An overview of the health aspects involved in working with epoxy and composite materials, and the measures taken to minimise exposure during construction.
Health aspects
When fully absorbed in the various aspects of laminating composite structures, it becomes clear that there are moments during fabrication that can be both tricky and potentially hazardous.
I chose to work with epoxy rather than polyester or vinylester resins. Apart from the strong styrene smell associated with polyester—which would be a serious nuisance to my family (the garage doubles as a workshop) and to our neighbours—epoxy resins offer far superior mechanical properties.
Epoxy does, however, have a significant potential downside when it comes to health. It is absolutely essential to minimise direct contact with epoxy as much as possible. Proper protective measures, such as high-quality gloves and adequate respiratory protection, are mandatory. It is well known that many people develop allergic reactions to epoxy. I have personally witnessed this among colleagues in a company where epoxy-based wood repair systems were used. Once an epoxy allergy develops, working with epoxy becomes extremely problematic, if not impossible. For me, that would effectively mean the end of the project. This was one of the reasons for choosing a laminating technique in which direct contact with epoxy is largely avoided.
The risks are not limited to liquid epoxy—particularly the hardener. Sanding cured or partially cured epoxy can also pose health hazards, whether due to epoxy dust or fine particulate matter in general. Machining Corecell foam, fibreglass laminates, or carbon laminates also carries health risks. Adequate respiratory protection is therefore essential at all times.
warning
I have been working with epoxy since 1980 and have processed many thousands of kilograms over the years. Fortunately, I remain healthy to this day—and I intend to keep it that way, as developing an epoxy allergy remains a real risk. Knock on wood.
Here are some accounts from other people who work with epoxy products and have been less fortunate. Be warned: it is not pleasant reading. Minimising exposure to epoxy is therefore highly desirable.