Managing Lead Exposure During Paint Stripping Works

The Challenge

A construction contractor undertaking refurbishment works required specialist support during lead-based paint stripping activities using heat guns. These tasks are recognised as high-risk, with the potential for generating airborne lead dust and fumes that can pose significant health risks to workers if not adequately controlled.

The organisation sought independent occupational hygiene expertise to:

• Assess the risk of employee exposure to airborne lead.
• Confirm whether existing control measures and respiratory protection were effective.
• Obtain clear, defensible evidence to support regulatory compliance and worker reassurance.

The Approach

Sysco Environmental carried out a comprehensive lead exposure assessment, designed and delivered in line with HSG 248 and MDHS 14/4 guidance.

The assessment included:

• Personal air monitoring of operatives carrying out paint stripping.
• Static air monitoring â€‹within the workshop, lead removal area and airlock.
• Hand wipe sampling before and after handwashing to assess contamination and hygiene effectiveness.
• Observation of work practices, LEV performance, RPE usage and decontamination procedures.
• Accredited laboratory analysis of all samples.

Monitoring was undertaken during normal operations to ensure results reflected real-world exposure conditions.

The Findings

The monitoring programme provided critical insight into exposure risks associated with the works:

• Airborne lead concentrations ranged from <0.005 mg/m³ to 0.21 mg/m³, equating to <3% up to 140% of the Workplace Exposure Limit (WEL).
• Certain work activities presented a likelihood of exposure above the WEL.
• Existing Respiratory Protective Equipment (RPE) was found to provide adequate protection when correctly selected and worn.
• Hand wipe results indicated high levels of lead contamination, even after decontamination, highlighting weaknesses in personal hygiene controls.
• Time spent away from the immediate work area significantly influenced individual exposure levels, reinforcing the importance of task-based exposure assessment.

These findings demonstrated that while some controls were effective, the overall health risk remained high without strict procedural compliance.

The Recommendations

Sysco Environmental provided clear, practical recommendations focused on reducing risk and improving control consistency, including:

• Continued mandatory use of suitable RPE for all lead paint stripping activities.
• Enhanced personal hygiene procedures, with emphasis on thorough handwashing after completing tasks.
• Conducting lead-related work under semi-controlled conditions using trained operatives only
• Formalising standard operating procedures covering:
  Lead exposure risks and training
  Contamination control and spread management
  PPE and RPE selection and maintenance
  Waste handling and disposal
  Ongoing personal and background monitoring

The Outcome
By implementing the findings and recommendations, the contractor achieved:

• Clear evidence of compliance with UK occupational exposure requirements. 
• Confidence that existing engineering controls and RPE were effective when used correctly.
• Improved understanding of secondary exposure risks, particularly from surface contamination.
• A defensible basis for strengthening controls and protecting worker health.

Most importantly, the assessment delivered reassurance — demonstrating that risks were understood, measured, and responsibly managed.

Why This Matters

Lead exposure risks are often underestimated, particularly during refurbishment activities. This case study demonstrates how targeted occupational hygiene monitoring supports informed decision-making, protects worker health, and builds confidence through transparency — not just compliance.