Spray Booth – LEV Thorough Examinations

Spray Booth’s Within Industry

A spray booth Local Exhaust Ventilation (LEV) system is a critical engineering control designed to protect workers and the wider workplace from exposure to hazardous airborne contaminants generated during spray processes. These systems are commonly used in industries such as vehicle body repair, manufacturing, furniture finishing, and metal fabrication, where paints, lacquers, solvents, and coatings are applied by spraying. During operation, fine droplets and vapours are released into the air, many of which can be harmful if inhaled or allowed to accumulate.

The primary function of a spray booth LEV system is to capture and remove overspray, fumes, and vapours at source, preventing them from spreading into the workroom. Air is drawn through the booth in a controlled airflow pattern—typically downdraught, semi-downdraught, or cross-draught—ensuring contaminants are carried away from the operator’s breathing zone. The extracted air passes through a series of filters that remove paint particles and other solids before the air is either discharged safely outside or, where permitted, recirculated under controlled conditions.

Effective filtration is a key component of spray booth LEV systems. Pre-filters capture larger paint particles, while finer filters prevent smaller particulates from reaching fans, ductwork, or the external environment. Poorly maintained or blocked filters can significantly reduce airflow, leading to ineffective capture of contaminants and increased exposure risk. For this reason, routine inspection, cleaning, and replacement of filters are essential to maintain system performance.

Under the Control of Substances Hazardous to Health (COSHH) Regulations 2002, spray booth LEV systems must be properly maintained and thoroughly examined and tested at least every 14 months by a competent person. This statutory examination assesses airflow performance, capture effectiveness, filter condition, and overall system integrity. The examination provides documented evidence that the LEV system continues to adequately control exposure to hazardous substances.

What’s covered during your SEIS Thorough Examination.

Here’s a detailed breakdown of what is covered during an inspection and testing of a Spray Booth, in accordance with COSHH2002 Regulation 9 . The purpose is to ensure the system is safe, serviceable, and fit for purpose. Below is an in depth description of how your equipment is thoroughly examined;

Examination of Airflow and Capture Performance

One of the most critical parts of the inspection is verifying that the spray booth provides adequate airflow to capture overspray and solvent vapours at source. This includes:

  • Measuring air velocities across the booth face or within the working zone

  • Confirming airflow direction keeps contaminants away from the operator’s breathing zone

  • Assessing whether airflow is consistent and free from dead spots or turbulence

If airflow falls below design or benchmark levels, the booth may no longer provide effective control—even if it appears to be operating normally.

Condition of Filters and Filtration Stages

The inspection examines all filtration components, including:

  • Pre-filters and paint arrestor filters

  • Secondary or final filters

  • Evidence of overloading, damage, bypassing, or incorrect installation

Blocked or degraded filters can severely restrict airflow and allow hazardous substances to escape into the workplace or atmosphere. Filter condition is assessed in relation to airflow performance, not just cleanliness.

Fans, Ductwork, and Mechanical Integrity

The competent person will inspect the mechanical elements of the LEV system, including:

  • Extract fan condition and performance

  • Ductwork integrity, leakage, corrosion, or damage

  • Dampers, access doors, and joints

Any deterioration that could reduce system effectiveness or create safety risks—such as leaks or vibration—is identified and recorded.

Booth Structure and Containment

The spray booth itself is examined to ensure it continues to provide effective containment, including:

  • Doors, seals, and panels

  • Booth enclosure integrity

  • Evidence of uncontrolled leakage of overspray or fumes

Poor containment can undermine even a well-performing extraction system.

Controls, Indicators, and Safety Features

The inspection also checks that system controls and indicators are functioning correctly, such as:

  • Airflow indicators or pressure gauges

  • Interlocks (where fitted)

  • Warning devices or alarms

These features are important for alerting operators to reduced performance or system failure.

Comparison with Original Design or Benchmarks

Where available, test results are compared against:

  • Original commissioning data

  • Manufacturer’s design specifications

  • Recognised industry guidance (such as HSE benchmarks)

This helps determine whether the spray booth is still operating as intended and providing adequate control.

