevent the temperature rising above the design level.
3.4 The possibility of the temperature overshootingthe set point should not be ignored. Thus the ovenshould be equipped with a separate high-temperature limit control, of the non-self-resetting type.
3.5 Drying/curing times should be restricted by theuse of automatic timing devices.
3.6 All combustion units should be fitted with flamefailure devices.
3.7 Automatic fire safety valves should be fitted toshut off the fuel supply in the event of fire.
Electrical equipment
3.8 An assessment of the work areas and storage areasshould be carried out, and appropriate ‘zones’assigned in accordance with BS 60079-10 (ref. 3).Expert advice may need to be sought for thisassessment. Certified explosion-protectedelectrical apparatus and cabling appropriate forthe relevant zones should then be selected.
3.9 When flammable liquids or dusts are present,although control measures are taken to minimisetheir uncontrolled release as far as is reasonablypracticable, there will always remain thepossibility of an explosive/flammable atmosphereforming. In such ‘hazardous areas’, all sources ofignition, including those associated with electricalsparks or hot surfaces of electrical apparatus,should be excluded or protected. Hazardous areasare classified into zones as described in thedefinitions section above.
3.10 Should it be necessary to use electrical apparatus(including wiring) in hazardous areas, it isimperative that it is suitably explosion-protected,with the degree of protection selected according toits probability of being exposed to a flammableatmosphere.
Additional advice is contained inRecommendations for the selection of electrical andnon-electrical equipment for use in atmospherescontaining flammable and explosive gases or vapours(ref. 22).
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3.11 All fixed containers, pipe work, mixers and otherequipment should be electrically bonded andearthed.
3.12 Flexible leads should be provided to bond portableor mobile containers during mixing, filling ordischarging operations when static electricity islikely to be generated.
3.13 Portable lights or electrical equipment shall beprohibited, unless it is suitable to operate withinthe appropriate zone.
Smoking
3.14 Smoking must be prohibited inside the premisesand in all areas (including external areas) whereflammable liquids are used or stored. Appropriatenotices should be prominently displayed.
3.15 Where a smoking shelter is provided it must be:
• subject to a specific fire risk assessment;
• constructed of non-combustible materials;
• where practicable, sited at least 10m awayfrom any building or structure (20m on a sitewhere a timber framed structure is beingerected);
• provided with suitable metal ashtrays and aseparate metal waste bin with a fitted metallid; and
• provided with a suitable fire extinguisher.
3.16 The immediate area around the shelter and theshelter itself should be kept clear of combustiblematerials including windblown debris andvegetation.
3.17 Raised, slatted floors or decking should not beused and concealed or semi-open spaces should besealed to ensure combustible debris cannotaccumulate beneath the shelter.
3.18 The use of combustible curtains, canopies anddrapes to protect smokers from the elements mustbe avoided.
3.19 In no circumstances should the shelter be sitednear:
• windows;
• ventilation intakes or extracts;
• entrances and exits from the premises;
• hazardous materials;
• waste storage containers (such as skips orbins); or
• beneath a canopy or low slung eaves.
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3.20 Areas where smoking is allowed but no shelter isprovided must be free of combustible materialsand be equipped with firefighting equipment,metal ash trays and a separate metal waste bin witha fitted metal lid.
3.21 A ‘no smoking’ policy must be established inoutside areas where fire hazards exist. Such areasmay include refuse and storage areas containingcombustible materials, flammable liquids, gascylinders, foam plastics, fibreboard and timber.‘NO SMOKING’ notices must be displayedprominently in these areas.
Electrostatic spraying and coating process (powder-and solvent-based paints)
3.22 Only equipment certified for use in the relevanthazard zone should be used. Electrostatic sprayingsystems for powder should be in accordance withBS EN 50177: 1996 (ref. 23).
3.23 Only the spraygun or electrodes and the cablesconnected to them should be sited within thespray booth or enclosure, unless speciallyprotected.
3.24 High tension cables leading to automaticreciprocating guns should be protected againstmechanical damage during operation.
3.25 Regular inspection of high voltage lines should becarried out to ensure that they remain in a safecondition.
3.26 Airflow interlocks should be provided to cut offthe power in the event of cessation or reduction ofthe exhaust airflow.
3.27 All personnel, equipment and structures within aradius of 3m of the charged electrodes of the gunor equipment should be effectively connected to acommon earth. This includes the floor, or floorcovering which should be of conducting material,the spray booth or enclosure, ventilating ducts andpipe work carrying flammable liquids or powders,and in particular any paint solvent cans in whichthe gun or head is cleaned after use. Whereverpossible, containers of flammable paint should beoutside the 3m zone; any within must be of metaland be earthed.
3.28 Operators should wear anti-static conductingfootwear. The wearing of plastic or rubber soledshoes, or plastic or rubber gloves, should beavoided.
3.29 To ensure that earth conductivity is maintained,regular tests should be carried out. Hangers fromwhich items are suspended for spraying, and alsoconveyor hooks, should be cleaned weekly,particularly where the conveyor passes through adrying or baking oven after leaving the sprayingarea. The resistance to earth of any metal surfacesin the spraying area should not exceed 1ohm.
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3.30 When cleaning electrostatic guns and feed lines,the high voltage supply should be switched off,and when dismantling guns for further cleaningor nozzle changes, the air and fluid suppliesshould also be switched off.
3.31 On automatic plant, interlocks should beprovided to prevent personnel access when theplant is in operation.
3.32 Further guidance is available in the BritishCoatings Federation Code of Practice (ref. 24).
Stoving/curing
3.33 Ovens should not be located immediatelyadjacent to the area used for surface finishapplication work, unless separated by non-combustible 30-minute fire-resistant partitioning.
3.34 Attention should be paid to building constructionto ensure that any combustible materials are keptto a minimum and are properly protected againstexposure. Combustible materials should be sitedno closer than 1m to ovens.
3.35 Oven design should incorporate smooth interiorsurfaces and good interior access to allow easycleaning. Fittings such as racks, trays and hooksshould be non-combustible and readily removableor accessible for easy cleaning.
3.36 Oven walls should be insulated to keep theexterior surfaces at modest temperatures. Wherethis is not possible, guard rails and warning signsshould be provided to keep personnel andproperty clear.
3.37 Ovens should be provided with explosion venting,in accordance with Annex D of BS EN 1539:2000 (ref. 25).
3.38 Oven ductwork should be metal, have a clearancefrom combustible materials of at least 225mmand vent to the open in a safe place.
3.39 Service openings should be provided for cleaningaccess.
3.40 Ducts should avoid passing through firebreakfloors or walls.
3.41 Ducts from separate ovens should not bemanifolded together.
3.42 Ovens should comply with BS EN 1539: 2000 (ref. 25).
3.43 Ovens should have the manufacturer’s operatingrequirements for loading capacity, temperature,ventilation requirement, any restricted solventsand other important details clearly shown on thenameplate.
3.44 Ovens should have a remote manually operatedfuel cut-off valve, which is easily accessible in anemergency.
3.45 Automatic controls should initiate an ovenshutdown in the event of flame failure, ventilationfan failure, conveyor and turntable drive failureand excess oven temperature. Restart should onlybe on a manual reset system.
4. Containment
4.1 Only the minimum quantity of paint and otherflammable liquids should be present in the mixingroom and all containers should be kept closedwhenever possible to reduce the amount ofevaporation.
