Composite materials are now widely used in many industrial sectors. Their unique combination of lightness, rigidity and mechanical strength makes them materials of choice for manufacturing technical structures.
They are found in particular in:
- aeronautics
- automotive
- marine
- wind energy
- plastics processing
- sports equipment
A composite material consists of two main elements:
- a polymer matrix, generally a polyester, vinylester or epoxy resin
- a fibrous reinforcement, most often fiberglass or carbon fiber
The transformation of these materials involves several industrial processes that can generate atmospheric pollutants and industrial dust.
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Composite Manufacturing Processes
The manufacturing of composite parts relies on different transformation processes.
The most common in industry are:
- hand lay-up
- simultaneous spray-up
- vacuum infusion (see case study)
- press molding
- oven curing
- mechanical machining
- sanding and finishing
These processes allow fibers to be impregnated with a resin and then polymerize the assembly to obtain a rigid part.
However, these operations can generate different types of pollutant emissions.
Main Pollutants in Composite Workshops
Several types of pollutants can be encountered in composite manufacturing workshops.
Volatile Organic Compounds (VOCs)
Polyester and vinylester resins often contain styrene, a reactive monomer that can evaporate into the air during manufacturing.
Also found are:
- industrial solvents
- resin vapors
- catalyst or hardener emissions
These substances belong to the family of volatile organic compounds (VOCs).
See the use case detailing the risk related to volatile organic compounds and styrene
Composite Dust
Machining and finishing operations produce dust composed of:
- fiberglass
- carbon fibers
- polymerized resin particles
This dust can be very fine and remain suspended in the air.
Industrial Fumes and Mists
Certain operations can also generate:
- polymerization fumes
- gelcoat spray mists
- chemical vapors
These emissions can degrade air quality in workshops.
Health Risks in the Composites Industry
Exposure to pollutants generated during composite manufacturing can cause different health effects on operators.
According to prevention recommendations published by INRS, dust and chemical substances present in certain industrial processes can cause:
- respiratory irritation
- skin irritation
- eye irritation
- headaches
- fatigue
- allergic sensitization
Fine dust from machining can also be inhaled and penetrate the respiratory tract.
Prevention of these risks is an important issue in composite workshops.
| Substance / Agent | Classification (CMR) | OEL (indicative) | Main Risks | Remarks |
|---|---|---|---|---|
| Styrene | CMR cat. 2 (suspected carcinogen) | 20 ppm (≈ 86 mg/m³) – 8h | Neurological effects, irritation, suspected cancer | Very common in polyester resins |
| Fiberglass dust | Not classified CMR | 1 fiber/cm³ (indicative) | Skin, eye, respiratory tract irritation | Depends on diameter and biopersistence |
| Carbon fibers | Not classified CMR | No specific OEL (ref. dust: 3 mg/m³ alveolar) | Respiratory risks (fine dust) | Conductive, may also pose electrical risks |
| Epoxy resins | Not CMR (generally) but sensitizing | Variable depending on components | Skin allergies, occupational asthma | High risk with repeated contact |
| Amines (epoxy hardeners) | Some CMR depending on substance | Variable | Irritation, toxicity, sensitization | Check SDS product by product |
| Solvents (acetone, etc.) | Not CMR (variable depending on solvents) | Ex: acetone 500 ppm | Neurological effects, irritation | Highly dependent on products used |
| Composite dust | Not classified overall | 3 mg/m³ (alveolar fraction) | Fiber + resin mixture → respiratory effects | Risk underestimated in workshops |
Another case study: fiberglass dust during composite cutting.
Why Capture Composite Pollutants?
Capture and treatment of industrial pollutants allow:
- operator protection
- improved workshop air quality
- limited dust dispersion
- reduced industrial odors
- compliance with regulatory requirements
Source capture is one of the most effective methods to limit exposure.
OberA Solutions for Composite Pollutant Capture
OberA designs industrial solutions adapted to composite production environments.
These systems enable in particular:
- source capture of pollutants
- industrial dust extraction
- fine particle filtration
- VOC treatment
- improved workshop ventilation
These technologies contribute to improving working conditions and industrial air quality.
