CoP 48.0 - Spray Finishing

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Abu Dhabi Occupational Safety and
Health System Framework
(ADOSH-SF)
Code of Practice
CoP 48.0 – Spray Finishing
Version 4.1
February 2026

ADOSH-SF – Codes of Practice
CoP 48.0 – Spray Finishing- Version 4.1 – 16th February 2026 Page 2 of 16
Table of Contents
1. Introduction ....................................................................................................................................................... 3
2. Training and Competency ............................................................................................................................. 5
3. Requirements .................................................................................................................................................... 6
3.1 Roles and Responsibilities ................................................................................................................. 6
3.2 Safety Requirements........................................................................................................................... 7
3.3 Paint Booths / Spray Finishing Booths ......................................................................................... 8
3.4 Spray Finishing Operations outside a Booth .............................................................................. 8
3.5 Spray Finishing Operations in a Workroom ............................................................................... 10
3.6 Spray Finishing in Confined Space ............................................................................................... 10
3.7 Mixing and Pouring............................................................................................................................. 11
3.8 Atmospheric Monitoring / Air Sampling ...................................................................................... 11
3.9 Storage and Labelling of Spray Finishing Materials............................................................... 12
3.10 Maintenance and Cleaning .............................................................................................................. 12
3.11 Occupational Health........................................................................................................................... 13
3.12 Emergency Response ........................................................................................................................ 13
4. References ....................................................................................................................................................... 14
5. Document Amendment Record ................................................................................................................. 15

ADOSH-SF – Codes of Practice
CoP 48.0 – Spray Finishing- Version 4.1 – 16th February 2026 Page 3 of 16
1. Introduction
(a) This Code of Practice (CoP) applies to all employers within the Emirate of Abu Dhabi
that perform spray finishing activities. This CoP is designed to incorporate
requirements set by UAE and Abu Dhabi Regulatory Authorities. If requirements of
this document conflict with requirements set by another regulatory authority,
employers are required to follow the more stringent requirement.
(b) This CoP sets requirements for spray finishing operations to include spray painting.
(c) Definitions applicable to this CoP:
(i) Absolute Pressure: Based on a zero-pressure reference point, the perfect
vacuum. Measured from this point, standard atmospheric pressure at sea level
is 14.7 pounds per square inch (psi) or 101.325 kilo Pascal’s (kPa). This is usually
expressed as psia where the 'a' indicates an absolute measurement or kPa.
(ii) Airless spraying: is a method by which pressure is applied directly to the paint,
which is forced out of a nozzle.
(iii) Atmospheric monitoring: Atmospheric monitoring is the sampling of workplace
atmospheres to obtain an estimate of inhalation exposure to hazardous
substances. Monitoring indicates whether the recommended exposure
standards are being exceeded or approached.
(iv) Electrostatic spray-guns: have electrically charged nozzles which transfer the
electric charge to droplets of paint which are then attracted to the edges and
back of the work piece, an effect known as the “wrap-around effect”. In some
automatic painting processes the objects to be painted are charged. Direct
current sources are used and handguns may be designed with safe nozzles
carrying a very low current at high voltage. Automatic guns carry much higher
currents which are potentially lethal.
(v) Hazardous Area: An area where flammable or explosive gas or vapor-air mixtures
(often referred to as explosive gas-air mixtures) are, or may be expected to be,
present in quantities which require special precautions to be taken against the
risk of ignition.
(vi) Lower explosive limit (LEL) of a combustible gas is the smallest amount of the
gas that supports a self-propagating flame when mixed with air (or oxygen) and
ignited. In gas-detection systems, the amount of gas present is specified as a
percentage (%) LEL. Zero percent (0%) LEL denotes a combustible gas-free
atmosphere. One hundred percent (100%) lower explosive limit denotes an
atmosphere in which gas is at its lower flammable limit. The relationship
between percent LEL and percent by volume differs from gas to gas.
(vii) Spray finishing / painting: refers to the process by which a liquid coating
substance, such as paint, is converted into a mist or aerosol in order to apply a
coating onto an object or surface. Spray painting is used in a variety of industries
and by a variety of employees. It is used in industrial operations, to paint motor
vehicles, buildings (inside and outside), structures, furniture, white goods, boats,
ships, aircraft and machinery.
(viii) In Spray Painting Process air is driven across the mouth of a small outlet under
such pressure as to draw the paint out and produce an air-paint mist from the