4.2 Dispensing drums should be fitted with self-closing taps and drip trays or containers. The useof hand-operated pumps is recommended.
4.3 The use of water-wash or water-backed booths isrecommended for removing airborne residues andvapours.
4.4 Explosion relief panels should be at least half thearea of the smallest side of the enclosure andvented to a safe area.
5. Exchange
5.1 At the outset, attention should always be given toeliminating flammable and highly flammableliquids from the workplace wherever possible.Serious consideration should be given to the needfor the use of such liquids in the process and thepossibility of replacing them with non-combustible liquids as alternatives – or at leastwith those having a flashpoint above 55°C.
6. Separation
6.1 The process should, wherever possible, be carriedout in a separate building away from otherworkshop areas, or a room or compartmentexclusively reserved for such work and separatedfrom the rest of the premises by walls, partitions,doors or ceilings (including glazing) providing atleast 30-minutes fire resistance.
Any glazing should be fixed and suitably sealed toconfine vapours, mists, residues, dusts anddeposits to the spray area.
6.2 The spraying enclosure should be of sufficient sizewholly to accommodate the articles to be painted,and to provide adequate working space, while atthe same time allowing unobstructed access toemergency exits.
6.3 Booths shall be provided with means of escape.
6.4 All doors to the spraying enclosure should be self-closing, and should be kept closed during the process.
6.5 The interior wall surface finish should be smooth.This assists and eases cleaning operations.
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Storage
6.6 It will normally be necessary for a suitable store tobe provided for all liquids, whether they are‘highly flammable’ or ‘flammable’. They should be kept in accordance with the Recommendationsfor fire safety in the storage and use of highlyflammable and flammable liquids series ofdocuments (refs 14 and 15).
6.7 The quantity of materials for immediate useshould be kept to a minimum and in no caseexceed the maximum quantity required for theoperation of one shift.
6.8 Storage of highly flammable and flammableliquids should be minimised and be subject to arisk assessment in accordance with DSEAR (ref. 4). Stored liquids should be kept inside asuitably marked, approved design safety locker orbin. At the end of the shift or day, any unused full or partially used containers should be returnedto the bulk store.
6.9 All drums and cans should be kept securely closedwhen not in use and when empty they shouldagain be closed and removed from the building.
Waste materials
6.11 In order to comply with the various environ-mental regulations (refs 16 to 21), it will usuallybe necessary to account for all discharges ofpotentially harmful materials and also to returnwastes for suitable treatment. This generallyresults in a need to store wastes until such time assufficient volume has been accumulated foreconomic handling.
6.12 Liquid waste materials will usually contain someproportion of highly flammable liquid, and thusthe same precautions for waste as for cleanmaterials should be taken, unless it can bepositively demonstrated that there is no fire riskfrom the waste concerned.
6.13 Liquid waste materials will often be collected in205-litre drums. These will need to be storedunder the conditions specified in theRecommendations set out in refs 14 and 15.
6.14 There can be a significant risk of a build-up ofstatic electricity when pouring flammable liquidsinto drums. A long-necked metal funnel should beused, to prevent splash filling, and earth bondingbetween the drum, funnel and the vessel beingemptied should be provided.
6.15 There is also a significant fire risk from thepresence of ‘empty’ tins and used air extract filterscontaining large quantities of combustibledeposits. All materials such as these should be keptin a suitable store (see refs 14 and 15). Cleaningrags soaked in thinners should be stored in metalreceptacles with metal lids.
6.16 Contaminated air extract filters may contain largequantities of combustible deposits and present asignificant fire risk, particularly if they have beenexposed to multi-coating processes in which thecombined coatings may be susceptible to chemicalreaction or spontaneous heating. Contaminatedfilters should be removed from the building assoon as they have been replaced, wetted down andkept in a suitable store or in external metalcontainers with metal lids.
Mixing rooms and distribution systems
6.17 The mixing of paints and other surface finishingsshould be undertaken in a purpose-built mixingroom.
6.18 Piping that conveys flammable liquids from mixingrooms or similar areas should be:
• constructed of steel or other materialcompatible with the hazard;
• secured in position;
• subject to a weekly visual inspection; and
• suitably bonded and earthed.
6.19 Piping should not pass through fire compartments,kitchens or ducting.
6.20 Shut-off valves linked to raise an alarm should beprovided where flexible tubing or hose is used.
6.21 The walls, ceiling and floor of a mixing roomshould be of at least 30-minutes’ fire resistance,with a self-closing 30-minute fire-resisting door.
6.22 The floor should be sloped or sills be formed acrossdoor openings to retain any spilt or leaking liquids.
7. Housekeeping
7.1 In view of the flammable nature of solid residues ofcellulose solutions, and in particular cellulosenitrate, strict attention should be paid to cleanlinesswhen these are used.
7.2 All places in booths where dusts and dry depositscan accumulate should be cleaned at least once aweek. Powders and dusts should be removed usinga vacuum cleaner, not by brushing.
7.3 Cleaning utensils should not be made ofaluminium, ferrous metals or other sparkingmaterials. Highly flammable liquids should not beused for cleaning purposes.
7.4 To facilitate cleaning, suitable peelable coatingsmay be used to line the booth. (Polythene sheetingheld in place with water or a detergent solution isnot suitable for this purpose.)
7.5 Scrapings and sweepings from spray depositsshould be placed immediately in metal receptacleswith metal lids, wetted down and removed fromthe building at the end of each day.
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RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
7.6 Any oily waste, disposable overalls and usedcleaning cloths should be deposited in metalreceptacles with metal lids and also be removedfrom the building at the end of each day.
7.7 Non-combustible absorbent material should bereadily available to soak up spillages. After use itshould be swept up, put in a metal receptacle witha metal lid and stored outside the building to awaitdisposal in accordance with the supplier’srecommendations.
7.8 In view of the risk of spontaneous ignition,enclosures used for cellulose finishes should not be used for vegetable oil paint (oil-basedsynthetics) and varnish processes unless theenclosures and ventilation ducting are thoroughlycleaned in accordance with the manufacturer’srecommendations before each changeover.
7.9 There are a number of proprietary cleaning unitsavailable which provide for the safe, efficient andquick cleaning of sprayguns and nozzles. It isrecommended that such a unit be installed andused in accordance with manufacturer’sinstructions.
7.10 Combustible materials should be kept at least 1maway from the outside of the booth.
7.11 The roof of the booth should not be used forstorage.
8. Maintenance
8.1 All equipment should be maintained in good orderin accordance with the manufacturer’s instructions.
8.2 Booths should be maintained on a regular basis, but at least every six months, as determined by an assessment. The maintenance, which shouldbe carried out by a competent engineer, should include testing of the safety controls andinspection of the ducting. When necessary, theductwork should be thoroughly cleanedthroughout its length.
8.3 The roof filters should be inspected, cleaned orreplaced at the time of the planned maintenancevisits.
8.4 Extract filters should be replaced monthly.
8.5 All maintenance or contractors’ work should becarried out under a permit to work system. Specialprecautions are necessary when work may generate heat or sparks and strict safety proceduresmust be followed in respect of any work involvingplant or equipment containing or used for thehandling of hazardous materials. Furtherinformation is provided in the FPA publicationRecommendations for hot work (ref. 26).