Operator Use and Process Changes

Although not a full risk assessment, the inspection considers whether:

  • The spray process has changed since the last examination

  • Different coatings, solvents, or application methods are now in use

  • The LEV system remains suitable for current activities

Process changes are a common reason for LEV systems becoming ineffective over time.

Report, Findings, and Legal Documentation

Finally, the competent person produces a written report of thorough examination and test, which includes:

  • Test methods and results

  • Identification of defects or performance issues

  • Clear conclusions on system effectiveness

  • Recommended remedial actions and timescales

This report is a legal requirement under COSHH and must be kept available for inspection by enforcing authorities.

 Summary

An LEV Thorough Examination ensures that the system is safe, compliant, and fit for use. It helps prevent accidents and work place illnesses caused by poorly maintained, or poorly operating systems. While it does not replace regular maintenance, PUWER and LEV (COSHH2002) inspections are a crucial legal requirement for keeping your working operations safe and avoiding costly breakdowns or incidents.

Why Spray Booth Thorough Examinations Matter For You & Your Business. 

Why COSHH2002 Thorough Examinations Of LEV Systems Matter

COSHH2002 LEV thorough examinations are a legal requirement in the UK for all Local Exhaust Ventilation equipment used at work, and for good reason. These inspections ensure that LEV equipment, such as fume cupboard, receiving hoods, spray booths, and captor hoods are safe to use, and fit for purpose. The environments of LEV equipment is required means that equipment failure can lead to catastrophic consequences, including serious injury, respiratory issues, work place illness and in the long term, fatalities. By carrying out regular, scheduled thorough examinations by a competent person, businesses can identify wear and tear, structural damage of ducting, or faulty mechanisms before they result in an incident.

Pros of Getting an LEV Thorough Examination in line with COSHH2002

Legal Compliance and Risk Reduction: The most obvious advantage is staying compliant with health and safety law. Compliance avoids potential legal action, fines, or even prosecution. More importantly, it drastically reduces the risk of workplace accidents caused by lifting equipment failure.

Improved Safety Culture: Regular inspections foster a proactive safety culture within the organisation. Employees are more likely to trust equipment and feel safe in their work environment when they know thorough checks are in place.

 Extended Equipment Lifespan: Regularly maintained and inspected equipment typically lasts longer. Examinations can identify early signs of damage or fatigue, allowing for preventative maintenance that avoids costly replacements or repairs.

 Insurance and Liability Protection: Insurers may require evidence of LOLER compliance in the event of an incident. Without valid inspection records, insurance claims could be denied or reduced, leaving the business liable for damages.

 Operational Efficiency: Detecting potential issues before they lead to equipment failure helps prevent unscheduled downtime. This keeps operations running smoothly and avoids the knock-on effects of delayed projects or interrupted workflows.

Cons of Failing to Carry Out COSHH2002 LEV Thorough Examinations

 Legal and Financial Consequences: Failing to comply with COSHH2002 can result in enforcement action from the Health and Safety Executive (HSE), including improvement notices, prohibition notices, fines, or even prosecution. Legal battles and associated costs can be financially crippling.

 Increased Risk of Accidents: Equipment that hasn’t been thoroughly examined is far more likely to fail. Such failures can lead to injuries or fatalities, particularly in high-risk environments like construction or manufacturing. Beyond the human cost, the reputational damage to a business can be severe and long-lasting.

 Higher Repair and Replacement Costs: Neglecting inspections can allow minor issues to develop into major faults. These may require costly emergency repairs or complete equipment replacement, expenses that could have been avoided through routine examinations.

 Loss of Business and Clients: Clients often expect their contractors or suppliers to uphold strict safety standards. A failure to meet legal obligations like COSHH2002 can result in lost contracts or blacklisting from future work, especially in regulated industries.

 Increased Insurance Premiums or Invalidated Coverage: As mentioned, insurers may increase premiums or deny coverage entirely if a business can't provide evidence of up-to-date COSHH2002 compliance, placing a heavier financial burden on operations.

LEV thorough examinations aren’t just a box-ticking exercise - they are an essential component of a responsible, safety-first approach to using lifting equipment. The benefits of compliance are wide-ranging, from protecting human life to reducing costs and maintaining operational integrity. Conversely, the risks of neglecting these inspections can be devastating on multiple levels.

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