British Coatings Federation – Electrostatic Powder Coating

LEVCentral Expert Commentary

Powder coating is one of the most widely used industrial finishing processes, providing durable, corrosion-resistant coatings without the use of conventional solvent-based paints. However, the process introduces a unique combination of hazards, including combustible dusts, high-voltage electrostatic equipment, compressed air systems and potential exposure to hazardous coating constituents.

The British Coatings Federation (BCF) Code of Safe Practice is regarded as the principal UK industry guidance for the safe application of coating powders by electrostatic spraying. The current fourth edition (2022) was produced with input from the Health and Safety Executive (HSE), which recommends the guidance to inspectors as an example of good industry practice. It covers both thermosetting and thermoplastic coating powders but excludes certain specialist powders, such as those containing TGIC or lead chromate pigments, which require additional precautions.

The guidance brings together the requirements of key legislation, including COSHH, DSEAR, the Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations (EPSR), PUWER and the Electricity at Work Regulations. It provides practical recommendations covering spray booth design, ventilation, dust collection systems, hazardous area classification, earthing, housekeeping, operator training and safe systems of work.

For LEV engineers, the document is particularly valuable because it explains how ventilation systems contribute not only to controlling airborne exposure but also to preventing combustible dust concentrations from reaching dangerous levels. Correct extraction rates, booth design, filter performance and routine maintenance are all fundamental to safe powder coating operations.

View Guidance

View Original BCF Code of Safe Practice

Key Learning Points

Safe application of thermosetting and thermoplastic coating powders.
Fire and dust explosion hazards associated with powder coating.
DSEAR compliance and hazardous area classification.
Electrostatic spraying principles and electrical safety.
Spray booth design and ventilation requirements.
Dust extraction and powder recovery systems.
Housekeeping and prevention of dust accumulation.
Earthing of equipment, operators and workpieces.
Safe operation of compressed air systems.
Inspection, maintenance and testing of powder coating equipment.
Operator training and safe systems of work.
Practical checklists for employers and duty holders.

Source Document Information

Organisation: British Coatings Federation (BCF)

Document: Code of Safe Practice – Powder Coating: Application of Coating Powders by Electrostatic Spraying

Edition: Version 4 (October 2022)

Document Type: Industry Code of Safe Practice

Primary Topics: Powder Coating, Electrostatic Spraying, LEV, DSEAR, COSHH, Explosion Prevention

Audience: Powder Coating Operators, LEV Designers, Commissioning Engineers, Occupational Hygienists, Health & Safety Professionals, Maintenance Engineers and Duty Holders.

Further Resources

Recommended Learning

Thought Leadership

Powder coating demonstrates how engineering controls often have multiple safety functions. The same extraction system that protects workers from inhaling airborne powder also plays a vital role in preventing combustible dust concentrations from developing within the spray booth. Similarly, good housekeeping not only improves cleanliness but also reduces the risk of secondary dust explosions.

The BCF Code recognises this integrated approach by bringing together occupational hygiene, ventilation engineering, electrical safety and explosion protection into a single practical document.

For LEV professionals, it serves as a reminder that successful system design must satisfy several objectives simultaneously: controlling exposure, maintaining process efficiency and ensuring the safe management of combustible dust hazards throughout the life of the installation.