9. Fire protection
9.1 A suitable number of appropriate portable fireextinguishers – approved and certificated by an
independent, third-party certification body –should be provided in accordance with BS 5306-8and maintained in accordance with BS 5306-3 (refs 27 and 28).
9.2 Consideration should be given to installing a fixedfirefighting system, such as sprinklers or suitablegaseous systems. This will be particularly relevantto very hazardous plant or processes that are criticalto the wellbeing of the business. When installing a sprinkler system, the guidance set out in BS EN 12845 and the associated TechnicalBulletins should be observed (ref. 29).
9.3 The design, installation, commissioning andmaintenance of fixed fire suppression systemsshould be undertaken by a company approved andcertificated by an independent, third-partycertification body
9.4 Sprinkler heads, dry powder or gas dischargenozzles and fusible links where installed in processareas should be protected from accumulation ofpaint spray deposits and consequent clogging bymeans of paper coverings which should be changedat least weekly.
10. Fire safety management
10.1 A suitable and sufficient fire risk assessment of thepremises must be undertaken in compliance withthe Regulatory Reform (Fire Safety) Order 2005 orequivalent legislation in Scotland and NorthernIreland (refs 6 to 9). An assessment should also beundertaken in compliance with the DangerousSubstance and Explosive Atmospheres Regulations2002 (DSEAR).
10.2 A scheme should be established and monitored forthe training and periodic refresher training ofpeople who are using or could be using potentiallyhazardous materials. The training should includean understanding of: fire hazards, fire safetyprecautions and action in the event of a fire.
11. Powder coating (electrostatic, cloud chambers andfluidised bed)
11.1 Powder coating should only be carried out in apurpose-built non-combustible booth or enclosure,ideally constructed of metal or metal and wiredglass (some plastics are now used but should besubject to a specific risk assessment). Thebooth/enclosure should contain as few ledges orother horizontal surfaces on which powder depositscan accumulate as possible, and be of sufficient sizeto accommodate the articles being coated.
11.2 Airflow rates should be sufficient to ensure that thepowder concentration does not exceed 50% of theminimum explosive concentration. Where this isnot known, a figure of 10g/m should not beexceeded. For booths, the airflow at the openingshould not be less than 0.4m/s.
RC 32 Paint 4/8/08 11:04 Page 10
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
11
11.3 An airflow switch should be incorporated so thatthe powder application plant cannot be usedwithout the ventilation systems running.
11.4 When small articles are being coated, grilles shouldbe fitted across the air extract inlet, to prevent thembeing sucked into the ductwork or fan.
11.5 Powder handling equipment such as hoppers,feeders, sieves, filters and collectors shouldpreferably be located outside the workroom butmust be close enough to minimise the length ofducting necessary.
11.6 Ducts should be metal, as short as possible and haveno sharp bends or internal obstructions on whichpowder deposits can accumulate.
11.7 Fans and ducts should be accessible for cleaning.
11.8 Excess powder or dust should be removed from thespray booth or other enclosure by means ofadequate mechanical ventilation to a filter, collectoror similar separator, and the cleaned air either re-circulated or exhausted to the open.
11.9 To avoid the creation of dust clouds, cleaningshould be by industrial vacuum cleaner.
11.10Powder hoppers, filters, sieves and collectors shouldhowever be provided with explosion venting; therequired vent area depending on the expectedintensity of an explosion, the strength of thestructure, the type of vent closure and other factors.Explosion vents should vent directly, or via straightmetal ducts not exceeding 3m in length, into theopen air at a safe place.
11.11The temperature of preheated articles, whenentering the coating plant, should be below theignition temperature of the paint powder. Toachieve this, the temperature of the preheating ovenshould be thermostatically controlled to a lowerlevel and an interlock fitted to cut off the heatsupply should the conveyor system stop moving.
RC 32 Paint 4/8/08 11:04 Page 11
12
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
Yes
No
N/A
Act
ion
requ
ired
Due
dat
eSi
gn o
n12
.1G
ener
al (
Sect
ion
1)co
mpl
etio
n
12.1
.1W
here
ver
pote
ntia
lly h
azar
dous
mat
eria
ls ar
e st
ored
or
used
, is
a lis
t of
the
su
bsta
nces
pre
sent
mai
ntai
ned,
alo
ng w
ith d
etai
ls of
the
ir q
uant
ities
and
loca
tions
, as
req
uire
d in
the
CO
SHH
Reg
ulat
ions
?
12.1
.2Is
sui
tabl
e st
aff t
rain
ing
in p
lace
to
ensu
re a
ll pe
rson
nel a
re a
war
e of
the
haz
ards
in
the
wor
kpla
ce a
nd a
pply
VIC
ES
to e
nsur
e a
safe
r w
orki
ng e
nvir
onm
ent
for
all?
12.2
Vent
ilati
on (
Sect
ion
2)
12.2
.1H
as a
dequ
ate
mec
hani
cal v
entil
atio
n be
en p
rovi
ded
at lo
w le
vel w
here
ne
cess
ary,
with
dire
ct d
ischa
rge
to t
he o
pen
air?
12.2
.2A
re e
xhau
st d
ucts
free
of s
harp
ben
ds o
r le
dges
and
tak
en d
irect
ly t
o th
e op
en a
ir t
hrou
gh a
n ex
tern
al w
all o
r th
e ro
of?
12.2
.3A
re t
he p
oint
s of
disc
harg
e of
vap
ours
site
d w
ell c
lear
of b
oth
pote
ntia
l ign
ition
so
urce
s an
d en
try
poin
ts t
o bu
ildin
gs?
12.2
.4Is
the
re a
sep
arat
e ve
ntila
tion
fan
and
duct
for
each
boo
th, w
ith m
otor
s lo
cate
d ou
tsid
e th
e du
ctw
ork?
12.2
.5A
re fa
ns a
nd d
ucts
acc
essib
le fo
r cl
eani
ng, w
ith a
cces
s ha
tche
s pr
ovid
ed a
t du
ctw
ork
bend
s?
12.2
.6A
re fa
ns s
tart
ed a
t le
ast
two
min
utes
bef
ore
the
proc
ess
com
men
ces
and
left
to
run
for
at le
ast
five
min
utes
aft
er t
he p
roce
ss h
as c
ease
d?
12.2
.7If
an
auto
mat
ic t
imer
is u
sed,
are
mea
ns o
f im
med
iate
shu
tdow
n pr
ovid
ed fo
r em
erge
ncy
use?
12.2
.8Is
an
airf
low
or
diffe
rent
ial p
ress
ure
switc
h w
hich
mon
itors
the
flow
of a
ir
prov
ided
in t
he in
let
or e
xhau
st d
uct
and
mai
ntai
ned
at t
he s
ettin
g de
term
ined
by
the
CO
SHH
ass
essm
ent?
12.2
.9In
the
cas
e of
pro
cess
es c
arri
ed o
ut o
ther
tha
n in
pro
prie
tary
veh
icle
fin
ishin
g un
its, i
s ad
equa
te v
entil
atio
n pr
ovid
ed b
y m
echa
nica
l mea
ns
to p
reve
nt c
once
ntra
tions
of v
apou
r or
dus
t ap
proa
chin
g th
e lo
wer
fla
mm
able
lim
it of
the
mat
eria
ls in
use
?
12.2
.10
Are
wat
er-w
ash
or w
ater
-bac
ked
boot
hs u
sed
for
rem
ovin
g ai
rbor
ne
resid
ues
and
vapo
urs?