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jet of the spray-gun. In addition, the paint may be fed under pressure to the gun.
Spray painting may be carried out by hand or automatically.
(ix) There are three classes of hazardous area or zone: zone 0, zone 1 and zone 2. A
zone is an area around a process or activity where a flammable atmosphere may
be present. The definitions of the three hazardous zones are given in Table 1
below. It is advisable to exclude electrical equipment from the spray area. Any
electrical equipment that has to be inside the spray area shall be designed and
constructed for use in a zone 1 or zone 2 according to the hazardous area
classification. All other sources of ignition shall be removed from the hazardous
area.
Zone Definition
Zone 0 An area in which an explosive gas mixture is continuously
present or present for long periods.
Zone 1 An area in which an explosive gas mixture is reasonably
foreseeable to occur in normal operation.
Zone 2
An area in which an explosive gas mixture is not reasonably
foreseeable to occur in normal operation, and, if it does occur, is
reasonably foreseeable to do so only infrequently and will exist
for a short period only.
Table 1: Hazardous Zones

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2. Training and Competency
(a) Employers shall ensure that OSH training complies with the requirements of:
(i)
ADOSH-SF – Element 5 – Training, Awareness and Competency.
(ii)
ADOSH-SF – Mechanism 7.0 – Occupational Safety and Health Practitioner and
Service Provider Registration.
(b) Employers shall ensure all relevant employees and contractors that perform tasks that
spray finishing operations are trained, but not limited to:
(i) physical hazards associated with spray finishing operations;
(ii) design specification, capabilities and limitations of spray finishing systems and
their uses at the work site;
(iii) methods and procedures that will prevent exposure to hazards associated with
spray finishing operations;
(iv) safe storage and handling procedures;
(v) safe work practices;
(vi) required use, maintenance and storage of PPE;
(vii) emergency response procedures;
(viii) health hazards associated with chemical used in spray finishing at the work site;
(ix) signs and symptoms of exposure to spray finishes used at the work site; and
(x) operator maintenance requirements spray finishing systems.
(c) Employers shall ensure managers and supervisors of spray finishing operations shall
be trained on:
(i) requirements listed in Section 2(b);
(ii) maintenance requirements of spray finishing system to ensure they are working
appropriately and within specifications;
(iii) how to recognize unsafe work practices when performing spray finishing
operations; and
(iv) how to identify when spray finishing systems are not working appropriately.
(d) After an employee receives training on spray finishing operations, a competent person
shall evaluate the employee performing spray finishing operations to ensure they
have understood the training and are following safe work practices.
(e) All training shall be conducted prior to an employee performing any spray finishing
operations and annually thereafter. Retraining shall also be conducted if an employee
is not following safe work practices.

