An investigation of occupational metal exposure in thermal spraying processes

A cross-sectional study of 34 workers engaged in thermal spraying at six worksites was undertaken in order to determine levels of exposure to and uptake of metals during different metal spraying activities. Levels of exposure to cobalt, chromium and nickel were highest in plasma sprayers and, on occasions exceeded UK Occupational Exposure Limits. Exposure to metals during detonation gun and electric arc spraying was better controlled and levels remained below the relevant Occupational Exposure Limits throughout the study period. Urinary levels of cobalt and nickel mirrored the airborne concentrations and the highest urine concentrations were again found in plasma sprayers. Urinary chromium levels were highest in electric arc sprayers, which may also reflect an increased body burden in this group due to a longer history of exposure. The findings clearly indicate that exposure to and uptake of metals may exceed UK Occupational Limits or Standards when spraying is performed manually or semi-automatically and where control relies on local exhaust ventilation (LEV) and personal respiratory protective equipment (RPE).