Auto Body Shop Safety Manual

What Should an Auto Body Shop Safety Manual Include?

The contents of an Auto Body Shop Safety Manual should reflect the shop’s actual operations.

A collision repair facility performing structural repairs, welding, body work, sanding, paint preparation, and complete refinishing may require substantially more programs than a shop performing only minor cosmetic repairs.

Depending on operations, the manual may address:

• Collision repair.
• Damaged vehicle hazards.
• Spray painting and refinishing.
• Spray booths.
• Paint mixing.
• Isocyanates.
• Respiratory protection.
• Sanding and dust control.
• Body fillers and adhesives.
• Welding, cutting, and grinding.
• Frame straightening.
• Vehicle lifts and support.
• Hand and power tools.
• Hazard Communication.
• Flammable liquids.
• PPE.
• Fire prevention.
• Emergency procedures.

Programs should be selected according to the work actually performed and applicable requirements.

Auto Body Shop Safety Program

An effective Auto Body Shop Safety Program establishes responsibilities and procedures for identifying hazards, controlling employee exposures, maintaining equipment, performing collision repairs safely, and correcting unsafe conditions.

Management should provide the training, equipment, PPE, engineering controls, and resources necessary to perform body repair and refinishing work safely.

Managers and supervisors should:

• Identify shop hazards and chemical exposures.
• Ensure employees receive appropriate training.
• Maintain spray booths and ventilation systems.
• Ensure tools and equipment are maintained safely.
• Provide required PPE.
• Establish safe collision-repair procedures.
• Control fire and ignition hazards.
• Correct unsafe conditions.
• Investigate incidents and near misses.
• Follow up on corrective actions.

Employees should follow established procedures, use required PPE, properly operate ventilation and other controls, report defective equipment, and perform only work for which they have appropriate training and authorization.

Auto Body Shop Safety Inspections

Auto body shops should be inspected periodically to identify unsafe conditions and verify that established safety procedures are being followed.

Inspection topics may include:

• Spray booths.
• Ventilation systems.
• Filters.
• Paint-mixing areas.
• Flammable-liquid storage.
• Welding equipment.
• Compressed gas cylinders.
• Grinders and power tools.
• Vehicle lifts.
• Frame machines.
• Chemical containers and labels.
• PPE and respirators.
• Fire-protection equipment.
• Walking-working surfaces.
• Emergency equipment.

Deficiencies should be documented and corrected in a timely manner.

Job Safety Analysis (JSA/JHA)

A Job Safety Analysis or Job Hazard Analysis can be used to evaluate higher-hazard auto body operations.

JSAs/JHAs may be appropriate for:

• Spray painting.
• Paint mixing.
• Sanding.
• Welding and cutting.
• Grinding.
• Structural repairs.
• Frame straightening.
• Vehicle lifting.
• Damaged EV handling.
• Glass removal.
• Panel replacement.
• Chemical handling.

The analysis should identify task steps, hazards, and controls necessary to perform the work safely.

Collision Repair Safety

Collision-damaged vehicles can present hazards that may not be immediately apparent.

Before repair begins, employees should evaluate the vehicle and planned work for potential hazards involving:

• Vehicle stability.
• Sharp metal.
• Broken glass.
• Leaking fluids.
• Damaged fuel systems.
• Electrical systems.
• Batteries.
• Airbags and supplemental restraint systems.
• High-voltage components.
• Structural damage.

Employees should not begin work until significant hazards have been identified and appropriate controls established.

Vehicle Inspection Before Repair

Vehicles should be evaluated before entering the repair process.

The inspection should consider conditions that could affect employee safety, including:

• Collision damage.
• Fluid leaks.
• Fuel leaks.
• Damaged batteries.
• Unstable components.
• Broken glass.
• Sharp body panels.
• Electrical damage.
• Deployed or undeployed restraint systems.
• High-voltage systems.

Hazards should be communicated to employees performing subsequent repair operations.

Damaged Vehicle Hazards

Collision-damaged vehicles may contain loose or unstable parts, damaged wiring, leaking chemicals or fuels, sharp metal, and stored energy.

