SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

Transcription

1 SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 1ST EDITION OCTOBER 2006 MANUFACTURING

2 On 18 June 2017, the Occupational Health and Safety Regulations 2017 (OHS Regulations 2017) replaced the Occupational Health and Safety Regulations 2007 (OHS Regulations 2007), which expired on this date. This publication has not yet been updated to reflect the changes introduced by the OHS Regulations 2017 and should not be relied upon as a substitute for legal advice. Information on the key changes introduced by the OHS 2017 Regulations can be found in the guidance titled Occupational Health and Safety Regulations 2017: Summary of changes - available at data/assets/pdf_file/0011/207659/isbn- OHS-regulations-summary-of-changes pdf. However, this guidance document contains material of a general nature only and is not to be used as a substitute for obtaining legal advice. NEW Dangerous Goods (Storage and Handling) Regulations 2012 On 1 December 2012, the Dangerous Goods (Storage and Handling) Regulations 2012 (DG (S&H) Regulations 2012) replaced the Dangerous Goods (Storage and Handling) Interim Regulations 2011 (Interim Regulations) which expired on this date. The DG (S&H) Regulations 2012 have retained most of the legal requirements contained in the Interim Regulations. There are only a small number of changes. This document has not yet been updated to reflect the changes introduced by the DG (S&H) Regulations More information on the key changes introduced by these new regulations can be found in the guidance titled Information about: Key changes to dangerous goods storage and handling requirements available at worksafe.vic.gov.au/dgkeychanges and More information about: Incident reporting available at worksafe.vic.gov.au/incidentreporting

3 CONTENTS Introduction Why has this guide been produced? Injuries and health effects exposure to hazardous manual handling Injuries and health effects exposure to chemicals... 2 Manual handling of chemicals Consulting employees and health and safety representatives Information and training The legal status of this guide How to use this guide Tasks Manual handling chemicals during delivery, unloading and storage Unloading containers and bags from pallets and putting them into storage Unloading shipping containers and enclosed trailers manual handling Manual handling of gas bottles Manual handling chemicals in the workplace Moving chemicals and storing in work areas Packages and containers Examples of problems with packages and containers Identifying and fixing problems with packages and containers Container and package health & safety checklist Fixing container and packaging problems Adding handles to bags and sacks Effective closures Protective clothing and equipment Risks of using protective clothing and equipment Steps to follow before using protective clothing and equipment as a risk control Further information and guidance General Legislation Publications and further information available from WorkSafe Acknowledgements Emptying, decanting, measuring and mixing chemicals Cleaning components and parts Dipping components Disposing of waste chemicals The information presented in Safe Manual Handling of Chemicals in the Automotive Industry is intended for general use only. It should not be viewed as a definitive guide to the law, and should be read in conjunction with the Occupational Health and Safety Act Whilst every effort has been made to ensure the accuracy and completeness of this guide, the advice contained herein may not apply in every circumstance. Accordingly, the Victorian WorkCover Authority cannot be held responsible, and extends no warranties as to: the suitability of the information for any particular purpose; actions taken by third parties as a result of information contained in this publication. The information contained in Safe Manual Handling of Chemicals in the Automotive Industry is protected by copyright. The Victorian WorkCover Authority hereby grants a non-exclusive licence in this publication to the recipient of this publication on the condition that it is not disseminated for profit. The Victorian WorkCover Authority encourages the free transfer, copying and printing of the information in this publication if such activities support the purposes and intent for which the publication was developed. WorkSafe Victoria is a division of the Victorian WorkCover Authority.

