B-MAX 2012 – General Information – Body Repair Health and Safety and General Precautions – Description and Operation

General Information - Body Repair Health and Safety and General PrecautionsB-MAX 2012.75 (01/2012-)
Description and Operation


Appropriate repair methods and carrying out repair and paint jobs correctly is particularly important to the operating safety of vehicles and the safety of people.

warningWARNING: There is danger of injury through:

  • High voltage when electrical welding.
    Do not perform welding work in a damp environment or on a wet substrate. Use suitable insulation underneath.
  • Welding spatter and UV radiation.
    Wear protective clothing, gloves and welding mask or welding goggles.
  • Fire, explosion and hot surfaces in the work area.
    Always have a suitable fire extinguisher available when using welding or heating equipment.
    Remove flammable substances from the danger area. Remove the fuel tank and fuel pipes and hoses.
    Welding and grinding near the battery presents the danger of explosion. Remove the battery before you start working.
    During paint work there is an increased danger of fire or explosion. Prevent any sparks being created. Fire, open light and smoking are forbidden.
    Always ventilate the workplace well and use an extraction system.
    Wear protective footwear made from anti-static material.
    Only use tools made of wood, brass or copper to clean stands and extraction ducts. Do not use tools made of steel.
    Only fill or decant paint materials in a specially marked area.
  • Inhalation and/or absorption through the skin of harmful substances.
    Welding fumes grinding dusts and solvent vapours can be extremely harmful to the health.
    Sealants, underbody protection and paint residues must not be burnt down with an unshielded flame, as this will produce harmful substances.
    Always ventilate the workplace well and use an extraction system.
    Wear protective clothing.
  • Pyrotechnic components.
    Disconnect the battery negative clamp and cover the battery terminal.
    Remove any airbag components.
  • Noise
    Cutting, grinding and alignment work can cause a noise level over 85 dB (A).
    Always wear ear protection.
  • High Forces.
    The various body areas are subject to very high forces during realignment work. Should any component suddenly become detached during this process, there is a very great danger of injury.
    Pulling chains and pulling shackles must be secured with arrester cables.

As well as these general instructions on the dangers in body and paint shops, you must observe:

  • All valid local national and international regulations governing Health and Safety at Work
  • Safety instructions of material equipment and tool manufacturers

For additional information, refer to: (100-00 General Information)

Solvents, Sealants and Adhesives (Description and Operation),

Personal protection

Besides the body and limbs, several organs vital to life are in very particular danger. Because damage is mostly irreparable, special attention and comprehensive protection is necessary.

Protective equipment

Always use the appropriate protective equipment:

  • Protective helmet or welding mask
  • Breathing protection
  • Protective clothes gloves and safety boots
  • Ear defenders
  • Extraction systems

Always carry out an operational check on your protective equipment every time before you start working!

Breathing protection

warningWARNING: Vapor or spray mist containing isocyanates as a paint base or hardener can cause toxic respiratory disease (conditions similar to asthma) leading to permanent damage, even when inhaled in the lowest concentrations

The instructions for use provided by the manufacturer must be observed when working with breathing protection equipment.

During painting work and in the preparations for painting, gases, vapors, mists or dusts can appear in dangerous concentrations.

Breathing protection devices which are independent of the local atmosphere are most suitable.

In these types of isolation systems, a compressed air hose carries natural air from the compressor line into the protective mask. During supply, the air undergoes pressure reduction, water removal, fine filtration and usually warming to natural breath temperature.

Click to resize E59518

Part Number
Protective hood with fresh air supply
Protective clothing
Protective gloves
Protective footwear

Only for short periods of work or minimal concentrations of hazardous substances breathing protection devices with a combination filter is suitable as breathing protection equipment.

Click to resize E59517

Part Number
Activated charcoal filter
Coarse filter

Filter masks with wadding, sponge or colloid filters and also paper masks are all unsuitable for working with coating materials because they do not stop solvent vapors.

Eye protection

Cutting grinding welding solvents and paint bear fundamental risks for your eyes.

Damage ranging from irritation of the cornea to incurable illnesses is possible.

Solvents and paint – even water based – could not only be absorbed via your skin but also via your eyes.

Therefore always wear the appropriate eye protection for your work.

Protective goggles must be inert toward splashes of solvent, and must have side protection. Best protection during spray painting is offered by full mask respirators or helmet respirators with built-in visor.

Skin protection

Spray painters must wear suitable protective work clothing (flame-proof and anti-static). Also, when working with water based materials, comprehensive skin protection must be worn, because these materials are very easily absorbed through the skin.

Change your protective clothing at proper intervals. Clothes contaminated with coating materials can easily catch fire.

Do not choose clothes or underwear with a large content of easy melting synthetic fiber, because this material considerably increases the danger and degree of injuries (melted plastic on the skin!).

For areas of the skin which are not covered by protective clothing suitable skin protection cleaning and care agents must be used.

Ear protection

Cutting grinding compressors and extractor fans and ducts are the main sources of noise in body and paint shops.

Always wear suitable ear protection like ear plugs or ear defenders.

Protection of the vehicle

Protect affected areas from weld spatter and dust during all welding and grinding work on the vehicle. If metallic dust stays on the vehicle for some time, there is the likelihood of film rust formation. Grinding produces tiny spots of damage to the paint surface, which may cause corrosion. Also use suitable protective measures to protect the interior when performing repair operations which relate to the inside of the vehicle.

For this reason, make sure to:

  • Use carbon fiber blankets to protect the vehicle body and the interior.
  • Use covering film to protect the vehicle body from grinding dust and metal dust.
  • Use covering paper to protect the interior from grinding dust.

In addition, take into account:

  • Remove fuel supply components as necessary.
  • Protect working areas which are in danger of catching fire with a fireproof blanket.
  • Keep heat away from all components of the air conditioning system.
  • Remove all components in the space adjoining the repair area.

Electronic components

Increased use of comfort and safety electronics in modern vehicles requires additional attention to be paid during body work.

Over voltages produced during welding can cause electronic systems to be damaged. In particular, the safety instructions for performing welding work on vehicles with airbag systems must be adhered to.

warningWARNING: After disconnecting the power supply and before performing further work, a wait time of up to 15 minutes must be maintained, depending on the vehicle. Work on airbag systems may only be performed by persons who have a relevant certificate of competence.

For additional information, refer to: (501-20B Supplemental Restraint System)

Driver Airbag (Removal and Installation),
Driver Knee Airbag (Removal and Installation),
Passenger Airbag (Removal and Installation),
Side Airbag (Removal and Installation),
Side Curtain Airbag (Removal and Installation),
Restraints Control Module (RCM) (Removal and Installation).

Pay attention to the following points:

  • Disconnect the battery negative clamp and cover the battery terminal.
  • Disconnect the electrical connector at the airbag control module.
  • If welding is to be performed directly near a control module, it must be disconnected or removed.
  • Never connect the negative cable of the welder near an airbag or a control module.
  • Connect the negative cable of the welder close to the location of the weld.

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