Employees should use caution when opening hoods, trunks, doors, and damaged body panels.

Unstable components should be secured or removed before employees work in an area where unexpected movement could cause injury.

Vehicle Movement and Shop Traffic

Moving vehicles can expose technicians, painters, customers, and other employees to struck-by and caught-between hazards.

Shops should establish procedures for:

• Moving vehicles between work areas.
• Backing.
• Entering and exiting bays.
• Parking.
• Vehicle keys.
• Pedestrian traffic.
• Customer access.
• Vehicle staging.

Drivers should verify that travel paths are clear before moving vehicles.

Vehicle Preparation

Vehicle preparation may include disassembly, trim removal, masking, sanding, cleaning, body work, and surface preparation.

Employees should consider hazards involving:

• Sharp components.
• Broken glass.
• Tools.
• Chemicals.
• Dust.
• Electrical systems.
• Ergonomic positioning.
• Vehicle stability.

Removed components should be stored so they do not create trip or falling-object hazards.

Supplemental Restraint Systems and Airbags

Airbags and other supplemental restraint systems can contain stored electrical or mechanical energy and may deploy unexpectedly if handled improperly.

Employees performing work around these systems should:

• Identify applicable restraint components.
• Follow manufacturer procedures.
• Observe required waiting periods after power isolation.
• Avoid inappropriate electrical testing.
• Properly handle removed components.

Employees should receive appropriate instruction before servicing restraint systems.

Automotive Spray Painting

Spray painting can expose employees to hazardous vapors, aerosols, overspray, flammable materials, and fire or explosion hazards.

Spray-finishing operations should be performed in appropriate areas with required ventilation, fire protection, electrical controls, and other safeguards.

Employees should follow established procedures for:

• Preparing coatings.
• Entering spray areas.
• Operating ventilation.
• Using spray equipment.
• Wearing PPE.
• Controlling ignition sources.
• Cleaning equipment.
• Handling waste.

Spray Booth Safety

Spray booths should be constructed, operated, and maintained according to applicable requirements.

Employees should not use spray booths for unauthorized storage or allow unnecessary combustible material to accumulate.

Booth components should be maintained in safe condition, including:

• Ventilation.
• Filters.
• Lighting.
• Electrical equipment.
• Fire protection.
• Doors.
• Exhaust systems.

Conditions affecting safe booth operation should be reported promptly.

Spray Booth Ventilation

Required mechanical ventilation should be operating during spray-finishing operations.

Ventilation should control flammable vapors, mists, overspray, and employee exposure as appropriate to the operation.

Employees should not spray when required ventilation is not functioning properly.

Ventilation systems should continue operating after spraying when necessary to safely remove vapors generated by drying materials and residues.

Spray Booth Inspection and Maintenance

Spray booths and associated systems should be inspected and maintained at appropriate intervals.

Inspection may include:

• Exhaust fans.
• Ductwork.
• Filters.
• Airflow.
• Fire-protection equipment.
• Electrical components.
• Doors.
• Lighting.
• Accumulated residue.

Maintenance should be performed by appropriately trained or qualified personnel.

Spray Booth Filters

Filters should be installed, inspected, and replaced according to the booth design and manufacturer instructions.

Excessively loaded or damaged filters should not remain in service.

Used filters and other contaminated materials should be handled and stored according to their hazards and applicable requirements.

Paint Spray Equipment

Spray guns, hoses, pumps, pressure systems, and associated equipment should be inspected and maintained.

Employees should:

• Use equipment designed for the coating and process.
• Inspect hoses and connections.
• Control pressure.
• Report leaks.
• Follow manufacturer procedures.
• Depressurize equipment before servicing where necessary.

Defective equipment should be removed from service.

Ignition-Source Control

Ignition sources should be strictly controlled in spray-finishing and other areas where flammable vapors may be present.

Potential ignition sources include:

• Open flames.
• Smoking.
• Sparks.
• Hot work.
• Improper electrical equipment.
• Hot surfaces.
• Static electricity.