RC 32 Paint 4/8/08 11:04 Page 12
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
13
Yes
No
N/A
Act
ion
requ
ired
Due
dat
eSi
gn o
nco
mpl
etio
n
12.2
.11
Whe
n sp
rayi
ng is
per
form
ed o
utsid
e a
boot
h, fl
amm
able
liqu
ids
are
expo
sed
duri
ng t
rans
fer
or c
oate
d ob
ject
s ar
e ai
r dr
ied,
is s
uffic
ient
ve
ntila
tion
prov
ided
to
ensu
re t
he fl
amm
able
vap
our
conc
entr
atio
ns
do n
ot e
xcee
d 25
% o
f the
low
er e
xplo
sion
limit
(LE
L) in
any
par
t of
the
roo
m?
12.3
Igni
tion
(Se
ctio
n 3)
12.3
.1A
re a
ll so
urce
s of
igni
tion
such
as
nake
d fla
mes
, hot
sur
face
s an
d un
prot
ecte
d el
ectr
ical
equ
ipm
ent
excl
uded
from
the
spr
ayin
g ar
ea?
Hea
ting
12.3
.2Is
the
spr
ayin
g or
sto
rage
are
a he
ated
by
an a
ccep
tabl
e fo
rm o
f equ
ipm
ent?
(s
ee s
ectio
ns 3
.2.1
to
3.2.
3)
Boo
th te
mpe
ratu
res
12.3
.3A
re t
he o
pera
ting
tem
pera
ture
s co
ntro
lled
by t
herm
osta
ts, i
nter
lock
ed w
ith
the
heat
ing
sour
ce, t
o pr
even
t th
e te
mpe
ratu
re r
ising
abo
ve t
he d
esig
n le
vel?
12.3
.4Is
the
ove
n eq
uipp
ed w
ith a
sep
arat
e hi
gh t
empe
ratu
re li
mit
cont
rol,
of t
he
non-
self-
rese
ttin
g ty
pe?
12.3
.5A
re d
ryin
g/cu
ring
tim
es r
estr
icte
d by
the
use
of a
utom
atic
tim
ing
devi
ces?
12.3
.6A
re a
ll co
mbu
stio
n un
its fi
tted
with
flam
e fa
ilure
dev
ices
?
12.3
.7A
re a
utom
atic
fire
saf
ety
valv
es fi
tted
to
shut
off
the
fuel
sup
ply
in t
he
even
t of
fire
?
Elec
tric
al e
quip
men
t
12.3
.8H
as a
n as
sess
men
t of
the
wor
k ar
eas
and
stor
age
area
s be
en c
arri
ed o
ut,
and
appr
opri
ate
haza
rd ‘z
ones
’ ass
igne
d?
12.3
.9A
re a
ll so
urce
s of
igni
tion,
incl
udin
g th
ose
asso
ciat
ed w
ith e
lect
rica
l spa
rks
or h
ot s
urfa
ces
of e
lect
rica
l app
arat
us p
rote
cted
, exc
lude
d fr
om h
azar
d zo
nes?
12.3
.10
Is e
lect
rica
l app
arat
us (
incl
udin
g w
irin
g) in
haz
ardo
us a
reas
sui
tabl
y ex
plos
ion-
prot
ecte
d, w
ith t
he d
egre
e of
pro
tect
ion
sele
cted
acc
ordi
ng t
o its
pr
obab
ility
of b
eing
exp
osed
to
a fla
mm
able
atm
osph
ere?
RC 32 Paint 4/8/08 11:04 Page 13
14
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
Yes
No
N/A
Act
ion
requ
ired
Due
dat
eSi
gn o
nco
mpl
etio
n
12.3
.11
Are
all
fixed
con
tain
ers,
pipe
wor
k, m
ixer
s an
d ot
her
equi
pmen
t el
ectr
ical
ly
bond
ed a
nd e
arth
ed?
12.3
.12
Are
flex
ible
lead
s pr
ovid
ed t
o bo
nd p
orta
ble
or m
obile
con
tain
ers
duri
ng m
ixin
g,
fillin
g or
disc
harg
ing
oper
atio
ns w
hen
stat
ic e
lect
rici
ty is
like
ly t
o be
gen
erat
ed?
12.3
.13
Are
por
tabl
e lig
hts
or e
lect
rica
l equ
ipm
ent
proh
ibite
d, u
nles
s it
is su
itabl
e to
op
erat
e w
ithin
the
app
ropr
iate
zon
e?
Smok
ing
12.3
.14
Is s
mok
ing
proh
ibite
d in
side
the
prem
ises
and
in e
xter
nal a
reas
whe
re fl
amm
able
liq
uids
are
use
d or
sto
red,
with
app
ropr
iate
sig
ns d
ispla
yed?
12.3
.15
If a
sm
okin
g sh
elte
r ha
s be
en p
rovi
ded
has
it be
en:
• su
bjec
t to
a s
peci
fic fi
re r
isk a
sses
smen
t;•
cons
truc
ted
of n
on-c
ombu
stib
le m
ater
ials;
• w
here
pra
ctic
able
, site
d at
leas
t 10
m a
way
from
any
bui
ldin
g or
str
uctu
re
(20m
on
a sit
e w
here
a t
imbe
r fr
amed
str
uctu
re is
bei
ng e
rect
ed);
• pr
ovid
ed w
ith s
uita
ble
met
al a
shtr
ays
and
a se
para
te m
etal
was
te b
in w
ith a
fit
ted
met
al li
d; a
nd•
prov
ided
with
a s
uita
ble
fire
extin
guish
er?
12.3
.16
Is t
he im
med
iate
are
a ar
ound
the
she
lter
and
the
shel
ter
itsel
f kep
t cl
ear
of
com
bust
ible
mat
eria
ls in
clud
ing
win
dblo
wn
debr
is an
d ve
geta
tion?
12.3
.17
Is t
here
an
abse
nce
of r
aise
d, s
latt
ed fl
oors
or
deck
ing
with
any
con
ceal
ed o
r se
mi-o
pen
spac
es s
eale
d to
ens
ure
com
bust
ible
deb
ris
cann
ot a
ccum
ulat
e be
neat
h th
e sh
elte
r?
12.3
.18
Has
the
use
of c
ombu
stib
le c
urta
ins,
cano
pies
and
dra
pes
to p
rote
ct
smok
ers
from
the
ele
men
ts b
een
avoi
ded?
12.3
.19
Is t
he s
helte
r sit
ed a
way
from
:•
win
dow
s;•
vent
ilatio
n in
take
s or
ext
ract
s;•
entr
ance
s an
d ex
its fr
om t
he p
rem
ises;
• ha
zard
ous
mat
eria
ls;•
was
te s
tora
ge c
onta
iner
s (s
uch
as s
kips
or
bins
);•
a ca
nopy
or
low
slu
ng e
aves
?
RC 32 Paint 4/8/08 11:04 Page 14
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
15
Yes
No
N/A
Act
ion
requ
ired
Due
dat
eSi
gn o
nco
mpl
etio
n
12.3
.20
Are
are
as w
here
sm
okin
g is
allo
wed
but
no
shel
ter
is pr
ovid
ed fr
ee o
f com
bust
ible
m
ater
ials
and
equi
pped
with
fire
fight
ing
equi
pmen
t, m
etal
ash
tray
s an
d a
sepa
rate
m
etal
was
te b
in w
ith a
fitt
ed m
etal
lid?
