design ENVIRONMENT FOR

THE

May 2008 www.epa.gov/dfe EPA 744-F-08-003

Using Waterborne Basecoats 

in Collision Repair Shops: 

A Case Study Auto Refinishing Project 

What Is EPA’s Design for 

the Environment (DfE) 

Automotive Refinishing 

Partnership? 

EPA’s DfE Program forms 

partnerships to reduce risk to 

people and the environment through pollution 

prevention. DfE has been working with the 

automotive refinishing industry since 1997 to identify 

and promote safer, cleaner, and more efficient 

practices and technologies. The DfE team conducts 

best practices workshops and site visits for collision 

repair businesses and schools. A best practices 

outreach kit , checklists, fact sheets, case studies, 

health and safety information, and links to numerous 

resources are available on the DfE web site at 

http://www.epa.gov/dfe/pubs/projects/auto. 

A Switch to Waterborne Is on the Rise! 

Switching to waterborne 

from solvent-based 

automotive refinishing 

paints is becoming more 

popular in the U.S. for 

health and environmental

reasons, as well as stricter 

environmental regulations in 

California and Canada. 

Original equipment 

manufacturers (OEMs) and 

collision repair shops in 

Europe and some OEMs in 

the United States already 

use waterborne paints extensively. 

Larry Visser, the owner of Visor’s Collision Center in 

Chicago, switched to waterborne basecoats in 2005 

and learned a number of valuable lessons along the 

way. This case study shares Larry’s story and may 

help you decide if your shop is ready to make a 

switch from solvent-based to waterborne basecoats. 

Should You Consider a Switch? 

Larry successfully switched to waterborne basecoats 

and liked the results, which include: 

• Increased productivity: Fewer coats—and less 

time—are required to complete a job. As a result, 

Larry reports that he gets more jobs completed per 

week and uses less paint. Waterborne basecoats 

may cost more than solvent basecoats but, 

according to Larry, “the cost is more than offset by 

the increase you’ll see in worker productivity and 

the money you’ll save by purchasing less paint.” 

• Painter Retention: Initially, Larry found it difficult 

to convince his painter that switching to waterborne 

basecoats was a good thing. Now, Larry’s painter 

actually prefers using waterborne basecoats and 

enjoys a cleaner environment. Larry believes his 

painter is unlikely to leave his shop to work for a 

shop that still uses solvent basecoats. 

• Reduced insurance costs: Waterborne 

basecoats are less flammable and less toxic than

solvent-based paints. Larry believes this was a 

factor in lowering his shop’s insurance premiums. 

• Staying ahead of the regulatory curve: Larry 

finds it easier to comply with current federal and 

state regulations limiting volatile organic 

compounds (VOCs). By switching to waterborne 

basecoats, Larry’s shop has a head start in 

complying with future regulations that require 

further reductions of VOCs and/or hazardous air

pollutants (HAPs). 

• Customer satisfaction. There is some evidence 

that waterborne basecoats provide a more durable 

finish (e.g., less brittle and more chip resistant) than 

solvent-based finishes—an improvement Larry’s

customers appreciate. Larry’s customers also like 

the color match of waterborne basecoats with the 

OEM’s finish on their vehicle. 
Note: The mention or illustration of any product or company does not constitute an endorsement by the U.S. 

Environmental Protection Agency. 

EPA 744-F-08-003 www.epa.gov/dfe Page 2 

Benefits of Waterborne Paints 

Larry discovered that the benefits of waterborne 

basecoats stretch far beyond business—they make 

sense for worker health and safety, as well as the 

environment. Solvent-based automotive paints 

contain VOCs and hazardous air pollutants that

contribute to air pollution and cause numerous 

adverse health effects, including eye/skin irritation, 

and central nervous system effects. Organic solvents 

may also damage the liver and kidneys, and cause, 

cancer, respiratory, reproductive and other effects. 

Waterborne paints contain much lower levels of 

organic solvents and are less toxic than solventbased paints. However, automotive paint 

manufacturers stress that automotive paints should 

always be used by professionals, along with proper 

control technologies and protective equipment to 

minimize emissions of air toxics and prevent 

respiratory, eye, and dermal exposures. In addition, 

some basecoats still contain lead and hexavalent 

chromium pigments. 

Waterborne coatings, along with lead-free and 

chromium-free paints, are safer choices for the 

workplace and the environment! 

Warning! Automotive paints contain isocyanates 

(and polyisocyanates), the hardeners or catalysts in 

clear coats and some primers. Isocyanates are 

strong dermal and lung sensitizers and the leading 

cause of occupational asthma, so protect your skin 

and lungs from exposure to paints containing 

isocyanates. 

The Scene: Visser’s Collision Center 

Larry’s shop, Visser’s Collision Center, is a mediumsized collision repair shop in the Chicago area with 

two painters. The shop performs 15 to 20 jobs a

week and uses the Standox® paint system. 

Larry’s shop caters to high-end vehicles such as 

Mercedes and has been using waterborne basecoats 

since 2005. Larry 

decided to switch 

to waterborne 

basecoats for 

several reasons 

after his paint 

supplier recommended that his shop should try 

waterborne technology. Larry wanted to protect his 

workers from solvent exposures and he wanted to 

make the switch for business purposes—he feels that 

waterborne basecoats will become the trend in the 

industry. Larry wants to be one step ahead of the

curve. Since the paint supplier encouraged Larry to 

make the switch, Larry seized the opportunity and 

took full advantage of the supplier’s free training and 

support. 

Training your painter and following the paint 

manufacturer’s guidelines are keys to success! 

Larry and his painters worked closely with the paint 

supplier. The supplier came to the shop for two 

weeks to provide training for his painters and to set 

up the shop for use of waterborne basecoats. Today, 

both Larry and his painters are happy with the results 

and glad that they made the switch. 