Employees should understand restrictions applicable to spray and paint-handling areas.

Grounding and Bonding

Where required, conductive equipment and containers associated with spray finishing and flammable-liquid transfer should be appropriately grounded or bonded.

Employees should not remove or bypass grounding components.

Damaged grounding connections should be reported and corrected.

Overspray and Residue

Paint residue and overspray should not be allowed to accumulate excessively.

Booths, exhaust components, floors, and other affected surfaces should be cleaned at appropriate intervals.

Cleaning methods should not introduce unnecessary ignition or chemical hazards.

Spray Booth Cleaning

Before cleaning a spray booth, employees should consider:

• Coating residues.
• Cleaning chemicals.
• Ignition sources.
• Ventilation.
• PPE.
• Fire hazards.

Only appropriate tools and cleaning methods should be used.

Waste materials should be placed in suitable containers and removed according to established procedures.

Drying and Curing

Drying and curing operations can continue to release vapors after spraying is complete.

Employees should follow booth and coating-system procedures concerning:

• Ventilation.
• Heating equipment.
• Curing cycles.
• Ignition sources.
• Reentry.

Heating or curing equipment should be suitable for the intended operation.

Paint Mixing Room Safety

Paint mixing can expose employees to solvents, coatings, hardeners, catalysts, and flammable vapors.

Paint-mixing areas should be appropriately maintained and ventilated.

Employees should:

• Keep containers closed when not in use.
• Maintain labels.
• Review Safety Data Sheets.
• Control ignition sources.
• Use required PPE.
• Clean spills promptly.
• Store chemicals appropriately.

Only necessary quantities of materials should be maintained in work areas.

Automotive Paints and Coatings

Automotive coatings may contain hazardous ingredients requiring specific controls.

Before using a coating, employees should understand:

• Chemical hazards.
• Required ventilation.
• PPE.
• Respiratory precautions.
• Flammability.
• Mixing instructions.
• Storage requirements.

Employees should not assume products with similar uses have identical hazards.

Two-Component Coatings

Two-component coatings may involve reactive materials such as hardeners and catalysts.

Employees should follow product-specific instructions for:

• Mixing.
• Ventilation.
• PPE.
• Respiratory protection.
• Storage.
• Spill response.
• Waste handling.

Unnecessary skin contact should be avoided.

Isocyanate Exposure

Some automotive coatings, hardeners, primers, adhesives, and other products may contain isocyanates.

Exposure can occur through inhalation and skin contact.

Where isocyanates are present, the company should evaluate employee exposure and establish appropriate controls.

Controls may include:

• Product substitution where feasible.
• Spray-booth ventilation.
• Local exhaust ventilation.
• Respiratory protection.
• Gloves.
• Protective clothing.
• Employee training.

Employees should report symptoms potentially associated with exposure.

Exposure Assessment

Potential employee exposure to hazardous airborne contaminants should be evaluated when necessary to determine appropriate controls.

The assessment may consider:

• Chemicals used.
• Safety Data Sheets.
• Work methods.
• Frequency and duration.
• Ventilation.
• Existing exposure information.
• Air monitoring when necessary.

Controls should be adjusted when operations or products change significantly.

Respiratory Protection

Respiratory hazards can be significant during spray painting, sanding, welding, and other auto body operations.

Where respirators are required, the company should maintain a Respiratory Protection Program addressing:

• Respirator selection.
• Medical evaluation.
• Fit testing.
• Training.
• Inspection.
• Cleaning.
• Storage.
• Program evaluation.

Respirators should be selected according to the contaminants and conditions present.

Respirator Selection

Respirator selection should be based on an evaluation of the respiratory hazards.

Factors may include:

• Chemical identity.
• Exposure concentration.
• Form of contaminant.
• Oxygen availability.
• Assigned protection factor.
• Manufacturer limitations.
• Other workplace conditions.

Employees should use only respirators approved for the work through the company’s Respiratory Protection Program.