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3. Requirements
3.1 Roles and Responsibilities
3.1.1 Employer
(a) Employers shall undertake their roles and responsibilities in accordance with the
general requirements of
ADOSH-SF – Element 1 – Roles, Responsibilities and Self-
Regulation Section 3.2.5.
(b) Employers shall be responsible for performing a risk assessment in accordance with
ADOSH-SF – Element 2 – Risk Management to determine the risks associated to
identify areas where control measures and safe work practices are required to reduce
employee’s exposures to hazards associated with spray finishing operations and
hazards materials/chemicals.
(c) Employers shall implement the Occupational Health and Safety hierarchy of controls,
ADOSH-SF – Element 2 – Risk Management, when developing control measures to
remove or reduce employee exposure to hazards associated with spray finishing
operations.
(d) Employers shall ensure that protective equipment or other control measures shall be
used to keep the exposure of employees to hazards associated with spray finishing
and hazardous materials/chemicals within limits prescribed by applicable local and
federal regulations.
(e) Employers shall develop an inspection, testing and preventative maintenance plan to
ensure spray finishing systems are safe and working efficiently and according to
manufacturer’s specifications and applicable legal requirements.
(f) Employers shall ensure maintenance is performed on spray finishing systems as per
the preventative maintenance plan.
(g) Employers shall ensure spray finishing systems are tested and inspected regularly (at
a minimum annually) to ensure the system work in accordance with manufacturer’s
specifications and other applicable legal requirements.
(h) Employers shall monitor spray finishing operations to ensure employees are using
equipment, safety devices and personal protective equipment appropriately.
3.1.2 Employees
(a) Employees shall undertake their roles and responsibilities in accordance with the
general requirements of
ADOSH-SF – Element 1 – Roles, Responsibilities and Self-
Regulation Section 3.2.7.
(b) Employees shall report any activity or defect relating to spray finishing operations
which they believe is reasonably foreseeable to endanger their safety or that of
another person.
(c) Employees shall comply with safe work practices and standard operating procedures.

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(d) Employees shall use appropriate equipment or safety devices provided by the
employer in accordance with any training or instruction received in the use of the work
equipment or device concerned.
(e) Employees shall not perform any task requiring training until they have received the
required training and it is documented.
(f) Employees shall not operate any piece of equipment that they are not familiar with,
competent to operate and/or appropriately trained on its use.
3.2 Safety Requirements
(a) When performing risk assessments in accordance with
ADOSH-SF – Element 2 – Risk
Management, the following shall be considered:
(i) the chemicals used in the spray finishing operation and their impact on the
health of employee(s) and any impact they may have on the environment;
(ii) the condition of the spray finishing equipment being used (compressors, hoses,
couplings etc.) and if they are rated by an appropriate International Standard for
their intended use;
(iii) the type, frequency and duration of spray finishing operations;
(iv) the environment in which the spray finishing operations is to be undertaken;
(v) the level of experience of the personnel involved in the work; and
(vi) other identified hazards associated with the work.
(b) When using compressed gas systems, including pressurized air, as part of the spray
finishing system, the requirements of
ADOSH-SF – CoP 49.0 – Compressed Gases and
Air shall be complied with.
(c) All spray finishing operations shall be performed in spray booths that meet the
requirements of this CoP except when:
(i) where, by reason of its shape, size or weight, an article cannot readily be moved
or cannot fit into a booth and must be sprayed where it has been assembled, e.g.
boilers, structural steel fabrications, ships, boats, aircraft;
(ii) for infrequent spraying of heavy or bulky equipment; or
(iii) for minor operations such as spotting or touching up.
(d) For spray finishing operations that cannot be performed inside a booth, a risk
assessment shall be performed for the operation and alternative control measures are
implemented to limit employee exposure to the lowest level feasible. Employers shall
ensure compliance with exposures limits set by applicable local and federal
regulations.

