Abstract Introduction Considering the adverse carcinogenic and non-carcinogenic health effects of Volatile Organic Compounds (VOC) and specially Benzene, Toluene, Ethylbenzene and Xylenes (BTEX) which are widely used in vehicle manufacturing industry, it is clear that monitoring and control of occupational exposure to these substances is of utmost significance. More often than not the studies on occupational exposure to VOCs in vehicle manufacturing industry—specifically BTEX—have been carried out exclusively in paint shop units. The purpose of this study was to assess occupational BTEX exposure & health risk in different units of a vehicle manufacturing industry. Material and methods Foam injection unit (FIU), gluing unit (GU), repair shop unit (RSU), molding unit (MU) as well as paint shop units (PSU) were selected for this study. Sampling and analysis were conducted based on National Institute for Occupational Safety and Health (NIOSH) 1501 guidelines by utilizing MSA personal sampling pumps set to 0.2 l/m and Gas Chromatography equipped with Flame Ionization Detector (GC-FID). Risk characterization and assessment was performed using Environmental Protection Agency Risk Assessment Information System (EPA RAIS). Results and conclusion The results revealed that the concentration of benzene in gluing and paint shop units was above occupational exposure limits. Carcinogenic risk levels in 8 out of 10 units registered in the 1E-2 to 1E-4 range, and only two units registered a risk level below EPA’s acceptable risk level (10–6). The highest risk levels were measured in gluing, paint shop and repair shop units. Furthermore, the total non-carcinogenic hazard quotient was measured higher than 1 in 8 out of 10 studied units. Considering the abundance and wide use of VOCs -most notably BTEX- and the adverse carcinogenic and non-carcinogenic health effects of these compounds, it is advised to: change the type of paint used in paint shops, improve the existing ventilation systems, develop new and more efficient ventilation systems and conduct consistent training.
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