OCCUPATIONAL HEALTH RISKS FROM OVERSPRAY IN AUTOMOTIVE WORKSHOPS: A CFD-BASED ANALYSIS

Abstract

Overspray generated during automotive spray-painting processes poses significant occupational health risks, particularly in small to medium enterprises that often lack adequate ventilation and safety protocols. This study investigates the correlation between paint overspray dispersion and the development of health conditions such as Sick Building Syndrome (SBS) among workshop personnel. Utilizing Computational Fluid Dynamics (CFD) simulations, the research models the behaviour of airborne paint particles under varying spray angles and environmental conditions. The findings reveal that improper spraying techniques, especially at arced angles, result in a substantial increase in airborne particulates, with up to 70% of the paint material becoming airborne and failing to adhere to the target surface. Particle concentrations reached as high as 0.85 kg/m³ in simulated environments, with dispersion distances exceeding 1.5 meters from the spray origin. These conditions contribute directly to SBS symptoms such as respiratory irritation, headaches, and chronic fatigue. The study highlights the critical need for controlled spray environments, optimized spray techniques, and the implementation of effective extraction systems. It also provides evidence-based recommendations for mitigating health risks through informed workshop design and procedural interventions.