Is your extraction system protecting you, or putting your team at risk?
A well designed and maintained extraction system is your spray booth’s first and most important safety defence. By removing flammable vapours and combustible overspray, extraction systems protect workers from fire, explosion, and long-term exposure risks while ensuring processes run smoothly and within compliance.
An extraction system that is poorly designed, incorrectly installed, or inadequately maintained can create the exact dangers it’s meant to prevent. Ineffective ventilation allows vapours and particles to accumulate, forming combustible atmospheres where even a small spark or static discharge could lead to disaster. Even the newest and most compliant equipment requires regular inspection and upkeep to remain safe over time.
If you need support with flammable atmosphere risks and DSEAR compliance, get in touch.
Common Risks with Spray Booth Extraction Systems
Several issues can compromise the safety of spray booth extraction systems, each carrying the potential to escalate into dangerous working conditions:
Vapour build up – Insufficient airflow allows flammable vapours to accumulate, increasing the likelihood of explosive atmospheres forming inside the booth.
Blocked or clogged filters – When filters aren’t replaced on schedule, extraction efficiency drops, leaving hazardous vapours and overspray in circulation.
Poor ducting design – Ineffective layouts or dead zones in ductwork can cause vapours to stagnate, raising ignition risks.
Static electricity – Without proper earthing, ductwork and equipment can accumulate charge, creating a common ignition source.
Cross contamination – Faulty extraction can allow solvent vapours to migrate to other areas of the facility, where ignition sources are often harder to control.
Real Life Incidents to Learn From
Spray booth safety is critical, yet history shows that it’s not always taken seriously enough. Unfortunately, when procedures aren’t followed or risks are underestimated, the consequences can be severe. Here are two incidents that highlight what can happen when spray booth hazards are overlooked:
Spray Booth Explosion – Norwich, 2015
Two workers were spraying welded steel buckets and discharging paint into a 200-litre drum inside the booth. Over time, the drum started acting like a bomb as flammable paint and thinners built up. The resulting vapour cloud came into contact with multiple ignition sources, triggering a devastating explosion that killed both workers.
What went wrong?
No risk assessment had been carried out, meaning the workers were unaware of the dangers involved. With proper extraction, the vapours could have been removed, preventing them from reaching an ignition source.
Spray Booth Fire – Manchester, 2014
A worker was cleaning a spray booth floor where dried paint had accumulated. To make the job easier, he was permitted to use an industrial floor scrubber. However, the motor in the scrubber ignited a cloud of flammable vapour that had built up, causing a fire. The worker sustained 26% burns, and the company was fined £80,000.
What went wrong?
The planning for the cleaning task failed to account for the hazards associated with using flammable solvents. The employee had not received the correct training, nor was he adequately supervised. A lack of foresight and proper control measures turned a routine job into a life changing accident.
Signs Your Extraction System Could Be Putting You at Risk
Spray booths carry significant potential hazards, but there are warning signs that can alert you to problems before they escalate. Training your staff to recognise these signals is one of the most effective ways to protect people, property, and processes.
Look out for:
- Strong odours or visible haze inside the booth.
- Uneven airflow or ineffective overspray capture.
- Filters that frequently clog or aren’t replaced on time.
- Missing or overdue ATEX compliance checks and hazardous area classification reviews.
If you spot any of these issues, it’s essential to act quickly. Investigate the problem, check whether your extraction system is functioning correctly, and if in doubt, stop using the booth until it has been professionally assessed.
Best Practices for Safer Spray Booth Extraction
The most effective way to reduce risks is through regular, thorough testing of your extraction system. Routine maintenance ensures airflow remains consistent and that hazards don’t have the chance to accumulate. This process should include expert led risk assessments and compliance audits.
Key practices include:
- Using the correct filters for your system and replacing them according to schedule.
- Ensuring ductwork is properly earthed and bonded to prevent static discharge.
- Identifying and classifying hazardous areas so that all equipment meets the required safety standards.
By embedding these practices into your operations, you not only protect your staff but also safeguard your facility from costly incidents and regulatory penalties.
How Sigma-HSE can help
At Sigma-HSE, we specialise in helping organisations identify, understand, and control spray booth risks.
Our experts provide:
- Risk assessments and hazardous area classification to uncover risks in your processes and provide clear, prioritised steps to improve safety.
- Flammability and vapour testing to determine the risks specific to your materials and ensure compliance with DSEAR regulations.
- Process safety training to equip your teams with the knowledge to spot warning signs early and respond effectively.
If you’re working with spray booths and unsure whether your current processes are safe, we can help you take control. Get in touch today to better understand the risks, protect your staff, and create a safer environment for your entire operation.