Medical Evaluation and Fit Testing

Employees required to wear respirators should complete required medical evaluation before fit testing or required respirator use.

Employees using tight-fitting respirators should receive required fit testing.

Fit testing should be repeated as required and when changes could affect respirator fit.

Protective Clothing and Skin Protection

Auto body chemicals can create significant skin exposure.

Appropriate protection may include:

• Chemical-resistant gloves.
• Coveralls.
• Spray suits.
• Sleeves.
• Protective footwear.
• Head coverings.

PPE should be selected according to the chemicals and work performed.

Contaminated clothing should be handled in a manner that limits employee exposure.

Sanding Safety

Sanding can generate airborne dust and expose employees to noise, vibration, repetitive motion, and flying particles.

Employees should use appropriate:

• Dust-control equipment.
• Eye protection.
• Hearing protection where required.
• Respiratory protection where required.
• Ergonomic work practices.

Employees should avoid unnecessarily dispersing sanding dust throughout the shop.

Dust Control

Engineering controls should be used where feasible to reduce airborne dust.

Controls may include:

• Local exhaust ventilation.
• Vacuum-assisted sanding.
• Appropriate cleaning methods.
• Work-area isolation.

Dry sweeping or compressed air should not be used where doing so creates a hazardous airborne exposure.

Vacuum Sanding

Vacuum-assisted sanding equipment can capture dust close to the point where it is generated.

Equipment should be:

• Properly connected.
• Maintained.
• Emptied or serviced safely.
• Used according to manufacturer instructions.

Employees should report damaged hoses, seals, or collection components that reduce dust capture.

Surface Preparation

Surface preparation may involve sanding, grinding, chemical cleaning, rust removal, or other methods.

Before work begins, employees should evaluate:

• Coating hazards.
• Dust.
• Chemical exposure.
• Noise.
• Sparks.
• PPE.
• Ventilation.

Unknown coatings should be evaluated before aggressive removal methods are used when their composition may present a hazard.

Silica Exposure — When Applicable

Some abrasive-blasting or other surface-preparation operations may create respirable crystalline silica exposure.

Where applicable, the company should evaluate the work and implement required exposure controls.

Ordinary auto body sanding should not automatically be treated as a silica operation; applicability depends on the materials and processes involved.

Sandblasting — When Applicable

Shops performing abrasive blasting should evaluate the abrasive, coating being removed, ventilation, respiratory hazards, noise, and containment.

Appropriate PPE and respiratory protection should be provided where required.

Abrasive blasting should be performed only by employees trained for the operation.

Hexavalent Chromium — When Applicable

Some coatings, pigments, primers, or surface-treatment materials may create potential hexavalent chromium exposure during spraying or disturbance.

Where applicable, the company should evaluate employee exposure and establish required controls.

Controls may include:

• Engineering controls.
• Regulated areas.
• Respiratory protection.
• Protective clothing.
• Hygiene practices.
• Employee training.

A hexavalent chromium program is not automatically necessary for every auto body shop; applicability depends on the materials and exposures present.

Body Fillers

Body fillers and associated hardeners may expose employees to chemicals through skin contact and inhalation.

Employees should:

• Review Safety Data Sheets.
• Use appropriate gloves.
• Maintain ventilation.
• Follow mixing instructions.
• Avoid unnecessary skin contact.

Sanding cured filler should be performed using appropriate dust controls.

Adhesives, Sealants and Catalysts

Automotive adhesives, seam sealers, primers, catalysts, and related products may contain hazardous ingredients.

Employees should understand product hazards before use.

Containers should remain labeled and closed when not in use.

Ventilation and PPE should be provided according to the product and task.

Welding Safety

Collision repair may involve MIG welding, resistance welding, and other welding processes.

Employees should be trained for the equipment and work performed.

Procedures should address:

• Fire prevention.
• Welding fumes.
• Eye and face protection.
• Protective clothing.
• Electrical hazards.
• Vehicle fuel systems.
• Nearby combustibles.
• Ventilation.

MIG Welding

MIG welding equipment should be inspected and maintained in safe condition.

