Chemical and Safety Hazards in Costume, Makeup, and Props: The Most Dangerous Areas in Theater
The costume department, makeup room, and props shop are among the most chemically complex and potentially hazardous work environments in the theater building. They are also among the most frequently overlooked in safety programs. Dr. Doom identified this explicitly: these areas may be the most chemically hazardous in the industry. Every technician assigned to these departments must understand the specific hazards, the legal requirements, and the protective measures that apply.
Chemical Hazards in the Costume Shop
The costume shop uses a remarkable variety of chemical products in daily operations:
- Fabric dyes: reactive dyes, acid dyes, and direct dyes are commonly used in costume dyeing. Some azo-based dyes release aromatic amines on reduction, including compounds classified as probable or possible human carcinogens by IARC. Sensitization (allergic contact dermatitis) is a documented risk with reactive dyes.
- Dry-cleaning solvents: perchloroethylene (PERC) is the most commonly used dry-cleaning solvent in theatrical costume operations. PERC is classified as a probable human carcinogen (Group 1 by IARC). PERC is regulated under OSHA 29 CFR 1910.1000 (Table Z-2, air contaminants). The 8-hour TWA PEL is 100 ppm.
- Steam and pressing chemicals: distilled water or tap water is used in steamers. Sizing, starches, and fabric treatment sprays may contain solvents. Steam at high pressure is a burn hazard.
- Adhesives: heat-activated fusibles, spray adhesives (may contain acetone, hexane, or toluene), contact cements, and cyanoacrylate super glues. All require ventilation and PPE.
- Spray applications: spray starch, spray paint for shoes and accessories, spray hair color, spray-on fabric treatment. All spray applications create inhalable aerosols.
Ventilation in the Costume Shop
The costume shop is chronically underventilated in most theatrical facilities. Operations that require specific ventilation controls include:
- Dyeing: spot ventilation over dye vats. Acid dye baths using acetic acid generate acetic acid vapor at elevated temperature.
- Pressing and steaming: steam generation creates heat and humidity. If chemical-treated fabrics are being pressed, volatilization of the treatment chemicals is a concern.
- Spray applications: all spray operations require a ventilated spray booth or outdoor application. Spray adhesives in an unventilated room can reach explosive concentrations.
- Solvent-based adhesive application: local exhaust ventilation over the work surface.
OSHA 29 CFR 1910.94 requires that employers provide ventilation adequate to maintain air contaminant concentrations below the permissible exposure limits for specific operations including spray finishing and open surface tank operations. The costume shop frequently involves both.
Makeup and Prosthetics
Theatrical makeup and prosthetics involve a distinct category of chemical hazards:
- Spirit gum and remover: spirit gum is a resin-in-solvent adhesive (typically ethanol or isopropyl alcohol base). Spirit gum remover uses acetone or isopropyl alcohol. Sensitization reactions are possible.
- Latex and foam latex: natural rubber latex is a documented allergen. Latex allergy ranges from contact dermatitis to anaphylaxis. Workers who develop any reaction to latex must be removed from latex work and referred to a physician. Synthetic latex alternatives are available.
- Prosthetic adhesives: some theatrical prosthetic adhesives contain toluene. OSHA PEL for toluene is 200 ppm. Toluene is a reproductive hazard and CNS toxin at chronic exposure levels.
- Theatrical makeup products: most modern theatrical makeup is formulated for skin safety, but some specialty items (UV-reactive paints, metallic powders, aged formulations) may contain heavy metals or other hazardous ingredients. SDS review is required before use.
- Airbrush makeup application: creates an inhalable aerosol of all ingredients. A NIOSH-approved respirator appropriate for the specific ingredients is required if engineering controls do not reduce exposure below the action level.
The Props Department
The props department builds, modifies, and maintains a wide variety of objects using a correspondingly wide variety of materials and processes:
- Fiberglass and polyester resin: styrene from polyester resin is classified as a possible human carcinogen (IARC Group 2B). OSHA PEL is 100 ppm as an 8-hour TWA. Fiberglass fabrication requires a NIOSH-approved respirator for the styrene vapors and an N95 or P100 respirator for fiberglass particles.
- Polyurethane foam and casting resins: isocyanates are the leading occupational cause of new-onset asthma in industrial settings. Work with isocyanate-containing two-component polyurethane systems requires specific respiratory protection and medical surveillance.
- Casting silicones: generally low hazard but require skin contact precautions with catalyst components.
- Metal fabrication: welding generates metal fumes whose composition depends on the base metal and consumables. OSHA has PELs for iron oxide, manganese, hexavalent chromium (in stainless steel welding), and other metal fume components.
- Painting and finishing: organic solvent vapors, aerosols from spray application, lead from some specialty paints.
HazCom Compliance in Costume and Props
The costume and props departments are among the most frequently cited areas for HazCom non-compliance in theater operations. Common violations include unlabeled secondary containers, missing or outdated SDSs, workers using chemicals without training, and inadequate PPE. A comprehensive HazCom program for these departments must include a complete chemical inventory, a current SDS for every chemical, a container labeling program, documented training for every worker, and a PPE assessment and provision program.
PPE for Costume and Props Work
Required PPE varies by task but includes: nitrile gloves for any contact with dyes, adhesives, or solvents; safety glasses or chemical splash goggles for operations with splash potential; an appropriate respirator for spray applications, solvent work, fiberglass work, and welding; and acid-resistant aprons for dyeing operations. PPE selection must be based on the SDS for the specific chemical and confirmed with a hazard assessment.
Key Takeaways
- The costume shop may be the most chemically hazardous area in the theater building. PERC (dry-cleaning solvent) is a probable human carcinogen with a specific OSHA standard.
- Spray operations in costumes, props, and makeup require either a ventilated spray booth or outdoor application.
- Latex allergy is a serious occupational health risk. Workers with any latex reaction must be removed from latex work.
- Fiberglass and polyurethane foam work require specific respiratory protection (P100 for fiberglass, supplied air or APF-50 respirator for isocyanates).
- HazCom compliance in costume and props departments requires chemical inventory, current SDSs, labeling, documented training, and PPE.
References
Occupational Safety and Health Administration. (n.d.). Air contaminants. 29 CFR 1910.1000 Table Z-2 (tetrachloroethylene PEL: 100 ppm TWA). U.S. Department of Labor.
Occupational Safety and Health Administration. (n.d.). Hazard Communication Standard. 29 CFR 1910.1200. U.S. Department of Labor.
Occupational Safety and Health Administration. (n.d.). General industry ventilation. 29 CFR 1910.94. U.S. Department of Labor.
National Institute for Occupational Safety and Health. (2020). Isocyanates: Occupational hazard and prevention. https://www.cdc.gov/niosh/topics/isocyanates
International Agency for Research on Cancer. (2012). IARC monographs on the evaluation of carcinogenic risks to humans: Volume 100F. IARC.