Spray Booth Operations SWMS
Auto and industrial spray-booth operations for non-isocyanate finishes — booth start-up, ventilation interlock, overspray containment, RPE selection per coating SDS, media-filter change and hot-work exclusion.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
Spray booth operations involve atomising solvent-based and waterborne coatings inside a ventilated enclosure, generating flammable vapour-air mixtures, respirable overspray and chemical exposures that routinely exceed workplace exposure standards without engineered control. Even for non-isocyanate finishes, the work falls squarely within Part 7.1 of the Model WHS Regulations because paints, thinners and cleaning solvents are classified hazardous chemicals under the GHS, and AS/NZS 4114.1:2020 sets mandatory performance criteria for the booth itself. A Safe Work Method Statement is required whenever the work constitutes High Risk Construction Work under Schedule 1, when hazardous chemicals are used in quantities triggering manifest or placarding duties, and as a PCBU's primary risk-control record under regulation 38. This SWMS addresses booth start-up sequencing, ventilation interlocks, RPE selection driven by the coating SDS, filter media changes, and the absolute exclusion of hot work during and immediately after spraying. It is written to be signed on at every shift change and amended whenever a new coating system is introduced.
Hazards identified
7 hazards covered, sorted by priority.
Ignition causing deflagration, severe burns, structural booth damage and breach of WHS Reg 355 dangerous-goods control duty
Operator overexposure to solvents, CNS depression, chronic neurotoxicity and non-conformance with AS/NZS 4114.1 clause 2.4
Inhalation exposure exceeding workplace exposure standards, respiratory sensitisation and PCBU breach of WHS Reg 49
Ignition of vapour cloud, flash fire, operator burns and dangerous-goods incident reportable under WHS Act s38
Self-heating, smouldering fire, toxic smoke generation and breach of waste-storage duty under hazardous chemicals code
Dermatitis, chemical absorption, allergic contact sensitisation and failure of PPE adequacy duty under WHS Reg 44
Permanent noise-induced hearing loss and breach of exposure standard under WHS Reg 56
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Elimination — Eliminate solvent-borne coatings where possible by specifying compliant waterborne or high-solids alternatives reviewed against AS/NZS 4114.1:2020 booth design assumptions during procurement.
- 2Elimination — Prohibit all hot work, grinding and open-flame activity within five metres of the booth aperture during spraying and for thirty minutes after final extract purge cycle.
- 3Substitution — Substitute high-VOC cleaning solvents with lower-vapour-pressure equivalents documented in the coating manufacturer's SDS Section 8 and verified against workplace exposure standards.
- 4Engineering — Confirm ventilation interlock energises the spray gun supply only when extract fan achieves rated face velocity per AS/NZS 4114.1 clause 2.4 before each shift.
- 5Engineering — Maintain bonded and earthed decant points, conductive flooring and intrinsically safe lighting inside the booth in accordance with AS/NZS 60079.10.1 hazardous-area classification.
- 6Engineering — Install differential-pressure gauges across intake and exhaust filters with alarm setpoints triggering automatic gun lockout when media loading exceeds manufacturer threshold.
- 7Administrative — Implement a written start-up checklist covering fan run-up, filter pressure check, SDS review, RPE fit-test status and hot-work exclusion zone verification before any coating is loaded.
- 8Administrative — Schedule filter media changes during cold-booth windows, store spent media in lidded metal containers outdoors and document disposal under the hazardous chemicals waste register.
- 9PPE — Issue air-fed full-face respirators meeting AS/NZS 1716 with cartridge selection driven by the specific coating SDS, supported by annual quantitative fit-testing per AS/NZS 1715.
- 10PPE — Provide nitrile or laminate chemical-resistant gloves, solvent-resistant coveralls, Class 5 hearing protection and antistatic safety footwear, replaced when breakthrough or contamination is detected.
Applicable Codes of Practice
Triggers manifest, register, label, SDS access and health-monitoring duties for every coating and solvent stored or atomised inside the spray booth.
Sets mandatory face-velocity, extract, lighting and electrical-classification criteria that the booth must continue to meet under regulation 37 risk-control duty.
Approved Code under WHS Act s274 detailing booth operation, RPE selection, filter management and hot-work exclusion expectations for PCBUs and operators.
Drives air-fed respirator selection, fit-testing frequency and program documentation required to demonstrate adequate PPE under WHS Reg 44.
High-Risk Construction Work triggered
Atomising paints, thinners and cleaning solvents inside the booth generates direct inhalation and dermal exposure to GHS-classified hazardous chemicals during every shift.
PCBU must prepare, consult workers on, and retain the SWMS for the duration of the work plus incident-related extensions; penalties for non-compliance are substantial and indexed, with the current maximum following the prevailing WHS schedule.
Who this is for
- →Automotive refinish workshop owners and licensed operators
- →Industrial coatings applicators in fabrication facilities
- →WHS managers overseeing paint shop compliance audits
- →Apprentice spray painters under supervised competency training
What you receive
- ✓Editable DOCX template — Microsoft Word compatible
- ✓State-specific WHS legislation schedule (NSW/VIC/QLD/SA/WA/TAS/NT/ACT)
- ✓Hazard register with risk ratings + hierarchy-of-control mapping
- ✓Worker sign-on register, pre-start checklist, and incident escalation flow
Worked example
At a suburban smash-repair facility, the booth supervisor opens the morning pre-start brief by walking the two refinish technicians through this SWMS at the booth control panel. The supervisor steps through the hazard register, pausing on flammable vapour accumulation and ventilation interlock failure, then asks each technician to confirm the coating system scheduled for the day — a waterborne basecoat followed by a 2K clear. Because the clear's SDS Section 8 flags isocyanate-free polyaspartic chemistry with a hydrocarbon solvent carrier, the supervisor confirms air-fed respirators rather than cartridge half-masks, checks both technicians' fit-test cards are current under AS/NZS 1715, and signs the RPE selection line on the SWMS. The crew then verifies extract face velocity on the digital gauge against the AS/NZS 4114.1 setpoint, confirms the hot-work exclusion barricade is in place around the adjacent welding bay, and signs onto the document. Mid-morning the differential-pressure alarm triggers as filter media loads. Following the SWMS administrative control, the crew shuts down, purges the booth, isolates the gun supply, and changes the intake media into a lidded metal drum stored outdoors. The supervisor annotates the SWMS change-log noting the unscheduled filter swap, both technicians re-sign, and spraying resumes only once face velocity is reconfirmed in writing.
Related legislation
- WHS Act 2011 (model)
- WHS Regulation 2025
- Code of Practice — Hazardous Manual Tasks