Employees should use appropriate welding helmets, protective clothing, gloves, and ventilation.

Before welding on a vehicle, employees should identify nearby fuel, electrical, battery, coating, and combustible-material hazards.

Resistance and Spot Welding

Resistance or spot welding equipment should be used according to manufacturer instructions.

Employees should keep hands and body parts clear of electrode and pinch-point areas.

Equipment should be inspected and serviced appropriately.

Cutting

Cutting operations can generate sparks, hot metal, fumes, sharp edges, and fire hazards.

Employees should control combustible materials and protect nearby employees.

Cut material should be handled carefully because edges and surfaces may remain hot or sharp.

Grinding

Grinding can expose employees to wheel breakage, flying particles, sparks, noise, and fire hazards.

Employees should:

• Inspect grinding equipment.
• Maintain required guards.
• Use appropriate eye and face protection.
• Control sparks.
• Keep combustibles away.
• Use properly rated wheels.

Damaged wheels should not be used.

Metal Fumes

Welding, cutting, grinding, and heating coated metals can generate hazardous fumes or particles.

Employees should identify coatings and materials when necessary to evaluate potential exposure.

Appropriate ventilation, work practices, and respiratory protection should be used where required.

Hot Work

Before hot work begins, employees should evaluate the area for:

• Fuel.
• Fuel lines.
• Batteries.
• Upholstery.
• Paints and solvents.
• Combustible materials.
• Flammable vapors.
• Hidden spaces.

Required fire-prevention controls should be established before work begins.

Compressed Gas Cylinders

Compressed gas cylinders should be:

• Properly secured.
• Protected from damage.
• Stored appropriately.
• Kept away from excessive heat.
• Handled with suitable equipment.

Valves, regulators, hoses, and connections should be maintained in safe condition.

Frame and Structural Straightening

Frame and structural repair can involve substantial pulling forces and stored energy.

Employees should inspect equipment and plan the pull before applying force.

The work area should be controlled to prevent employees from unnecessarily entering potential line-of-fire areas.

Frame Machines

Frame machines should be operated only by trained and authorized employees.

Employees should follow manufacturer procedures for:

• Vehicle anchoring.
• Pulling equipment.
• Chains.
• Clamps.
• Hydraulic equipment.
• Measuring systems.

Damaged equipment should be removed from service.

Chains and Pulling Equipment

Chains, hooks, clamps, and other pulling components should be inspected before use.

Components should be appropriate for the load and pulling configuration.

Employees should not use visibly damaged or improperly modified equipment.

Stored Energy and Exclusion Areas

Frame straightening and pulling operations can release substantial energy if equipment, chains, clamps, or vehicle components fail.

Employees should:

• Avoid standing in line with tensioned equipment.
• Establish appropriate exclusion areas.
• Keep unnecessary personnel away.
• Apply force gradually.
• Monitor equipment during the pull.

Work should stop if components shift unexpectedly.

Hand and Power Tools

Tools should be appropriate for the work, inspected before use, and maintained in safe condition.

Required guards and safety devices should remain installed.

Defective tools should be removed from service.

Pneumatic Tools

Pneumatic sanders, grinders, drills, impact tools, and other air-powered equipment should be properly connected and maintained.

Employees should inspect hoses and fittings and use appropriate operating pressure.

Air supplies should be disconnected before servicing or certain adjustments when necessary.

Compressed Air

Compressed air should be used only for appropriate purposes.

Employees should not direct compressed air toward themselves or another person.

Eye and other appropriate protection should be used according to the task.

Machine Guarding

Shop machinery and powered equipment should have required guards and safety devices.

Employees should not remove or bypass safeguards.

Equipment should be shut down and hazardous energy controlled before employees enter danger areas for servicing when required.

Automotive Lifts

Employees using automotive lifts should be trained and authorized.

Vehicles should be correctly positioned, lift capacity observed, appropriate lifting points used, and safety locks engaged according to manufacturer instructions.

Defective lifts should be removed from service.

Jacks and Jack Stands

Jacks should be used for lifting—not as the sole support for employees working beneath vehicles.