12.3
.21
Is a
‘no
smok
ing’
pol
icy
esta
blish
ed in
out
side
area
s w
here
fire
haz
ards
exi
st
with
‘NO
SM
OK
ING
’ not
ices
disp
laye
d pr
omin
ently
?
Elec
tros
tatic
spra
ying
and
coa
ting
proc
ess
12.3
.22
Is o
nly
equi
pmen
t ce
rtifi
ed fo
r us
e in
the
rel
evan
t ha
zard
zon
e us
ed?
12.2
.23
Are
ele
ctro
stat
ic s
pray
ing
syst
ems
for
pow
der
in a
ccor
danc
e w
ith
BS
EN
501
77: 2
006?
12.3
.24
Are
onl
y th
e sp
rayg
un o
r el
ectr
odes
and
the
cab
les
conn
ecte
d to
the
m s
ited
with
in t
he s
pray
boo
th o
r en
clos
ure,
unl
ess
spec
ially
pro
tect
ed?
12.3
.25
Are
hig
h te
nsio
n ca
bles
lead
ing
to a
utom
atic
rec
ipro
catin
g gu
ns p
rote
cted
ag
ains
t m
echa
nica
l dam
age
duri
ng o
pera
tion?
12.3
.26
Are
reg
ular
insp
ectio
ns o
f hig
h vo
ltage
line
s ca
rrie
d ou
t to
ens
ure
that
the
y re
mai
n in
a s
afe
cond
ition
?
12.3
.27
Are
air
flow
inte
rlock
s pr
ovid
ed t
o cu
t of
f the
pow
er in
the
eve
nt o
f ce
ssat
ion
or r
educ
tion
of t
he e
xhau
st a
irflo
w?
12.3
.28
Are
all
pers
onne
l, eq
uipm
ent
and
stru
ctur
es w
ithin
a r
adiu
s of
3m
of t
he c
harg
ed
elec
trod
es o
f the
gun
or
equi
pmen
t ef
fect
ivel
y co
nnec
ted
to a
com
mon
ear
th?
12.3
.29
Do
oper
ator
s w
ear
anti-
stat
ic c
ondu
ctin
g fo
otw
ear
and
is th
e w
eari
ng o
f pla
stic
or
rub
ber
sole
d sh
oes,
or p
last
ic o
r ru
bber
glo
ves
avoi
ded?
12.3
.30
Are
reg
ular
tes
ts c
arri
ed o
ut t
o en
sure
tha
t ea
rth
cond
uctiv
ity is
mai
ntai
ned?
A
re h
ange
rs fr
om w
hich
item
s ar
e su
spen
ded
for
spra
ying
, and
also
con
veyo
r ho
oks,
clea
ned
wee
kly,
par
ticul
arly
whe
re t
he c
onve
yor
pass
es t
hrou
gh a
dry
ing
or b
akin
g ov
en a
fter
leav
ing
the
spra
ying
are
a?
12.3
.31
Whe
n cl
eani
ng e
lect
rost
atic
gun
s an
d fe
ed li
nes,
is th
e hi
gh v
olta
ge s
uppl
y sw
itche
d of
f, an
d w
hen
dism
antli
ng g
uns
for
furt
her
clea
ning
or
nozz
le c
hang
es, a
re t
he a
ir
and
fluid
sup
plie
s al
so s
witc
hed
off?
RC 32 Paint 4/8/08 11:04 Page 15
16
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
Yes
No
N/A
Act
ion
requ
ired
Due
dat
eSi
gn o
nco
mpl
etio
n
12.3
.32
Are
inte
rlock
s pr
ovid
ed o
n au
tom
atic
pla
nt t
o pr
even
t pe
rson
nel a
cces
s w
hen
the
plan
t is
in o
pera
tion?
Stov
ing/
Cur
ing
12.3
.33
Are
ove
ns lo
cate
d aw
ay fr
om a
reas
imm
edia
tely
adj
acen
t to
the
are
a us
ed fo
r su
rfac
e fin
ish a
pplic
atio
n w
ork,
unl
ess
sepa
rate
d by
non
-com
bust
ible
30-
min
ute
fire
resis
tant
par
titio
ning
?
12.3
.34
Has
att
entio
n be
en p
aid
to b
uild
ing
cons
truc
tion
to e
nsur
e th
at a
ny c
ombu
stib
le
mat
eria
ls ar
e ke
pt t
o a
min
imum
and
are
pro
perly
pro
tect
ed a
gain
st e
xpos
ure?
12.3
.35
Doe
s ov
en d
esig
n in
corp
orat
e sm
ooth
inte
rior
sur
face
s an
d go
od in
teri
or a
cces
s to
allo
w e
asy
clea
ning
, and
are
fitt
ings
– s
uch
as r
acks
, tra
ys a
nd h
ooks
–
non-
com
bust
ible
and
rea
dily
rem
ovab
le o
r ac
cess
ible
for
easy
cle
anin
g?
12.3
.36
Are
ove
n w
alls
insu
late
d to
kee
p th
e ex
teri
or s
urfa
ces
at m
odes
t te
mpe
ratu
res?
(W
here
thi
s is
not
poss
ible
, are
gua
rd r
ails
and
war
ning
sig
ns p
rovi
ded
to k
eep
pers
onne
l and
pro
pert
y cl
ear?
)
12.3
.37
Are
ove
ns p
rovi
ded
with
exp
losio
n ve
ntin
g, in
acc
orda
nce
with
Ann
ex D
of
BS
EN
153
9: 2
000?
12.3
.38
Is o
ven
duct
wor
k m
etal
, with
a c
lear
ance
from
com
bust
ible
mat
eria
ls of
at
leas
t 22
5mm
and
ven
ts t
o th
e op
en in
a s
afe
plac
e?
12.3
.39
Are
ser
vice
ope
ning
s pr
ovid
ed fo
r cl
eani
ng a
cces
s?
12.3
.40
Do
duct
s av
oid
pass
ing
thro
ugh
fireb
reak
floo
rs o
r w
alls?
12.3
.41
Do
duct
s w
hich
are
from
sep
arat
e ov
ens
rem
ain
inde
pend
ent
thro
ugho
ut
thei
r le
ngth
?
12.3
.42
Do
oven
s co
mpl
y w
ith B
S E
N 1
539:
200
0?
12.3
.43
Do
oven
s ha
ve t
he m
anuf
actu
rer’s
ope
ratin
g re
quire
men
ts fo
r lo
adin
g ca
paci
ty,
tem
pera
ture
, ven
tilat
ion
requ
irem
ent,
any
rest
rict
ed s
olve
nts
and
othe
r im
port
ant
deta
ils c
lear
ly s
how
n on
the
nam
epla
te?
12.3
.44
Do
oven
s ha
ve a
rem
ote
man
ually
ope
rate
d fu
el c
ut-o
ff va
lve,
whi
ch is
eas
ily
acce
ssib
le in
an
emer
genc
y?
RC 32 Paint 4/8/08 11:04 Page 16
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
17
Yes
No
N/A
Act
ion
requ
ired
Due
dat
eSi
gn o
nco
mpl
etio
n
12.3
.45
Do
auto
mat
ic c
ontr
ols
initi
ate
an o
ven
shut
dow
n in
the
eve
nt o
f fla
me
failu
re,
vent
ilatio
n fa
n fa
ilure
, con
veyo
r an
d tu
rnta
ble
driv
e fa
ilure
and
exc
ess
oven
te
mpe
ratu
re?