4 INTRODUCTION WHY HAS THIS GUIDE BEEN PRODUCED? Many tasks undertaken in the automotive industry involve the manual handling of chemicals, placing employees at risk of injuries and adverse health effects due to manual handling and/or exposure to chemicals. This guide will help workplaces control risks and reduce injuries and adverse health effects by: identifying tasks that require the manual handling of chemicals which may lead to injury or illness; identifying the work areas and work processes involving these tasks; providing practical tools to assist in identifying risks and developing risk controls; and providing practical risk control solutions that will eliminate or reduce risks. Consultation with the Victorian automotive industry helped the development of this guide. The work areas, jobs and tasks covered have been identified by the industry as the primary areas that need to be addressed. Risk control solutions have also been developed in consultation and with the support of the industry. This guide may also be of use in other industries and workplaces where chemicals are handled. This guide is provided in accordance with section 7(1)(f) of the Occupational Health and Safety Act 2004 to assist employers, employees, their health and safety representatives (HSRs) and others to comply with their duties and obligations. It provides guidance on controlling risks that may arise from the manual handling of chemicals, while also referring to controlling employee exposure to chemicals and associated areas. However, it is not intended to and should not be read as providing guidance on the management of hazardous substances and dangerous goods and the risks associated with them, as these are covered by a range of Acts, Regulations, Codes of Practice and WorkSafe publications and guidelines. This guide does not address every single situation where chemicals are manually handled in the workplace. For further information see page 42. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 1

5 INTRODUCTION Musculoskeletal disorders from manual handling Muscle sprains and strains Injuries to muscles, ligaments, spinal discs and other structures in the back Abdominal hernias Exposure to substances Chemical burns and irritation of the skin, eyes, etc. Cancer, birth defects Routes of exposure Injuries to soft tissues such as nerves, ligaments and tendons in the wrists, arms, shoulders, neck or legs Poisoning Diseases of certain organs such as the skin, lungs, liver, kidneys and nervous system Inhalation Ingestion INJURIES AND HEALTH EFFECTS EXPOSURE TO HAZARDOUS MANUAL HANDLING Tasks such as unloading containers from pallets, transporting them to storage areas, moving 205 litre (44 gallon) drums, carrying containers to work areas, cleaning components, cleaning leaks and spills, emptying bags and sacks and decanting or mixing substances typically occur in the automotive industry. These tasks may cause injuries, such as musculoskeletal disorders (MSDs). However, it is important to note that not all manual handling is hazardous. Hazardous manual handling refers to manual handling with any of the following characteristics: repetitive or sustained application of force, awkward postures or sustained movements; application of high force; exposure to sustained vibration; or unstable or unbalanced loads or loads that are difficult to grasp or hold. MSDs are often caused by incorrect manual handling and often includes: muscle sprains and strains; injuries to muscles, ligaments, spinal discs and other parts of the back; injuries to soft tissues, e.g. nerves, ligaments and tendons in the wrists, arms, shoulders, neck or legs; and abdominal hernias. INJURIES AND HEALTH EFFECTS EXPOSURE TO CHEMICALS Manual handling chemicals in the automotive industry can also expose employees to chemicals that may affect employees health immediately or take months, or even years, to appear. These effects include: poisoning; irritation; chemical burns; sensitisation; cancer; birth defects; and diseases of certain organs such as the skin, lungs, liver, kidneys and nervous system. The severity of the health effects depends on the substance, nature and extent of the exposure. Chemicals that have the potential to harm health are known as hazardous substances. They may be solids, powders, liquids or gases, pure chemicals or mixtures. When used in the workplace, these chemicals often generate vapours, fumes, dusts and mists. A wide range of chemicals are classified as hazardous. These may enter the body in a number of ways, depending on the chemical and how it is used (the nature of the work). The major routes of exposure to hazardous chemicals in the workplace are: breathing in (inhaling) vapours, fumes, dusts and mists; absorption into the body from direct contact with the skin, eyes, etc.; or swallowing (ingesting) or injecting into the body (for example, unclean hands, smoking or contaminated food). Skin absorption 2 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

