PPE Selection >> Surface Preparation

Figure 1: Illustrates a "safe" set-up for hot work where PPE is required
Figure 1: Illustrates a "safe" set-up for hot work where PPE is required

OSHA hierarchy of controls is:

  1. Engineering Controls
  2. Administration Controls
  3. Personal Protective Equipment (PPE)

Surface preparation requires preplanning and evaluation of the area for potential hazards before work is begun. Usually, a Shipyard Competent Person (SCP), Certified Industrial Hygienist (CIH), or Certified Marine Chemist (CMC) is needed to help evaluate hazards and select PPE. Additional hazards will exist if work is done in enclosed or confined spaces (see confined space).

Surface preparation operations present a significant risk for skin, eye, and respiratory exposure to toxic and corrosive chemicals, as well as risk of burns, cuts, and lacerations. Surface preparation operations often require the use of respiratory protection equipment. Employers must comply with the OSHA respirator standard [29 CFR 1915.154 and 29 CFR 1910.134].

Typical surface preparation operations are as follows:

Each of these surface prep operations may present unique hazards. Therefore, a qualified person must select PPE based on the specific operation. Use of appropriate combinations of the following PPE will provide adequate protection:

Review the General Shipyard Worker PPE before proceeding with this section.

PPE is required when performing abrasive blasting and must provide protection from the impact of the rebounding abrasive blast material (for example sand, metal slag) and toxic effects of the abrasive blast material and coatings (such as paint, grease) being removed. Due to possible surges of pressure in the hose line and potential static electricity shocks, fall protection may be necessary. Hearing protection is important in this operation due to the high noise levels usually associated with this operation. For more information, see Surface Preparation: Mechanical Removers in Ship Repair.

PPE is required when using chemical paint removers (such as methylene chloride, sodium hydroxide/lye) and must provide protection from skin contact, skin absorption, and inhalation. Reactions between the cleaner and the material being removed may produce additional toxic vapors or liquids.

Note: During these operations, it is important to have an emergency eye and body flushing station.

For more information, see Surface Preparation: Mechanical Removers in Ship Repair.

Figure 2: Eye wash station
  • Fixed or portable eye wash stations/safety showers should meet ANSI Z358.1-1998: Emergency Eye Wash and Shower Equipment.

PPE is required when performing flame removal of hardened coatings (such as paint) and must provide protection from the fumes and smoke created from this process. [29 CFR 1915.34(b)(1)]

For more information, see Surface Preparation in Ship Repair.

PPE is required when performing mechanical paint removal (such as by grinding, needle gunning, pneumatic chipping). Due to high noise, flying particles, and dust, hearing and eye protection are required and respiratory protection may be required for all these operations. Due to the sparks produced, by grinding, protective clothing is required. [29 CFR 1915.152(a) and (b)] Anti-vibration devices should be used to reduce the effect of excessive vibration from pneumatic tools.

For more information, see Surface Preparation: Mechanical Paint Removers in Ship Repair.

PPE is required when using hydro-blasting as a surface preparation method and must protect the worker from injury from the hazards of the high-pressure water stream, often from 1000 to 30000 psi. Due to the pressure reaction of turning the stream on and off, fall protection may be necessary. Due to high noise, hearing protection may be required. The PPE should also protect the worker from skin contact with the material being removed, which in many cases can be toxic.

For more information, see Surface Preparation in Ship Repair.

PPE is required when performing solvent degreasing (such as with xylene, mineral spirits, acetone) to provide protection from skin contact, skin absorption, and inhalation. Reactions between the degreaser and the material being removed may produce additional toxic vapors or liquids. Note: During these operations, it is important to have an emergency eye and body flushing station.

For more information, see Surface Preparation in Ship Repair.

Figure 3: Warning sign for sandblasting

Potential Hazard

  • Chemical absorption or burns due to skin exposure to chemical cleaner or residues
  • Abrasions and amputations from particles generated by grinding, chipping, and blasting operations
  • Hearing loss from excessive noise
  • Burns due to contact with steam or hot water
  • Burns and amputations from contact with high-pressure steam, water, or air streams from high-pressure equipment
  • Struck-by injuries and falls caused by uncontrolled high-pressure hoses
  • Heat-related illnesses due to a combination of PPE use, heat-producing equipment, work activity, and environmental conditions. See Surface Preparation: Mechanical Removers - Work Environmental Temperature-Related Hazards.
Figure 4: Abrasive blaster with appropriate PPE

Requirements and Example Solutions

  • Blasting hood and heavy canvas or leather aprons are required to protect the head and body of the blaster from the impact of rebound abrasives. (See Fig 2.) [29 CFR 1915.34(c)(3)]
  • Gear should provide skin protection from water, steam burns and high-temperature water during pressure spraying. (See Fig 3.)
  • Figure 5: Worker steam cleaning without gloves and face shield
    Gear must provide skin protection from corrosive and toxic chemicals that may be spilled, sprayed, or splashed during their use. (See Fig 4.) [29 CFR 1915.33(a)]
  • Attached hoods should be used and when there is head or neck exposure.
  • When respirators are used, hoods should be tightened over the respirator to prevent interference with the face seal and allow proper removal of gear.
  • Figure 6: Workers with chemical protective suits
    Heat stress program should be used
  • Leather garments provide such protection provided that they are free of flammable or combustible materials such as oil, grease, and solvents.
Figure 7: Worker using solvent to degrease deck

For more detailed information, review Hand and Body Protection.