When employees work under a vehicle raised with a jack, the vehicle should be supported by appropriately rated and positioned support equipment.

Improvised supports should not be used.

Hybrid and Electric Collision Vehicles — When Applicable

Collision-damaged hybrid and electric vehicles can present high-voltage and energy-storage hazards.

Employees should be able to identify vehicles containing high-voltage systems and understand which tasks they are authorized to perform.

Manufacturer-specific procedures should be followed.

High-Voltage Systems

High-voltage vehicle components may remain energized after the vehicle is turned off.

Procedures should address:

• Vehicle identification.
• High-voltage cables and components.
• Shutdown.
• Isolation.
• Stored energy.
• Verification.
• Required PPE and tools.
• Re-energization.

Only appropriately trained employees should perform high-voltage work.

Collision-Damaged EV Batteries

A collision-damaged high-voltage battery may present electrical, chemical, thermal, and fire hazards.

Employees should not handle or dismantle damaged high-voltage batteries unless trained and authorized.

Damaged vehicles should be evaluated and stored according to appropriate manufacturer and emergency procedures.

Hazard Communication

Auto body shops using hazardous chemicals should maintain an applicable Hazard Communication Program.

The program should address:

• Chemical inventory.
• Container labeling.
• Safety Data Sheets.
• Employee information and training.
• Non-routine tasks.

Employees should understand how to obtain chemical hazard information before using a product.

Chemical Safety

Auto body chemicals may include:

• Paints.
• Primers.
• Clear coats.
• Hardeners.
• Catalysts.
• Solvents.
• Degreasers.
• Adhesives.
• Sealants.
• Body fillers.
• Cleaning products.

Employees should follow product labels, Safety Data Sheets, and company procedures.

Flammable and Combustible Liquids

Paints, solvents, cleaners, fuels, and other flammable or combustible liquids should be stored and handled appropriately.

Procedures should address:

• Approved containers.
• Storage.
• Dispensing.
• Ignition sources.
• Ventilation.
• Spill control.
• Waste.

Quantities in work areas should be appropriately limited.

Solvents and Cleaners

Employees should review product hazards before using solvents and cleaners.

Employees should avoid unnecessary skin contact and vapor exposure.

Suitable gloves, eye protection, ventilation, and other controls should be used as appropriate.

Chemical Storage

Chemicals should be stored according to their hazards and compatibility.

Storage areas should be:

• Orderly.
• Appropriately ventilated where required.
• Protected from ignition sources.
• Secured when necessary.

Containers should remain closed and properly labeled.

Personal Protective Equipment

PPE should be selected according to the hazards associated with each task.

Depending on operations, PPE may include:

• Safety glasses.
• Goggles.
• Face shields.
• Chemical-resistant gloves.
• Welding PPE.
• Hearing protection.
• Protective footwear.
• Coveralls or spray suits.
• Respiratory protection.

Employees should inspect and properly use assigned PPE.

Eye and Face Protection

Eye and face hazards can occur during sanding, grinding, welding, cutting, chemical handling, compressed-air use, and body repair.

Appropriate eye protection should be worn whenever an eye hazard exists.

Face shields should supplement rather than replace required primary eye protection where both are necessary.

Hearing Conservation — When Applicable

Grinding, sanding, pneumatic tools, hammering, and other body-shop operations can generate significant noise.

Employee exposure should be evaluated where warranted.

Where applicable, the company’s Hearing Conservation Program should address monitoring, hearing protection, training, and audiometric testing.

Manual Lifting and Material Handling

Employees may move:

• Vehicle panels.
• Doors.
• Hoods.
• Bumpers.
• Glass.
• Wheels.
• Parts.
• Paint and chemical containers.
• Equipment.

Mechanical assistance or team lifting should be used when loads cannot be handled safely by one employee.

Ergonomics

Collision repair can involve prolonged bending, kneeling, overhead work, sanding, reaching, hammering, and repetitive tool use.