6 INTRODUCTION Hazardous chemicals include: acute toxins such as cyanide; substances harmful after repeated or prolonged exposure such as mercury and silica; corrosives such as sulphuric acid and caustic soda; irritants such as ammonia; sensitising agents such as isocyanates; and carcinogens such as benzene and vinyl chloride. Other chemicals employees may be exposed to and harmed by are known as dangerous goods, classified on the basis of immediate physical or chemical effects such as fire, explosion, corrosion and poisoning, affecting property, the environment or people. Hazardous substances and dangerous goods are covered by separate legislation, which focus on controlling the risks described above. As many hazardous substances are also classified as dangerous goods, the requirements of both pieces of legislation apply in these cases. As there may be overlaps, each legislation complements the other, ensuring the effective control of all risks. Requirements for managing hazardous substances and dangerous good risks are specified in the Dangerous Goods Act, Regulations and Codes of Practice and the Hazardous Substances Regulations. WorkSafe publications that provide information and guidance about hazardous substances and dangerous goods are listed on page 42. MANUAL HANDLING OF CHEMICALS Manual handling of chemicals can create extra risks compared to other manual handling jobs and tasks. Employees manually handling containers of chemicals may adopt awkward postures and movements in order to: avoid contact with residues and contaminants on the outside of containers or being exposed to vapours or fumes from open containers; or avoid spillages while carrying, emptying, decanting, measuring and mixing chemicals. The use of protective clothing and equipment can increase manual handling risks by restricting movement, limiting grip, increasing the physical effort required to do the job and increasing heat stress. Sometimes when completing manual handling tasks, protective clothing and equipment may be used incorrectly, increasing exposure to chemicals. Measures to reduce or eliminate the need to use protective clothing and equipment can reduce manual handling risks. Reducing manual handling risks associated with protective clothing and equipment can also mean such equipment is used properly because it is more comfortable (e.g. less sweating) and interferes less with doing the job at hand. Implementing manual handling risk controls can reduce exposure to chemicals Manual handling risk controls can reduce exposure to chemicals by preventing damage to chemical packages and reducing spills, leaks and clean ups when: delivering, unloading and storing chemicals; and moving chemicals within the workplace and storing them in work areas. Changing the packaging e.g. size, shape and weight can reduce manual handling risks and exposure to chemicals. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 3

7 INTRODUCTION Implementing risk controls to reduce exposure to chemicals can also reduce manual handling risks For example, using a vacuum cleaner fitted with HEPA (High Efficiency Particulate Air) filters to clean spilt powders and dusts improves manual handling as there is less bending, less repetitive forceful movements and less physical effort required compared to sweeping. Caution needs to be taken to ensure a vacuum cleaner is not used on chemical spills unless specifically designed to do so. Before: Dry sweeping can create airborne dust in the breathing zone. CONSULTING EMPLOYEES AND HEALTH AND SAFETY REPRESENTATIVES When identifying, assessing and controlling health and safety risks posed by the manual handling of chemicals, consultation with affected employees and their HSR is essential. Everyone has a role to play in workplace health and safety. Healthier and safer work environments and improved productivity can be more easily achieved when employers and employees discuss risks and problems and work together to find solutions. Consultation is required under sections 35 and 36 of the Occupational Health and Safety Act It must involve the sharing of information, giving employees the opportunity to express their views, valuing their views and taking them into account when making decisions. Labour hire employees, employees of contractors and their supervisors and managers must be included in any workplace consultation. INFORMATION AND TRAINING Where necessary, training and support must be provided to employees, supervisors and managers to ensure they can effectively identify, assess and control risk and meet all legal duties and responsibilities. After: Use a mobile vacuum cleaner fitted with a HEPA filter. 4 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