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3.3 Paint Booths / Spray Finishing Booths
(a) Booths shall provide a continuous, uniform and evenly distributed supply of air flow
throughout the spray-painting area to the exhaust outlets. There shall be no pockets
of still air in the booth.
(b) The source of air supply shall be located in an appropriate area to ensure a clean and
uncontaminated primary source.
(c) Employees (e.g. spray painters) shall not be positioned between the spray gun and the
ventilation exhaust duct.
(d) Booths shall maintain an internal negative pressure during operation to prevent
leakage of contaminants into surrounding work areas. Booths shall be equipped with
a negative pressure gauge.
(e) Booths shall be equipped with a gauge or alarm to indicate if airflow drops below the
minimum set air flow rate to capture contaminants.
(f) Booth ventilation system shall remain on for five (5) minutes after completing
spraying operations to purge the chamber.
(g) Booths shall provide a level of air velocity at any point within the booth that complies
with the following requirements:
(i) minimum air velocity for downdraft booths and cross-draft booths where drafts
from outside the booth is equal to or less than 0.2 meters per second: 0.5 meters
per second;
(ii) minimum air velocity for downdraft booths and cross-draft booths where drafts
from outside the booth is more than 0.2 meters per second: 0.8 meters per
second; and
(iii) minimum air velocity for electrostatic spray painting and spray finishing without
operator: 0.4 meters per second.
3.4 Spray Finishing Operations outside a Booth
(a) Where it is not reasonably practicable to do the spray finishing in a booth and it is
carried out in a building or structure other than a confined space, the building or
structure shall be of open construction or a mechanical exhaust system shall be used
to prevent the buildup of flammable or toxic fumes.
(b) Appropriate control measures shall be implemented to protect the spray finisher, other
employees or persons in the vicinity, and the environment, from hazards associated
with spray finishing operations. A spray finishing exclusion zone, with restrictions on
entry, shall be designated around the area where the spray finishing is being carried
out. An exclusion zone in itself will not provide appropriate protection and shall be
used in conjunction with other appropriate control measures.
(c) All spray finishing operations shall be conducted in an isolated location, “exclusion
zone.” A spray finishing process is not effectively isolated from other operations if
paint from the spray finishing operation can be inhaled by any persons engaged in
work near the area. Neither is it effectively isolated from plant, machinery or

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equipment if there is danger of the plant being ignited by a source of ignition
associated with the plant, machinery or equipment.
(d) In general, the exclusion zone shall be at least 6 metres horizontal and 2 metres
vertical clearance above and below the place where the spray finish is being applied;
however, in determining the size of the exclusion zone, the following factors shall be
considered:
(i) the nature of the substance being sprayed;
(ii) the work environment, including wind speed, ambient temperature and
humidity;
(iii) fire and explosion hazards;
(iv) the location and physical conditions of the site; and
(v) whether other people are reasonably foreseeable to be in the vicinity.
Relocation of employees not involved in spray finishing activities to other parts
of the workplace may be necessary.
(e) Greater vertical clearance may be required when spray finishing in stairwells and other
areas which allow vertical movement of vapors.
(f) Once a spray finishing exclusion zone has been established, a number of procedures
shall be implemented to control risks. These include:
(i) physical barriers and warning signs to prevent unprotected persons from
entering the exclusion zone;
(ii) shrouding of the area where spraying is to occur;
(iii) restricted entry of unprotected persons into the exclusion zone for a time period
that ensures airborne concentrations of hazardous substances have reduced to
below the relevant exposure standards;
(iv) removal of hazardous substances that are not immediately needed for spray
finishing work, to reduce unnecessary exposure and fire or explosion risks;
(v) removal of stored wastes such as solvent-soaked rags and waste paint from
within the exclusion zone to control fire or explosion risks;
(vi) removal of electrical and ignition sources, including smoking, from within the
exclusion zone to control fire and explosion risks;
(vii) restriction of spraying when wind speed is greater than 15 kilometers per hour;
and
(viii) restriction of spraying within 50 meters of the boundary to adjacent premises
or a greater separation where car parks and other sensitive property is located.
(g) Consideration shall be given to ensure spray drift in walkways, public areas and air
conditioning intake vents is controlled. Persons other than the spray painter shall not
enter the exclusion zone during a spray-painting operation unless equivalent personal
protective equipment is worn. A sign stating “SPRAY PAINTING AREA - AUTHORISED
PERSONNEL ONLY” shall be prominently displayed at the exclusion zone.