Controls may include:

• Adjustable stands.
• Vehicle positioning.
• Tool selection.
• Mechanical assistance.
• Work-height adjustment.
• Task rotation where appropriate.

Employees should report recurring ergonomic concerns.

Ventilation

Ventilation systems should be appropriate for the contaminants and processes present.

Potential sources requiring control include:

• Spray painting.
• Paint mixing.
• Sanding.
• Welding.
• Cutting.
• Grinding.
• Solvents.
• Cleaning chemicals.

Local exhaust ventilation should be used where necessary to capture contaminants near their source.

Shop Housekeeping

Body shops should control accumulation of:

• Sanding dust.
• Overspray.
• Paint residue.
• Used masking materials.
• Solvent-contaminated materials.
• Tools.
• Parts.
• Hoses.
• Cords.

Work areas, aisles, emergency exits, and access to fire equipment should remain clear.

Walking-Working Surfaces

Floors should be maintained to reduce hazards from:

• Oil.
• Grease.
• Water.
• Paint.
• Solvents.
• Cords.
• Hoses.
• Tools.
• Vehicle parts.

Spills and other hazards should be corrected promptly.

Slips, Trips and Falls

Employees should maintain clear walking paths and properly store hoses, cords, tools, and parts.

Temporary hazards should be appropriately marked or controlled until eliminated.

Fire Prevention

Fire prevention is particularly important in auto body operations because flammable materials and ignition-producing activities may exist within the same facility.

Procedures should address:

• Spray operations.
• Flammable liquids.
• Ignition sources.
• Welding and cutting.
• Grinding.
• Combustible residues.
• Chemical storage.
• Fire extinguishers.
• Emergency exits.

Employees should understand their responsibilities during a fire emergency.

Emergency Action Plan

Auto body shops should establish procedures for foreseeable emergencies, including:

• Fire.
• Chemical releases.
• Serious injuries.
• Vehicle incidents.
• High-voltage vehicle emergencies.
• Severe weather.
• Medical emergencies.

Employees should understand alarm systems, evacuation procedures, emergency contacts, and assembly locations.

First Aid

First-aid supplies should be readily available according to workplace hazards and applicable requirements.

Employees should know how to obtain emergency medical assistance.

Emergency washing facilities should be provided where required by corrosive chemical exposures.

Spill Prevention and Response

Shops should establish procedures for spills involving paints, solvents, fuels, oils, hardeners, and other chemicals.

Employees should understand:

• Reporting.
• PPE.
• Spill-kit use.
• Cleanup.
• Waste disposal.
• When evacuation or specialized response is necessary.

Employees should not respond beyond their training and assigned responsibilities.

Hazardous Waste Management — When Applicable

Auto body operations may generate regulated wastes from paints, solvents, cleaning materials, contaminated filters, and other processes.

Waste streams should be evaluated and managed according to applicable environmental requirements.

Containers should be appropriately identified, maintained, and stored.

Driving and Vehicle Movement

Employees who move or road-test customer vehicles should be appropriately licensed and authorized.

Drivers should:

• Wear seat belts.
• Avoid distracted driving.
• Obey traffic laws.
• Adjust controls before driving.
• Evaluate obvious vehicle safety concerns.

Collision-damaged vehicles should not be driven when their condition makes operation unsafe.

Customer and Visitor Safety

Customers and visitors should be restricted from active body-repair, welding, frame-straightening, and spray-finishing areas unless appropriately authorized.

Controls may include:

• Signs.
• Barriers.
• Designated waiting areas.
• Employee escorts.

Visitors should not enter hazardous work areas unnecessarily.

Auto Body Shop Safety Training

Employees should receive training appropriate to their assigned duties and exposures.

Training may include:

• Spray-finishing safety.
• Chemical hazards.
• Isocyanates.
• Respiratory protection.
• Sanding and dust control.
• Welding and cutting.
• Grinding.
• Frame machines.
• Hand and power tools.
• Vehicle lifting.
• PPE.
• Fire prevention.
• Emergency procedures.

Employees should receive required training before performing tasks requiring specific knowledge, qualification, or authorization.

