Characterization of Airborne Particulates and Worker Exposures in Electro-static Powder Coating Operations

This study was to examine the airborne particulates/dusts and worker exposures in electro-static powder coating operations. Temporal variation and size distribution of dusts were assessed using direct-reading instrument, while the worker task-specific dust exposures (n = 41) were measured in three factories using conventional filter method. Additionally, toxic metal levels in the coating powder (n = 27) were analyzed to assess hazard potentials. Continuous monitoring of airborne respirable dust levels indicated large temporal variation across a normal working day. The particulate levels outside spraying booths were generally low (below 0.10 mg m−3) during normal spraying operation, but short-term level may reach as high as 21.8 mg m−3 (averaged at 4–5 mg m−3) when specific task such as cleaning the pipelines and spraying booth, was performed. Exploratory assessment on particle size distribution at four major working zones, administration, uploading, spraying, and baking, indicated no major difference among the zones, and between factories. The particle count median aerodynamic diameter was 0.88–1.69 µm, while the mean number concentrations were 10.97, 15.17, 18.49, and 27.03 (# cm−3) for zones administration, uploading, spraying, and baking, respectively. The worker task-specific dust exposures were found low during normal spraying, with the mean short-term total and respirable dust concentrations being 0.88 and 0.41 mg m−3, respectively. Both levels increased to 3.48 and 5.19 mg m−3, respectively (P < 0.05), if powder changing and system cleaning were done. Short-term total and respirable dust concentrations were 94.2 and 56.1 mg m−3, respectively, when complete cleaning process was performed inside spraying booth. Both levels exceeded the short-term exposure limits. The mean concentration of metals in the powder samples were 6.78, 9.52, 10 717, 2805, 1020, and 1361 µg g−1 for Pb, Cr (total), Al, Fe, Cu, and Sr, respectively. This study demonstrated that cleaning of spraying booth resulted in high dust exposures well exceeding the exposure limit. Toxic metals, particularly Pb, Cd, and Cr (total), levels measured in the powder samples were found low, and the resulting exposures were below the exposure limits, indicating relative low risks associated with the exposure at current dust levels.