A Successful Conversion to Waterborne 

Many shops can successfully use waterborne 

automotive paints. If you have a well maintained, clean 

shop and dedicated and talented workers, you should 

consider using waterborne technology. As Larry 

observed, “the switch to waterborne basecoats was 

fairly easy with the help of my paint supplier and the 

dedication of my painters. The product has saved 

time and increased productivity and protects the 

health of my workers and the community.” 

The Challenges... 

Although sold on a switch to waterborne basecoats, 

Larry still faced several challenges to get the new 

system up and running, as described below. 

• Booth Modifications: Waterborne basecoats need 

heat and additional airflow to dry properly. Larry 

retrofitted his two existing spray booths with 

Junair’s QADsTM auxiliary air movement system, 

which provides additional blowers and heat to 

existing spray booths that are required for 

waterborne systems. The estimated cost to retrofit 

one spray booth is approximately $25,000. Larry 

says that spray booth filter maintenance is very 

important, since clogged filters interfere with the 
Note: The mention or illustration of any product or company does not constitute an endorsement by the U.S. 

Environmental Protection Agency. 

EPA 744-F-08-003 www.epa.gov/dfe Page 3 

Photo provided courtesy of DuPont Performance Coatings 

booth’s airflow and affect the drying process. 

Occasionally, a shop can also use a portable 

blower to provide additional air movement for small 

jobs and cut-ins. 

Photo provided courtesy of Junair Americas 

• Adjustments to Spraying Technique: 

Waterborne basecoats cover and dry differently 

than conventional coatings. Waterborne basecoats 

also differ in their viscosity, making them 

particularly sensitive to changes in temperature and 

humidity. To compensate for these differences, 

Larry purchased new spray guns with the proper 

spray tips (1.0-1.3 mm) and his painters adjusted 

their spraying technique and drying time depending 

on temperature and humidity. Larry’s painters 

adjusted quickly and felt comfortable with the 

spraying technique after only one week of training

by the paint supplier. Larry also discovered that 

waterborne basecoats require only one to two coats 

to provide coverage and the color matching was 

excellent. However, since fewer coats are needed, 

it can be more challenging to achieve a proper 

blend. Because fewer coats also mean that less 

paint is needed per job, Larry’s painters have 

learned how to adjust the amount of paint to mix for 

each job. 

• Disposal of Used Cleaning Water and Paint 

Waste: Spray guns and other equipment in contact 

with waterborne basecoats must be cleaned with

water between each color change. Used cleaning 

water must be disposed of as hazardous waste. 

Larry’s shop set up a separate collection drum for 

this wastewater and contracted with a new 

hazardous waste hauler to take it away. Larry 

noted that it was a challenge to determine the 

proper disposal of this wastewater. However, he

found a new hazardous waste hauler that handles

both his wastewater and other hazardous waste 

generated at his shop. 

Always check with local authorities about proper 

handling, storage, and disposal of hazardous 

waste. 

• Mixing Room Modifications: Generally, 

waterborne basecoats must be maintained at a 

temperature above 55oF, or the shelf life is 

significantly reduced. This created a significant 

challenge for Larry because the room gets fairly 

cold over night and on weekends during the winter 

months. Keeping potential fire hazards in mind, 

Larry is considering adding heat to the space or 

other paint storage options as a long-term fix. 
Note: The mention or illustration of any product or company does not constitute an endorsement by the U.S. 

Environmental Protection Agency. 

EPA 744-F-08-003 www.epa.gov/dfe Page 4 

The Regulatory Landscape 

Taking the First Steps 

If you decide to make the switch to waterborne basecoats, take these initial steps to make this change: 

1. Contact your paint supplier about waterborne basecoat options and training opportunities. Your painters will need 

training on how to effectively spray waterborne coatings, including use of spray gun tips that provide a larger spray fan 

for applying thinner coats. 

2. Evaluate your shop’s equipment, especially the spray booth, and make the appropriate upgrades. The key to optimal 

drying of waterborne paints is in the temperature, humidity, and air movement over the surface. One source suggests 

uniform air flows of at least 11,000 cfm, sufficient heating, and clean air, among other factors. You may need to retrofit 

your existing booth, use portable blowers, or a combination. 

3. Spray gun passages and paint cups should be constructed from corrosion-resistant materials (e.g., stainless steel or 

plastic). Consider replacing your aluminum cups with single-use/disposable plastic cups. 

4. Evaluate your shop’s air supply and filtration system. Compressed air used in spraying waterborne coatings, as well 

as the hoses, must be very clean and free of any lubricating oil residues. Even a minute quantity of oil can 

contaminate the coating. 

5. Using dedicated spray guns and cleaning systems for waterborne vs. solvent-based coatings is highly recommended, 

due to the different cleaning methods and waste streams generated by each. 

In the U.S., some state and local jurisdictions are 

taking the lead in regulating automotive refinishing 

emissions. California and several northeastern states 

have developed practice standards for shops in 

selected air districts to reduce VOC emissions. 

Canada is also requiring a switch to waterborne 

basecoats. Keeping on top of the regulatory 

landscape can help you decide if the time is right to 

switch to waterborne basecoats. 

How Can I Get More Information on Switching 

to Waterborne Basecoats? 

Talk to your paint and equipment suppliers and ask 

them to determine if your shop is a candidate for 

waterborne technology. Visit a facility that uses 

waterborne technology. Read about waterborne 

conversions in the trade press and on paint 

manufacturer’s web sites. Take the first step! 

For additional information, visit the DfE Auto 

Refinishing Partnership website at 

http://www.epa.gov/dfe/pubs/projects/auto 

and the virtual auto body shop on the CCARGreenlink website at http://www.ccargreenlink.org/cshops.