8 INTRODUCTION HOW TO USE THIS GUIDE The red, amber and green or traffic light format will help identify high-risk activities and assist workplaces in implementing safer work practices. The rationale is simple: to reduce injury rates and compensation claims, high-risk situations must be controlled. Companies with red (high-risk) work practices who fail to implement risk control measures for these practices may be in breach of legislation, and may be placing the health and safety of their employees at risk. The red column is split into two sections: one is for the actions (postures, movements or forces) that may cause the risk of MSD and the other is for potential sources of that risk. A better understanding of what causes the risk of MSD (or the source of the risk) results in more effective risk control. Potential sources of the risk are listed, although each workplace may identify other reasons why those actions are being undertaken and should control these accordingly. If high-risk practices are followed in your workplace, you should determine if the solutions listed in the green column may be effective. If this is not reasonably practicable, consider putting in place the comparable practice in the amber column as an interim solution. Generally, the manual handling solutions in the amber and green sections provide different options as the tasks, and the risks, will vary according to the specifics at each workplace. It is important any controls implemented address the risk factors in the task. RED (HIGH RISK) AMBER SOLUTION GREEN SOLUTION The practices in the red column should not be used in workplaces; an employer who allows these practices to be used is likely to be in breach of OHS legislation. The solutions in the amber column are less effective in reducing risk than those in the green column, and should be regularly reviewed with the aim to move towards higher order solutions (green). The solutions in the green column are the most effective at reducing risk and should be regarded as the target for all workplaces. Red, high risk, column Solutions should continue to be reviewed as higher order controls become more practicable Are any solutions from the green column reasonably practicable for the workplace? (Undertake practicability test) NO Implement solutions from the amber, reduced-risk, column YES Implement a solution from the green, low risk solution, column These guidelines apply no matter what the time of day, or day of the week Note: In most cases, solutions in the green column reflect the most effective control, while the amber column provides interim solutions. However, if you are able to demonstrate an appropriate risk assessment process has been undertaken and are able to verify that the reasonably practicable test has been applied to the controls you implement, then amber (interim) control measures may be reasonably practicable. The interim solutions should be reviewed as green (higher order) solutions become more reasonably practicable. For more information identifying and controlling potential risks visit or contact the WorkSafe Advisory Service on WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 5

9 TASKS 1. Manual handling chemicals during delivery, unloading and storage Unloading containers and bags from pallets and putting them into storage Unloading shipping containers and enclosed trailers manual handling Manual handling of gas bottles Manual handling chemicals in the workplace Moving chemicals and storing in work areas Emptying, decanting, measuring and mixing chemicals Cleaning components and parts Dipping components Disposing of waste chemicals WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

10 1. MANUAL HANDLING CHEMICALS DURING DELIVERY, UNLOADING AND STORAGE The delivery, unloading and storage of chemicals can potentially expose employees to chemicals and a range of manual handling risks. Low risk control solution: bulk delivery, unloading and storage of chemicals Bulk bags or boxes holding up to 1000kg or more of material. When large amounts of chemicals are used, the low risk control solution is bulk supply, storage and handling of chemicals whenever reasonably practicable. This eliminates or reduces manual handling and employees being exposed to hazardous substances during handling. Bulk refers to supply in large quantities and in containers such as pallet bags or palcons that must be handled mechanically. It does not mean bulk as defined in the Dangerous Goods (Storage and Handling) Regulations Any proposed changeover to bulk supply and handling of chemicals must be assessed in consideration of the Dangerous Goods Act, Regulations and Code of Practice and the Hazardous Substances Regulations. Examples of bulk delivery, unloading and storage at an automotive manufacturing site Most major ingredients are supplied in pallet bulk bags that are unloaded into the storage area and then moved to the inside of the plant by forklift. Other ingredients may be delivered by truck and pumped directly into silos before being pumped into the plant. In both of these cases, hazardous manual handling has been eliminated, while productivity and financial gains have also been achieved. Suppliers will often meet some of the costs associated with implementing the new infrastructure required for bulk handling. Liquid chemicals can be supplied in bulk stackable containers. Bulk silo storage. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 7

11 1. MANUAL HANDLING CHEMICALS DURING DELIVERY, UNLOADING AND STORAGE UNLOADING CONTAINERS AND BAGS FROM PALLETS AND PUTTING THEM INTO STORAGE HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION Exerting force while in an awkward posture. Lifting, lowering and exerting force while in an awkward posture. Bending the back more than 20 degrees or twisting. Carrying a load: more than twice a minute; more than 30 seconds at a time; or with long duration (more than 30 minutes at a time or more than 2 hours over a shift). POTENTIAL SOURCE OF RISK Unloading heavy containers and packages from pallets by hand, then carrying and putting them into storage areas. Ensure there is enough space in unloading and storage areas, which allows pallets to be unloaded as near as possible to storage areas and reduces the distances containers must be carried. It also allows the use of mechanical handling aids. Bulk supply and storage. High force Lifting, carrying and lowering heavy loads. Repetitive bending below the knees and use of high force to de-palletise bags of material. Crowded and congested unloading and storage areas. Increase space in unloading and storage areas to allow forklift access. Provide sufficient pallet racking that follows the 2005 WorkSafe Pallet Racking Guidance Note. Unload pallets with a forklift and store on pallet racking. Increase available unloading and storage space by reducing the range of chemicals used and having a just-in-time system for ordering and stocking to avoid overstocking. Refer to WorkSafe Victoria s Guidance Note Production Flow Fluctuations Managing Risks to Health and Safety. Crowded storage area. Lifting and lowering above shoulder height. Storage areas should be well maintained and regularly inspected, providing enough room as well as easy forklift and pallet jack access. Sufficient, easy access pallet racking used to store materials. 8 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