Is r
esta
rt o
nly
on a
man
ual r
eset
sys
tem
?
12.4
Con
tain
men
t (S
ecti
on 4
)
12.4
.1Is
onl
y th
e m
inim
um q
uant
ity o
f pai
nt a
nd o
ther
flam
mab
le li
quid
s pr
esen
t in
the
m
ixin
g ro
om, w
ith a
ll co
ntai
ners
kep
t cl
osed
whe
neve
r po
ssib
le t
o re
duce
the
am
ount
of e
vapo
ratio
n?
12.4
.2A
re d
ispen
sing
drum
s fit
ted
with
sel
f-cl
osin
g ta
ps a
nd d
rip
tray
s or
con
tain
ers?
12.4
.3A
re e
xplo
sion
relie
f pan
els
at le
ast
half
the
area
of t
he s
mal
lest
sid
e of
the
enc
losu
re,
and
do t
hey
vent
to
a sa
fe a
rea?
12.5
Exch
ange
(Se
ctio
n 5)
12.5
.1Is
att
entio
n al
way
s gi
ven
to e
limin
atin
g fla
mm
able
and
hig
hly
flam
mab
le li
quid
s fr
om t
he w
orkp
lace
whe
reve
r po
ssib
le?
12.6
Sepa
rati
on (
Sect
ion
6)
12.6
.1Is
the
pro
cess
car
ried
out
in a
sep
arat
e bu
ildin
g aw
ay fr
om o
ther
wor
ksho
p ar
eas,
or a
roo
m o
r co
mpa
rtm
ent
excl
usiv
ely
rese
rved
for
such
wor
k an
d se
para
ted
from
th
e re
st o
f the
pre
mise
s by
wal
ls, p
artit
ions
, doo
rs o
r ce
iling
s (in
clud
ing
glaz
ing)
pr
ovid
ing
at le
ast
30-m
inut
es fi
re r
esist
ance
?
12.6
.2Is
the
spr
ayin
g en
clos
ure
of s
uffic
ient
siz
e w
holly
to
acco
mm
odat
e th
e ar
ticle
s to
be
pai
nted
and
to
prov
ide
adeq
uate
wor
king
spa
ce, w
hile
at
the
sam
e tim
e al
low
ing
unob
stru
cted
acc
ess
to e
mer
genc
y ex
its?
12.6
.3A
re b
ooth
s pr
ovid
ed w
ith m
eans
of e
scap
e?
12.6
.4A
re a
ll do
ors
to t
he s
pray
ing
encl
osur
e se
lf-cl
osin
g, a
nd k
ept
clos
ed d
urin
g th
e pr
oces
s?
12.6
.5Is
the
inte
rior
wal
l sur
face
fini
sh s
moo
th t
o as
sist
and
ease
cle
anin
g op
erat
ions
?
Stor
age
12.6
.6Is
the
sto
rage
of p
aint
s an
d so
lven
ts m
ade
the
subj
ect
of a
fire
risk
ass
essm
ent?
RC 32 Paint 4/8/08 11:04 Page 17
18
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
Yes
No
N/A
Act
ion
requ
ired
Due
dat
eSi
gn o
nco
mpl
etio
n
12.6
.7Is
a s
uita
ble
stor
e pr
ovid
ed fo
r al
l liq
uids
, whe
ther
the
y ar
e ‘h
ighl
y fla
mm
able
’ or
‘fla
mm
able
’?
12.6
.8Is
the
qua
ntity
of m
ater
ials
for
imm
edia
te u
se k
ept
to a
min
imum
and
in n
o ca
se
allo
wed
to
exce
ed t
he m
axim
um q
uant
ity r
equi
red
for
the
oper
atio
n of
one
shi
ft?
12.6
.9Is
the
sto
rage
of h
ighl
y fla
mm
able
liqu
ids
min
imise
d an
d su
bjec
t to
a r
isk a
sses
smen
t in
acc
orda
nce
with
DSE
AR
?
12.6
.10
Are
all
drum
s an
d ca
ns k
ept
secu
rely
clo
sed
whe
n no
t in
use
and
, whe
n em
pty,
ke
pt c
lose
d an
d re
mov
ed fr
om t
he b
uild
ing?
Was
te m
ater
ials
12.6
.11
Are
the
dru
ms
used
to
stor
e liq
uid
was
te m
ater
ials
kept
und
er t
he c
ondi
tions
sp
ecifi
ed in
the
app
ropr
iate
reg
ulat
ions
(re
fs 2
0 to
25)
?
12.6
.12
Is a
long
-nec
ked
met
al fu
nnel
use
d to
pre
vent
spl
ash
fillin
g, a
nd a
re t
here
pr
ovisi
ons
for
bond
ing
and
eart
hing
the
dru
ms,
funn
els
and
vess
els
bein
g em
ptie
d?
12.6
.13
Are
mat
eria
ls su
ch a
s ‘e
mpt
y’ t
ins
and
used
air
ext
ract
filte
rs c
onta
inin
g la
rge
quan
titie
s of
com
bust
ible
dep
osits
kep
t sa
fely
in a
sui
tabl
e st
ore?
Mix
ing
room
s and
dist
ribu
tion
syste
ms
12.6
.14
Is t
he m
ixin
g of
pai
nts
and
othe
r su
rfac
e fin
ishin
gs u
nder
take
n in
a
purp
ose-
built
mix
ing
room
?
12.6
.15
Is p
ipin
g th
at c
onve
ys fl
amm
able
liqu
ids
from
mix
ing
room
s or
sim
ilar
area
s co
nstr
ucte
d of
ste
el o
r ot
her
mat
eria
l com
patib
le w
ith t
he h
azar
d, s
ecur
ed in
pos
ition
su
bjec
t to
a w
eekl
y vi
sual
insp
ectio
n, a
nd s
uita
bly
bond
ed a
nd e
arth
ed?
12.6
.16
Is p
ipin
g ro
uted
so
as n
ot t
o pa
ss t
hrou
gh fi
re c
ompa
rtm
ents
, kitc
hens
or
duct
ing?
12.6
.17
Are
shu
t-of
f val
ves
linke
d to
rai
se a
n al
arm
pro
vide
d w
here
flex
ible
tu
bing
or
hose
is u
sed?
12.6
.18
Are
the
wal
ls, c
eilin
g an
d flo
or o
f a m
ixin
g ro
om o
f at
leas
t 30
-min
utes
’ fire
re
sista
nce,
with
a s
elf c
losin
g 30
-min
ute
fire-
resis
ting
door
?
12.6
.19
Is t
he fl
oor
slope
d or
hav
e sil
ls be
en fo
rmed
acr
oss
door
ope
ning
s to
ret
ain
any
spilt
or
leak
ing
liqui
ds?
RC 32 Paint 4/8/08 11:04 Page 18
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
19
Yes
No
N/A
Act
ion
requ
ired
Due
dat
eSi
gn o
nco
mpl
etio
n
12.7
Hou
seke
epin
g (S
ecti
on 7
)
12.7
.1In
vie
w o
f the
flam
mab
le n
atur
e of
sol
id r
esid
ues
of c
ellu
lose
sol
utio
ns a
nd in
pa
rtic
ular
cel
lulo
se n
itrat
e, is
str
ict
atte
ntio
n pa
id t
o cl
eanl
ines
s w
hen
thes
e ar
e us
ed?