New and Short-Service Employees

New and inexperienced employees may be unfamiliar with spray-finishing hazards, body-shop chemicals, specialized equipment, and collision-repair procedures.

Orientation should address applicable hazards before employees begin work.

New employees should not operate spray equipment, frame machines, welding equipment, lifts, or other specialized equipment until required instruction and authorization have been completed.

Supervision should reflect the employee’s experience and familiarity with the work.

Auto Body Shop JSA/JHA

JSAs/JHAs can be developed for recurring or higher-hazard body-shop operations.

Useful topics may include:

• Spray painting.
• Paint mixing.
• Sanding.
• Welding.
• Cutting and grinding.
• Frame straightening.
• Panel replacement.
• Vehicle lifting.
• Glass removal.
• Damaged EV handling.
• Chemical handling.

The JSA/JHA should reflect the actual vehicle, equipment, chemicals, task, and work conditions.

Auto Body Shop Toolbox Talks

Short safety meetings can reinforce hazards associated with current shop operations.

Useful topics may include:

• Spray-booth safety.
• Isocyanates.
• Respirator use.
• Sanding dust.
• Paint mixing.
• Flammable liquids.
• Welding.
• Grinding.
• Frame machines.
• PPE.
• Housekeeping.
• Fire prevention.

Toolbox talks supplement formal training but should not replace required task-specific training.

Additional Auto Body Safety Programs

Depending on the services performed, equipment used, chemicals present, and employee exposures, additional programs may include:

• Automotive Lift Safety.
• Chemical Safety.
• Compressed Air Safety.
• Compressed Gas Cylinders.
• Driving and Fleet Safety.
• Electrical Safety.
• Emergency Action Plan.
• Ergonomics.
• Fire Prevention.
• First Aid.
• Flammable and Combustible Liquids.
• Grinding Safety.
• Hand and Power Tools.
• Hazard Communication.
• Hazardous Waste Management.
• Hearing Conservation.
• Hexavalent Chromium.
• Lockout/Tagout.
• Machine Guarding.
• Manual Lifting and Material Handling.
• Personal Protective Equipment.
• Respiratory Protection.
• Sandblasting Safety.
• Silica Exposure.
• Spill Prevention and Response.
• Vehicle Maintenance Safety.
• Welding, Cutting and Hot Work.
• Walking-Working Surfaces.

Programs should be selected according to actual operations rather than automatically included simply because a company performs auto body or collision repair.

Building an Auto Body Shop Safety Manual

The most useful Auto Body Shop Safety Manual is based on the services employees actually perform.

Consider whether employees:

• Perform collision repair.
• Spray automotive coatings.
• Mix paints and hardeners.
• Work with isocyanate-containing products.
• Sand painted or filled surfaces.
• Perform abrasive blasting.
• Weld or cut metal.
• Grind body panels.
• Perform structural repairs.
• Operate frame machines.
• Use automotive lifts.
• Service hybrid or electric vehicles.
• Handle flammable liquids.
• Use respirators.
• Generate regulated wastes.

These activities help determine which individual safety programs should be included.

A shop performing only minor body repairs should not receive a manual filled with programs for operations it never performs. Likewise, a full collision-repair and refinishing facility may require extensive chemical, respiratory, spray-finishing, welding, fire-prevention, and specialized equipment programs.

Customized Auto Body Shop Safety Manuals

Companies can request a customized Auto Body Shop Safety Manual containing programs selected according to the collision-repair operations, refinishing processes, chemicals, equipment, vehicles, and employee exposures present.

Manuals can be developed for collision repair centers, independent body shops, dealership body shops, automotive refinishing facilities, fleet body-repair operations, and other automotive collision businesses.

Applicable programs can be selected for spray painting, spray booths, isocyanates, respiratory protection, sanding, welding, grinding, frame equipment, chemicals, PPE, flammable liquids, fire prevention, vehicle lifting, and other auto body hazards.

Individual safety programs can also be selected when a company needs to add or update a particular program within an existing safety manual.