Figure 8: Air-line respirator

Potential Hazards

Respirators protect the lungs and upper respiratory tract from dust, mists, fumes, and vapors that are associated with the cleaners and residues. Worker illness may result from:

  • Inhalation exposure to toxic or corrosive chemicals
  • Exposure to oxygen-deficient atmospheres
  • Exposure to dust (such as silica, lead, and chromate)
Figure 9: Abrasive blaster on barge creating large dust cloud

Requirements and Example Solutions

  • Abrasive blasting hoods with supplied breathing air or positive pressure air helmets are required to be used by blasters when blasting in enclosed areas. [29 CFR 1915.34(c)(3)(i)]
  • Other workers in the blasting area where unsafe concentrations of abrasive materials and dust are present are required to wear appropriate respiratory protection (such as air-line or air-purifying respirator). See Fig 7 & 8. [29 CFR 1915.34(c)(3)(iii)]
  • Figure 10: Other workers exposed to abrasive grit
    Flame removal of coatings in enclosed spaces requires the use of supplied air respirators. An air purifying respirator with appropriate filters can be used when performing this work in the open. Air monitoring is used to determine the type of respirator required. [29 CFR 1915.34(b)(1)]
  • A supplied-air respirator may be required when grinding on surfaces containing lead, cadmium, mercury, or beryllium in enclosed spaces, and air purifying respirators are required for grinding on these metals in the open air. [29 CFR 1915.34(a)(4)]
  • Air-supplied respirators may be necessary to provide adequate respiratory protection.
  • If a half face mask respirator is used, eye and face protection may also be required in the form of a face shield and goggles.
Figure 11: Worker with protective clothing and air-line respirator

For more detailed information, review Respiratory Protection.

Figure 12: Worker with disposable suit, gloves and face protection

Potential Hazards

  • Chemical absorption or burns due to skin exposure to chemical cleaner or residues.
  • Eye and face injury from particles generated by grinding, chipping and blasting operations.
  • Worker face and eye exposure to corrosive or toxic chemicals that may splash or be sprayed.
Figure 13: Workers using pressure washing with face protection

Requirements and Example Solution

  • Full-face respirators should be used when toxic chemicals which can be absorbed through the skin are used.
  • Face shields are necessary to protect the face skin outside the respirator if a half face respirator is used.
  • Face shields alone are not for protection for the eyes and safety glasses must be worn under the face shield for adequate protection.

For more detailed information, review Eye and Face Protection.

Figure 14: Emergency eye/face wash
  • Fixed or portable eye wash stations/safety showers should meet ANSI Z358.1-1998: Emergency Eye Wash and Shower Equipment.
Figure 15: Workers with appropriate foot protection (such as, rubber boots)

Potential Hazards

  • Lacerations or amputations due to exposure to high-pressure water and steam.
  • Slips and falls due to slippery surface.
  • Foot related illnesses due to wading in water.
  • Chemical absorption or burns due to skin exposure to chemical cleaner or residues.
  • Burns due to contact with steam or hot water.
  • Hypothermia or frost bite from working in cold and/or wet conditions. See Cleaning Operations: Work Environmental Temperature-Related Hazards.
Figure 16: Safety boots

Requirements and Example Solutions

  • Boots (e.g., chemical resistant, waterproof) should provide skin protection from:
    • corrosive and toxic chemicals that may be spilled, sprayed or splashed during their use.
    • trauma during high-pressure spraying.
    • steam burns and high-temperature water.
    • prolonged exposure to water and similar non-hazardous liquids.
  • Boots should be worn with the legs of the protective clothing over them to prevent liquids from entering the boots.
  • Slip-resistant soled boots should be worn when working on slippery surfaces.

For more detailed information, review Foot Protection.

Figure 17: Worker cleaning with chemical-resistant gloves

Potential Hazards

  • Chemical absorption or burns due to skin exposure to chemical cleaner or residues.
  • Burns due to contact with steam or hot water.
  • Frostbite from working in cold and/or wet conditions. See Cleaning Operations: Work Environmental Temperature-Related Hazards.
Figure 18: Leather gloves used by blasters

Requirements and Example Solutions

  • Gear should provide skin protection from:
    • corrosive and toxic chemicals that may be spilled, sprayed or splashed during their use.
    • water during pressure spraying.
    • trauma during high-pressure spraying.
    • steam burns and high-temperature water.
  • Gloves should be sealed to the protective clothing to prevent liquids from entering the glove.
  • For specific operations, inner gloves may be required.
Figure 19: Worker grinding with leather gloves