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(h) Where spray finishing using two-pack paints containing isocyanates is carried out in
the open air, all persons within 15 meters of the spraying operation shall wear
respiratory protection.
3.5 Spray Finishing Operations in a Workroom
(a) When it is not reasonably practicable to use a booth to contain the spraying operation,
for example when spraying large items of steelwork or equipment. In this case,
spraying may be carried out in a workroom provided appropriate control measures are
implemented.
(b) If the room to be used for spraying is within a building, there shall be half-hour fire
separation between the spray room and the rest of the building. If the spray area is
part of a larger room (for example, a hangar), employers shall divide the room with
fire-resistant curtains to define the spraying area and provide fire protection.
(c) Before spraying, all potential sources of ignition shall be removed. Unprotected
electrical equipment shall be removed or isolated. If there has to be any electrical
equipment in the spray room, a risk assessment and hazardous area classification shall
be carried out to decide the level of protection required.
(d) Employers shall conduct continuous atmospheric monitoring / air sampling to ensure
compliance to permissible LEL.
(e) Ventilation shall be provided to maintain the concentration below 25% at any point of
time (occasional peaks) and shall be maintained below 10% of the LEL on a continuous
monitoring basis. Monitoring using an explosimeter is required. The use of a spray
system, that reduces the quantity of solvent used and the overspray produced, is
recommended. Care shall be taken to ensure that the ventilation system is effective
at low level and anywhere vapors could accumulate.
(f) Applicable controls listed in other relevant sections of this document shall be followed.
3.6 Spray Finishing in Confined Space
(a) Spray finishing operations that are conducted in confined spaces shall be performed
in accordance with the requirements of
ADOSH-SF – CoP 27.0 – Confined Spaces and
ADOSH-SF – CoP 21.0 – Permit to Work Systems.
(b) Employers shall consider if it is reasonably practicable that a flammable liquid is be
ignited at a temperature lower than the stated flash point when the paint is atomized.
Ignition sources identified as a part of risk assessment shall be eliminated prior to the
commencement of spraying.
(c) Sources of ignition inside the confined space shall be prohibited and any lighting used
shall be protected to a standard appropriate for flammable and explosive
atmospheres.
(d) Any unprotected equipment used, such as fan motors, compressors, switches and
alarms shall be sited in safe areas outside the confined space where they cannot be
exposed to flammable concentrations of vapor.

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(e) Ventilation within the confined space until the coating is dry and there is no further
risk of a flammable atmosphere.
3.7 Mixing and Pouring
(a) During any mixing and pouring of spray finishing materials, the employer shall ensure:
(i) appropriate ventilation is maintained;
(ii) all containers are appropriate, grounded, bonded and labelled;
(iii) Safety Data Sheets are available;
(iv) appropriate protective equipment is worn (refer to the relevant SDS);
(v) mixing and pouring shall be conducted by mechanical means where reasonably
practicable;
(vi) appropriate spill kits and equipment are available; and
(vii) spills are cleaned up immediately.
(b) If spray painting substances are splashed on clothing or the body, the contaminated
clothing shall be immediately removed and the skin thoroughly cleaned with soap and
water.
(c) Solvents and thinners used to clean work areas shall not be used to clean employee’s
skin.
(d) Unused or surplus liquid shall be returned to the container designated for that liquid.
3.8 Atmospheric Monitoring / Air Sampling
(a) When hazardous materials are used for spray finishing, the work atmosphere shall be
monitored though air sampling to assess the employee exposures.
(i) air sampling results shall be compliant to applicable local and federal regulations;
and
(ii) if air sampling results exceed the permissible exposure limits, then controls shall
be implemented to reduce / prevent employee exposures.
(b) If monitoring results indicate that control measures are required to reduce / prevent
employee exposures, air sampling shall be used to assess the effectiveness of the
control measures.
(c) Air sampling records shall be maintained that include:
(i) who performed the sampling;
(ii) procedures used for air sampling;
(iii) location of air sampling;
(iv) date and time of sampling;
(v) serial number of equipment used for sampling;
(vi) calibration data for sampling equipment;

