To assess workplace exposure to nickel during thermal spraying, an air quality study was conducted at a thermal spray facility between 2007 and 2010 and 22 thermal spray operators were monitored. Results show that certain activities and operations have the potential for high exposure to nickel compounds. It is also shown that the biological agent tolerance value (BAT-value) of water-insoluble nickel compounds can be respected if specific technical, organizational, and personal-protective measures are consistently implemented.