12 1. MANUAL HANDLING CHEMICALS DURING DELIVERY, UNLOADING AND STORAGE UNLOADING CONTAINERS AND BAGS FROM PALLETS AND PUTTING THEM INTO STORAGE HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION Exerting force while in an awkward posture. POTENTIAL SOURCE OF RISK Pallet is located on the ground. Use height adjustable pallet lifters to lower, raise and rotate pallets. Use vacuum lifters to move containers off pallets and onto storage racks and shelves. Lifting, lowering and exerting force while in an awkward posture. Bending the back more than 20 degrees or twisting. Carrying a load: more than twice a minute; more than 30 seconds at a time; or with long duration (more than 30 minutes at a time or more than 2 hours over a shift). Provide a pallet stand. High force Lifting, carrying and lowering heavy loads. Use mechanical aids such as height adjustable trolleys to move containers from unloading to storage areas. Vacuum lifters can be used for all types of packages. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 9

13 1. MANUAL HANDLING CHEMICALS DURING DELIVERY, UNLOADING AND STORAGE UNLOADING CONTAINERS AND BAGS FROM PALLETS AND PUTTING THEM INTO STORAGE HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION High force Lifting, carrying and lowering heavy loads. POTENTIAL SOURCE OF RISK Weight of containers or bags. Order chemicals in smaller containers and bags. Caution should be taken to ensure repetitive manual handling of smaller containers or bags is assessed. Increase size of container (e.g. palcons) so materials must be handled mechanically. Bulk supply eliminates the need to physically handle chemicals. Exerting force while in an awkward posture. Lifting, lowering and exerting force while in an awkward posture. Bending the back more than 20 degrees or twisting. Carrying a load: more than twice a minute; more than 30 seconds at a time; or with long duration (more than 30 minutes at a time or more than 2 hours over a shift). Unloading 20 litre tins from pallets on the ground, carrying them to storage areas and stacking them on shelves. Provide a height adjustable trolley that can be set at the same height as the bottom of the tins. Tins are loaded onto the trolley and moved to storage racks. Storage racks are fitted with rollers and tins are slid from the trolley onto the racks then pushed to back of racks and retrieved with push sticks/pick sticks. Supply in bulk containers so paint must be handled mechanically. High force Lifting, carrying and lowering heavy loads. Paint tins are mechanically loaded into custom made racks fitted with rollers. 10 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

14 1. MANUAL HANDLING CHEMICALS DURING DELIVERY, UNLOADING AND STORAGE UNLOADING CONTAINERS AND BAGS FROM PALLETS AND PUTTING THEM INTO STORAGE HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION High force Exerting force from an awkward posture. Applying sudden forces. Applying uneven, fast or jerky forces during pushing and pulling. POTENTIAL SOURCE OF RISK Containers stuck together during transport to stabilise the pallet load. Containers are difficult to separate from each other. Use stretch-wrap and banding to stabilise the loads on pallets during transport. Bulk supply and storage. Pushing or pulling hard to move objects. Lifting, lowering and exerting force while in an awkward posture. Bending the back more than 20 degrees or twisting. Working with one or both hands above shoulder height: more than twice a minute; more than 30 seconds at a time; or Crowded and congested unloading and storage areas may cause pallets to be stacked on top of each other. Provide a stable platform/steps to raise employee and eliminate reaching above shoulder height. Provide a stable raised surface (e.g. scissor lift) at the same height as containers on the top layer and move containers onto this surface. Ensure there is enough room in unloading areas so pallets are not stacked unnecessarily. Implement work systems so that pallets are not stacked during the unpacking process. Bulk supply and storage. with long duration (more than 30 minutes at a time or more than 2 hours over a shift). High force Operator forced to manually unload pallets above shoulder height using high force. Lifting heavy loads in an awkward posture. Exerting force while in an awkward posture. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 11