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(vii) analytical methods used for sampling;
(viii) laboratory used to analysis of samples;
(ix) laboratory certifications;
(x) chain of custody for the samples;
(xi) sampling results; and
(xii) report of findings and corrective actions.
(d) Laboratory analysis shall be conducted by laboratories approved by the Emirates
Standardization and Metrology Authority (ESMA).
3.9 Storage and Labelling of Spray Finishing Materials
(a) Materials shall be labeled, handled, stored and segregated as per the manufacturer’s
requirements and that of
ADOSH-SF – CoP 1.0 – Hazardous Materials.
(b) Labels shall be securely attached to containers so that they cannot be inadvertently
or accidentally detached during use, transport and storage.
3.10 Maintenance and Cleaning
(a) When spray finishing equipment is in use, it shall be cleaned daily or at the end of each
shift.
(b) Employers shall develop a maintenance program that ensures equipment is working
appropriately and provides early detection of any defect in control measures that
could result in a reduced level of protection.
(c) Spray finishing equipment shall be inspected prior to use on each shift. Examination
of the equipment shall include:
(i) visual inspection of equipment looking for worn equipment, damaged
equipment, integrity of joints / connections / hoses and any leaks;
(ii) personal protective equipment shall be inspected to ensure it is clean and is not
damaged; and
(iii) if a local exhaust ventilation system is used, it shall be inspected to ensure it is
working appropriately and filters are in good condition.
(d) Service records shall be maintained that include:
(i) equipment and control measures which require servicing;
(ii) nature of the servicing needed;
(iii) frequency of the servicing;
(iv) who is responsible for the servicing;
(v) documentation of defects and how they were corrected; and
(vi) performance testing and evaluation.

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3.11 Occupational Health
(a) Employees shall not be allowed to eat, drink, or smoke in the vicinity of spray finishing
operations. No open containers of food or drink shall be stored within or close to spray
finishing operations where contaminants could enter the open container.
(b) Changing rooms and showers shall be provided at the worksite for employees working
in spray finishing operations, as per the requirements
of ADOSH-SF – CoP 8.0 – General
Workplace Amenities.
(c) Employers shall have a first program in compliance with
ADOSH-SF – CoP 4.0 – First Aid
and Medical Treatment.
(d) Employers shall have a medical surveillance program in compliance with
ADOSH-SF –
CoP 5.0 – Medical Surveillance.
3.12 Emergency Response
(a) Emergency Response procedures compliant to
ADOSH-SF – Element 6 – Emergency
Management shall be developed for all spray finishing operations. Requirements for
emergencies involving spray finishing operations include medical emergencies,
chemical spills, leaks, fire, explosions etc. as identified through the Risk Assessment
as required by Section 3.1(a) of this CoP.
(b) First aid procedures in accordance with
ADOSH-SF – CoP 4.0 – First Aid and Medical
Treatment shall be developed.

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4. References
• OSHA Ventilation Standard for General Industry (29 CFR 1910.94)
• Work Safe Western Australia Commission- Code of Practice on
Occupational Safety and Health Act 1984 and Occupational Safety and
Health Regulations 1996
• UK HSE Book HSG 178- The Spray of Flammable Liquid
• UK HSE Book HSG 188- Health Risk Management- Guide to working with
solvents

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5. Document Amendment Record
Version Revision Date Description of Amendment
Page/s Affected
4.0
15th July 2024
System acronym updated from OSHAD-SF
to ADOSH-SF to accurately reflect
document title
Throughout
Change from OSHAD to ADPHC
Change of Logo
Minor editorial changes throughout the
document without changing requirements.
Title of Mechanism 7.0 updated to ADOSH-
SF – Mechanism 7– Occupational Safety
and Health Practitioner and Service
Provider Registration
OSHAD-SF - Mechanism 8.0 - OSH
Practitioner Registration deleted
4.1
16th February
2026
Minor editorial changes throughout the
document without changing requirements
Throughout