At a recent CIC meeting, the Repair Process and Procedures committee presented a discussion on body filler, commonly known as Bondo. The presentation was excellent, but they left out one critical topic, in my opinion, which was safety. Question: Is body filler dust toxic? 

Yes, body filler is toxic. It contains volatile organic compounds (VOCs) such as styrene, which produce strong vapors and are classified as a possible human carcinogen. It also poses a hazard when it is sanded, as inhaling the airborne dust can cause respiratory irritation and organ damage.  

Styrene is considered a toxic chemical. High or prolonged exposure primarily affects the central nervous system, causing symptoms such as headaches, dizziness, fatigue, and nausea. The U.S. National Toxicology Program classifies it as a "reasonably anticipated" human carcinogen. Let’s look at safety recommendations on how to mitigate styrene exposure and body filler dust. 

To reduce the risks of exposure to your employees, understand ventilation, protective gear, and respiratory measures. The proper personal protective equipment (respirators) for styrene exposure are organic vapor cartridge respirators, nitrite gloves, eye protection, and long sleeve coverings. What are the three types of cartridges needed in a collision repair center?

1. An organic Vapor cartridge uses carbon to adsorb chemical fumes. Using the NIOSH color-coding system, organic vapor cartridges are always identified by a black label. 
2. Organic vapor and particulate respirator cartridges (black and pink) provide dual-layer respiratory defense by combining a carbon sorbent layer to absorb chemical vapors with a particulate filter for microscopic airborne particles.  
3. Particulate respirator cartridges (pink) are designed to protect against airborne particles such as dust, mists, fumes, and fibers. Particulate filters also trap physical solids and liquid aerosols such as weld-through primer.

Please answer the following questions: 

• Do you supply everyone in your facility with the proper respirator for the job that they perform? (1910.134 a2) 

• Do you have a written Respirator Protection Program? (1910.134c) 

• Do you have a medical evaluation for all employees that require a respirator? (1910.134c) 

• Do you conduct a yearly respirator fit test? (1910.134f) 

• Do you provide for cleaning and cartridge replacement on a regular schedule? (1910.134h) 

• Do you make sure that respirators when not in use are stored in close container? (1910.134 h&i). 

If you answered “NO” to any of these questions, you have exposed you and your company to OSHA fines. Case in point, let me tell you about an event that I was present for in 2016. 

I was in Colorado conducting welding certification tests. The shop I was at was extremely well organized. An OSHA inspector arrived at the shop unannounced; he wanted to see a yearly lift inspection and OSHA’s procedures for limiting isocyanate exposure. He asked to see the latest yearly respirator fit test. The owner stated that he had not done it and at that point the inspector excused himself. He went to his car and returned wearing an OSHA jacket and a hard hat. He stated that he would be conducting a National Emphasis Program inspection. When finished, the inspector told the owner that he had a very clean and organized facility. The owner was given a citation (had 30 days to correct) and asked how much the fine was, which the inspector first stated $5,000. 

I thought my friend was going to have a coronary, but the inspector reduced it to $1,500 because the shop was so clean and organized. When he went to pay the fine and show that the respirator fit test had been done, the supervisor reduced the amount to $600. Last year, OSHA collected nearly $5,000,000 in repertory fines, with the top 3 categories being missing medical evaluations, lack of written programs (free online template available on Cal/OSHA website), and no annual fit testing. One last note — fines can be assessed up to $16,000. 

Here is another example of a federal agency (EPA) assessing a fine against at collision shop. Cooks Collision settled a multi-county environmental lawsuit in 2018 for $1.525 million regarding the illegal storage and disposal of hazardous waste across its California auto body repair shops. The civil action was brought by 15 District Attorneys after undercover investigations revealed the improper handling of auto body sanding dust, automotive paints, and solvent. OSHA compliance and safety controls set the permissible expose limits, PPE, and engineering controls for the workplace. The shop also needs well-ventilated areas with exhaust fans or vacuum assisted sanders of OSHA compliance. 

I have a couple of recommendations for eliminating or reducing bondo dust from your facility, which are vacuum sanding stations. 3M, Festool, Mirka, and Norton have their own sanding station, but I have used Pro Spot’s DE-Pro Sanding System and Milwaukee’s M18 Fuel 9-Gallon Dual Battery Dust Extractor.

The Pro Spot Dust-Free Sanding System is a 100% air-powered dust extraction unit designed for collision repair shops to safely manage explosive aluminum and steel dust. The hardware contains zero electrical motors or electronic components, which eliminates spark risks and is safe for direct use inside vehicle preparation areas. The back of the unit opens to allow easy access to dust collection back (follow proper disposal protocols). 

The Milwaukee Dual Battery Dust Extractor has an Automatic Filter Cleaning mechanism which provides the high sustained airflow to maintain productivity during dust extraction. This mechanism paired with two HEPA filters, delivers OSHA Table 1 Compliance.  

A side note: I am a woodworker (hobbyist) and this unit has eliminated nearly all of my sanding dust. I just loaned the unit to a body shop that does not have a sanding station and asked him to evaluate the system.

I failed to mention previously that body technicians and helpers, painters and helpers, and possibly a detailer will need yearly respirator fit tests because airborne isocyanates are still present in our body shops.

What is wrong with this picture? 

Before I answer the question, I want to discuss a major health risk that is lurking in every body shop in the United States every day. That health hazard is Isocyanates. 

Isocyanates are compounds containing the isocyanate group (NCO). They react with compounds containing alcohol (hydroxyl) groups to produce polyurethane polymers, which are components of polyurethane foams, thermoplastic elastomers, spandex fibers, and polyurethane paints. Isocyanates are the raw materials that make up all polyurethane products. Jobs that may involve exposure to isocyanates include painting, foam-blowing, and the manufacture of many Polyurethane products, such as chemicals, polyurethane foam, insulation materials, surface coatings, and adhesives. 

Health effects of isocyanate exposure include irritation of skin and mucous membranes, chest tightness, and difficult breathing. Isocyanates include compounds classified as potential human carcinogens and are known to cause cancer in animals. The main effects of hazardous exposures are occupational asthma and other lung problems, as well as irritation of the eyes, nose, throat, and skin. 

In the picture above, the painter is not wearing a paint suit (isocyanates will be absorbed through the skin), no gloves (skin absorption), and no goggles (eye absorption). It should be noted that safety glasses will not fully protect the eyes from vapor absorption; only tight-fitting goggles will.