12.7
.2A
re a
ll pl
aces
in b
ooth
s w
here
dus
ts a
nd d
ry d
epos
its c
an a
ccum
ulat
e cl
eane
d at
le
ast
once
a w
eek?
12.7
.3A
re c
lean
ing
uten
sils
mad
e of
mat
eria
ls ot
her
than
alu
min
ium
, fer
rous
met
als
or
othe
r sp
arki
ng m
ater
ials?
12.7
.4To
faci
litat
e cl
eani
ng, a
re s
uita
ble
peel
able
coa
tings
use
d to
line
the
boo
th?
12.7
.5A
re s
crap
ings
and
sw
eepi
ngs
from
spr
ay d
epos
its p
lace
d im
med
iate
ly in
met
al
rece
ptac
les
with
met
al li
ds, w
ette
d do
wn
and
rem
oved
from
the
bui
ldin
g at
th
e en
d of
eac
h da
y?
12.7
.6A
re a
ny o
ily w
aste
, disp
osab
le o
vera
lls a
nd u
sed
clea
ning
clo
ths
depo
sited
in m
etal
re
cept
acle
s w
ith m
etal
lids
and
also
rem
oved
from
the
bui
ldin
g at
the
end
of
each
day
?
12.7
.7Is
a n
on-c
ombu
stib
le a
bsor
bent
mat
eria
l rea
dily
ava
ilabl
e to
soa
k up
spi
llage
s?
12.7
.8Is
the
use
of v
eget
able
oil
pain
t (o
il-ba
sed
synt
hetic
s) a
nd v
arni
sh p
roce
sses
av
oide
d in
enc
losu
res
norm
ally
use
d fo
r ce
llulo
se fi
nish
es?
12.7
.9A
re p
ropr
ieta
ry c
lean
ing
units
use
d w
hich
pro
vide
for
the
safe
, effi
cien
t an
d qu
ick
clea
ning
of s
pray
guns
and
noz
zles
?
12.7
.10
Are
com
bust
ible
mat
eria
ls ke
pt a
t le
ast
1m a
way
from
the
out
side
of t
he b
ooth
?
12.7
.11
Is t
he r
oof o
f the
spr
ay b
ooth
free
from
sto
rage
?
12.8
Mai
nten
ance
(Se
ctio
n 8)
12.8
.1Is
all
equi
pmen
t m
aint
aine
d in
goo
d or
der
in a
ccor
danc
e w
ith t
he
man
ufac
ture
rs’ i
nstr
uctio
ns?
12.8
.2A
re b
ooth
s m
aint
aine
d on
a r
egul
ar b
asis,
but
at
leas
t ev
ery
six m
onth
s, as
de
term
ined
by
an a
sses
smen
t?
12.8
.3A
re t
he r
oof f
ilter
s in
spec
ted,
cle
aned
or
repl
aced
at
the
time
of t
he p
lann
ed
mai
nten
ance
visi
ts?
RC 32 Paint 4/8/08 11:04 Page 19
20
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
Yes
No
N/A
Act
ion
requ
ired
Due
dat
eSi
gn o
nco
mpl
etio
n
12.8
.4A
re e
xtra
ct fi
lters
rep
lace
d m
onth
ly?
12.8
.5Is
all
mai
nten
ance
or
cont
ract
ors’
wor
k ca
rrie
d ou
t un
der
a pe
rmit
to w
ork
syst
em?
12.9
Fire
pro
tect
ion
(Sec
tion
9)
12.9
.1W
here
haz
ardo
us m
ater
ials
are
used
or
stor
ed, a
re a
sui
tabl
e nu
mbe
r of
app
ropr
iate
po
rtab
le fi
re e
xtin
guish
ers
prov
ided
, app
rove
d an
d ce
rtifi
cate
d by
an
inde
pend
ent,
third
-par
ty c
ertif
icat
ion
body
?
12.9
.2H
as c
onsid
erat
ion
been
giv
en t
o in
stal
ling
a fix
ed fi
refig
htin
g sy
stem
, suc
h as
sp
rink
lers
or
suita
ble
gase
ous
syst
ems?
12.9
.3Is
the
des
ign,
inst
alla
tion,
com
miss
ioni
ng a
nd m
aint
enan
ce o
f fix
ed fi
re s
uppr
essio
n sy
stem
s un
dert
aken
by
a co
mpa
ny a
ppro
ved
and
cert
ifica
ted
by a
n in
depe
nden
t th
ird-p
arty
cer
tific
atio
n bo
dy?
12.9
.4W
here
spr
inkl
er h
eads
, dry
pow
der
or g
as d
ischa
rge
nozz
les
and
fusib
le li
nks
are
inst
alle
d in
pro
cess
are
as, a
re t
hey
prot
ecte
d fr
om a
ccum
ulat
ion
of p
aint
spr
ay
depo
sits
and
cons
eque
nt c
logg
ing
by m
eans
of p
aper
cov
erin
gs w
hich
are
cha
nged
at
leas
t w
eekl
y?
12.1
0Fi
re s
afet
y m
anag
emen
t (S
ecti
on 1
0)
12.1
0.1
Has
a s
uita
ble
and
suffi
cien
t fir
e ri
sk a
sses
smen
t of
the
pre
mise
s be
en u
nder
take
n in
com
plia
nce
with
the
Reg
ulat
ory
Ref
orm
(Fi
re S
afet
y) O
rder
200
5 or
equ
ival
ent
legi
slatio
n in
Sco
tland
and
Nor
ther
n Ir
elan
d?
12.1
0.2
Has
an
asse
ssm
ent
been
und
erta
ken
in c
ompl
ianc
e w
ith t
he D
ange
rous
Sub
stan
ce
and
Exp
losiv
e A
tmos
pher
es R
egul
atio
ns 2
002
(DSE
AR
)?
12.1
0.3
Has
a s
chem
e be
en e
stab
lishe
d an
d m
onito
red
for
the
trai
ning
and
per
iodi
c re
fres
her
trai
ning
of p
eopl
e w
ho a
re u
sing,
or
coul
d be
usin
g, p
oten
tially
ha
zard
ous
mat
eria
ls?
12.1
1Po
wde
r co
atin
g (S
ecti
on 1
1)
12.1
1.1
Is p
owde
r co
atin
g on
ly c
arri
ed o
ut in
a p
urpo
se-b
uilt
non-
com
bust
ible
boo
th
or e
nclo
sure
, ide
ally
con
stru
cted
of m
etal
or
met
al a
nd w
ired
glas
s?
12.1
1.2
Doe
s th
e bo
oth/
encl
osur
e co
ntai
n as
few
ledg
es o
r ot
her
hori
zont
al s
urfa
ces
as
poss
ible
, on
whi
ch p
owde
r de
posit
s ca
n ac
cum
ulat
e?
RC 32 Paint 4/8/08 11:04 Page 20
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
21
Yes
No
N/A
Act
ion
requ
ired
Due
dat
eSi
gn o
nco
mpl
etio
n
12.1
1.3
Are
air
flow
rat
es s
uffic
ient
to
ensu
re t
hat
the
pow
der
conc
entr
atio
n do
es n
ot e
xcee
d 50
% o
f the
min
imum
exp
losiv
e co
ncen
trat
ion?
