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This paper presents a mathematical model to predict breathing-zone overspray concentrations produced during spray painting as a function of the overspray generation rate, ventilation and work practices. The overspray generation rate required an estimate of the spray gun transfer efficiency, which was provided by a previously developed mathematical model. These models were evaluated in the field under two different scenarios: first in a controlled environment that approximated the assumptions of models, and then under actual spray painting conditions. Results from the first test showed the model overestimated transfer efficiency, but the measured exposures and predicted exposures were not significantly different. During actual spray painting operations, all task exposures were within a factor of three of the model predictions, and there was no statistical difference between the measured and predicted values. The predicted average exposure of each worker was within the 95% confidence interval. The overall mean exposure was within one standard error of the model prediction. The current study expands on the original exposure model by including a transfer efficiency model to provide a better estimate of the overspray generation rate. The theoretical foundation between exposure and its primary determinants is established, and this knowledge can be applied to design and can evaluate optimal control interventions. Also, the general methodology presented here for developing an exposure model is applicable to operations other than spray painting.

A Field Evaluation of the Impact of Transfer Efficiency on Worker Exposure During Spray Painting