Structural Steelwork Painting

Structural steelwork painting applies protective coatings to prevent corrosion of steel frames and connections.
Coatings include primer, intermediate, and finish coats using epoxy, polyurethane, or zinc-based systems.
Many structural paints contain solvents, isocyanates, or zinc dust that are harmful by inhalation and skin contact.
Spray application generates a fine mist that increases inhalation exposure compared to brush or roller methods.
Surface preparation by blast cleaning or power tool cleaning generates metallic dust and noise.
Working at height on steel structures requires safe access platforms or rope access for painting.
Enclosed or partially enclosed areas trap solvent vapour, creating explosion risk and health hazards.
Intumescent fire protection coatings applied to steelwork have their own specific COSHH requirements.
Wet and cold conditions affect coating adhesion — application must occur within specified temperature ranges.
Overspray and drips from painting operations can affect workers and activities on lower levels.

Chemical exposure	Solvents, isocyanates, and zinc dust in structural paints cause respiratory sensitisation, dermatitis, and metal fume fever.
Explosion risk	Solvent vapour accumulation in enclosed areas creates a flammable atmosphere with potential for explosion.
Working at height	Painting elevated steelwork exposes workers to fall hazards in positions that are difficult to protect.

Do

Don't

Complete a COSHH assessment for every coating product used in the painting system
Wear RPE with appropriate filters for the specific paint type and application method
Provide forced ventilation when spraying coatings in enclosed or partially enclosed areas
Monitor solvent vapour levels in enclosed spaces to prevent explosive concentrations
Use safe working platforms for painting at height — avoid overreaching from ladders
Protect workers on lower levels from overspray and drips with sheeting or exclusion zones
Apply coatings within the temperature and humidity range specified by the manufacturer
Wear chemical-resistant gloves and coveralls to prevent skin contact with paints
Inspect blast-cleaned surfaces and apply primer within the time limit before re-rusting
Store paints and solvents in designated bunded areas away from ignition sources

DON'T spray coatings in enclosed areas without forced ventilation and vapour monitoring
DON'T ignore isocyanate warnings — exposure causes permanent occupational asthma
DON'T apply coatings outside the specified temperature and humidity range
DON'T smoke or use naked flames near painting operations or solvent storage areas
DON'T allow blast-cleaned surfaces to rust before primer application — work within the limit
DON'T mix coating products from different manufacturers without engineer approval
DON'T remove RPE while spray mist or solvent vapour is still present in the area
DON'T paint at height without fall protection appropriate for the access method used
DON'T allow untrained workers to apply intumescent fire protection coatings
DON'T pour waste paint or solvents down drains — dispose through licensed waste routes

See also: Steel Erection Safety | Spray Painting Safety

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