(W
here
thi
s is
not
know
n, a
figu
re
of 1
0g/m
sho
uld
not
be e
xcee
ded.
)
12.1
1.4
Is a
n ai
rflo
w s
witc
h in
corp
orat
ed s
o th
at t
he p
owde
r ap
plic
atio
n pl
ant
cann
ot b
e us
ed
with
out
the
vent
ilatio
n sy
stem
s ru
nnin
g?
12.1
1.5
Whe
n sm
all a
rtic
les
are
bein
g co
ated
, are
gri
lles
fitte
d ac
ross
the
air
ext
ract
inle
t, to
pr
even
t th
em b
eing
suc
ked
into
the
duc
twor
k or
fan?
12.1
1.6
Is p
owde
r ha
ndlin
g eq
uipm
ent
– su
ch a
s ho
pper
s, fe
eder
s, sie
ves,
filte
rs a
nd
colle
ctor
s –
loca
ted
outs
ide
the
wor
kroo
m b
ut c
lose
eno
ugh
to m
inim
ise t
he le
ngth
of
duc
ting
nece
ssar
y?
12.1
1.7
Are
duc
ts m
etal
, as
shor
t as
pos
sible
with
no
shar
p be
nds
or in
tern
al o
bstr
uctio
ns
on w
hich
pow
der
depo
sits
can
accu
mul
ate?
12.1
1.8
Are
fans
and
duc
ts a
cces
sible
for
clea
ning
?
12.1
1.9
Is e
xces
s po
wde
r or
dus
t re
mov
ed fr
om t
he s
pray
boo
th o
r ot
her
encl
osur
e by
m
eans
of a
dequ
ate
mec
hani
cal v
entil
atio
n to
a fi
lter,
colle
ctor
or
simila
r se
para
tor,
and
the
clea
ned
air
eith
er r
e-ci
rcul
ated
or
exha
uste
d to
the
ope
n?
12.1
1.10
To a
void
the
cre
atio
n of
dus
t cl
ouds
, is
clea
ning
by
indu
stri
al v
acuu
m c
lean
er?
12.1
1.11
Are
pow
der
hopp
ers,
filte
rs, s
ieve
s an
d co
llect
ors
prov
ided
with
sui
tabl
e ex
plos
ion
vent
ing?
12.1
1.12
Is t
he t
empe
ratu
re o
f pre
heat
ed a
rtic
les,
whe
n en
teri
ng t
he c
oatin
g pl
ant,
belo
w
the
igni
tion
tem
pera
ture
of t
he p
aint
pow
der?
Is
the
tem
pera
ture
of t
he p
rehe
atin
g ov
en t
herm
osta
tical
ly c
ontr
olle
d to
a lo
wer
leve
l and
an
inte
rlock
fitt
ed t
o cu
t of
f th
e he
at s
uppl
y sh
ould
the
con
veyo
r sy
stem
sto
p m
ovin
g?
RC 32 Paint 4/8/08 11:04 Page 21
22
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
REFERENCES
1. RC31: Recommendations for fire safety inautomotive refinishing and spraying processes, FireProtection Association, 2007.
2. Health and safety series booklet HS (G) 203:Controlling exposure to coating powders, Health andSafety Executive, 2000.
3. BS EN 60079-10: 2003: Electrical apparatus forexplosive gas atmospheres: Classification ofhazardous atmospheres, British StandardsInstitution.
4. Dangerous Substances and ExplosiveAtmospheres Regulations 2002 (DSEAR), SI2002 No 2776, The Stationery Office.
5. Supplement to the Approved requirements and testmethods for the classification and packaging ofdangerous goods for carriage, HSE Books, 1999.
6. The Regulatory Reform (Fire Safety) Order 2005,SI 2005 No 1541, The Stationery Office.
7. The Fire (Scotland) Act 2005, asp 5. TheStationery Office.
8. Fire Safety (Scotland) Regulations 2006, ScottishSI 2006 No 456. The Stationery Office.
9. Fire and Rescue Services (Northern Ireland)Order 2006, SI 2006 No 1254 (NI9), TheStationery Office.
10. Business Resilience. A guide to protecting yourbusiness and its people, Fire Protection Association,2005.
11. The Petroleum (Consolidation) Act 1928 (asamended by DSEAR), The Stationery Office.
12. The Control of Substances Hazardous to HealthRegulations 2002 (COSHH), SI 2002 No 2677,The Stationery Office.
13. Health and safety booklet HS (G) 51: Storage offlammable liquids in containers, Health and SafetyExecutive, 1998.
14. RC20 Part 1: Recommendations for fire safety in thestorage and use of highly flammable and flammableliquids: General principles, Fire ProtectionAssociation, 2006.
15. RC20 Part 2: Recommendations for fire safety in thestorage and use of highly flammable and flammableliquids: Storage of flammable liquids in drums, cansand containers other than external fixed tanks, FireProtection Association, 2007.
16. Environmental Protection Act 1990, (c.43), TheStationery Office.
17. Groundwater Regulations 1998, SI 1998 No2746, The Stationery Office.
18. Water Resources Act 1991, (c.57), The StationeryOffice.
19. Environmental Protection (Duty of Care)Regulations 1991, SI 1991 No 2839, TheStationery Office.
20. Anti-Pollution Works Regulations 1999, SI 1999No 1006, The Stationery Office.
21. Control of Waste (Registration of Carriers andSeizures of Vehicles) Regulations 1991, SI 1991No 1624, The Stationery Office.
22. RC30: Recommendations for the selection ofelectrical and non-electrical equipment for use inatmospheres containing flammable and explosivegases or vapours, Fire Protection Association, 2005.
23. BS EN 50177: 1997: Automatic electrostaticspraying installations for flammable coating powder,British Standards Institution.
24. Application of powder coatings by electrostaticspraying (Code of safe practice), British CoatingsFederation, 2001.
25. BS EN 1539: 2000: Dryers and ovens, in whichflammable substances are released – Safetyrequirements, British Standards Institution.
26. RC7: Recommendations for hot work, FireProtection Association, 2001.
27. BS 5306-8: 2000: Fire extinguishing installationsand equipment on premises. Selection andinstallation of portable fire extinguishers. Code ofpractice, British Standards Institution.
28. BS 5306-3: 2003: Fire extinguishing installationsand equipment on premises. Code of practice for theinspection and maintenance of portable fireextinguishers, British Standards Institution.
29. LPC Rules for automatic sprinkler installationsincorporating BS EN 12845, Fire ProtectionAssociation, 2003.
FURTHER READING
1. HS (G) 178: The spraying of flammable liquids,Health and Safety Executive, 1998.
2. HS (G) 140: Safe use and handling of flammableliquids, Health and Safety Executive, 1996.
3. NFPA 33: Spray application using flammable orcombustible materials, National Fire ProtectionAssociation (USA), 2007.
RC 32 Paint 4/8/08 11:04 Page 22
RC32: Recommendations for fire safety in paint spraying processes (excluding automotive refinishing)
23
RC 32 Paint 4/8/08 11:04 Page 23
RC32
I ' Fi R h S f di h
for fire safety inpaint sprayingprocesses(excludingautomotiverefinishing)
RC 32 Paint 4/8/08 11:04 Page 24