15 1. MANUAL HANDLING CHEMICALS DURING DELIVERY, UNLOADING AND STORAGE UNLOADING CONTAINERS AND BAGS FROM PALLETS AND PUTTING THEM INTO STORAGE HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION POTENTIAL SOURCE OF RISK Arrange with supplier to reduce height of pallets. Bulk supply and storage. Lifting, lowering and exerting force while in an awkward posture. Bending the back more than 20 degrees or twisting. Working with one or both hands above shoulder height: more than twice a minute; more than 30 seconds at a time; or with long duration (more than 30 minutes at a time or more than 2 hours over a shift). Pallet is stacked above shoulder height. Provide a stable platform/steps to raise employee and eliminate reaching above shoulder height. Provide a stable raised surface (e.g. scissor lift) at the same height as containers on the top layer and move containers onto this surface. This pallet is over stacked and well above shoulder height. High force Lifting heavy loads in an awkward posture. Exerting force while in an awkward posture. Unloading containers and bags from pallets and putting them into storage exposure to chemicals Reducing the range of chemicals used and having a just-in-time stock control system reduces the amount of chemicals stored on-site, simplifies safe handling and use and makes identification of individual chemicals easier in the workplace. Improving manual handling as described above cuts the risk of damaging containers and causing spills and leaks. This also reduces employees exposure to hazardous chemicals, reducing clean ups and waste disposal. 12 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

16 1. MANUAL HANDLING CHEMICALS DURING DELIVERY, UNLOADING AND STORAGE UNLOADING SHIPPING CONTAINERS AND ENCLOSED TRAILERS MANUAL HANDLING Packing and unpacking shipping containers and pantechnicons (enclosed semi-trailers) is a manual handling task associated with severe injuries and musculoskeletal disorders. For further guidance and information see: WorkSafe Guide to Preventing Injury from Packing and Unpacking Shipping Containers and Enclosed Trailers, WorkSafe Guidance Note: Slip-sheets or Pallets Ease Packing and Unpacking of Shipping Containers, Unloading shipping containers and enclosed trailers exposure to chemicals Employees may be exposed to hazardous chemicals when imported shipping containers have been fumigated and their contents have been damaged in transit, causing spills and leaks in the container. For further information and guidance refer to WorkSafe Guidance Note: Fumigated Shipping Containers: Safe Transport and Unloading, Safely loading and unloading shipping containers can be challenging. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 13

17 1. MANUAL HANDLING CHEMICALS DURING DELIVERY, UNLOADING AND STORAGE Gas cylinders are not designed to be manually handled safely. MANUAL HANDLING OF GAS BOTTLES Gas cylinders are not designed for manual handling. They are cumbersome, heavy, awkwardly shaped, and some do not have handles. In almost all situations they must be transported and stored vertically, creating a risk of MSD occurring. For information and guidance on safe manual handling of gas bottles see the WorkSafe publication Delivering Large Gas Cylinders Dangerous goods and hazardous substances Gas cylinders contain dangerous goods and hazardous substances and are subject to regulatory control. Cylinders should be stored in an area that allows air movement to prevent any build up of harmful gases in the event of a leak. Refer to Australian Standards AS : The Storage and Handling of Gases in Cylinders. 14 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

18 2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE MOVING CHEMICALS AND STORING IN WORK AREAS HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION High force Pushing and pulling objects that are hard to move or stop. POTENTIAL SOURCE OF RISK Requirement to manually move 205 litre (44 gallon) drums. Use a mechanical aid such as a drum mover or overhead crane. Bulk distribution system. Example: In an engine casting plant two-part resins are delivered in bulk (pallet containers), unloaded by forklift and directly connected by hose to the casting process. Lifting or lowering heavy loads. Exerting high force while in an awkward posture. Manually moving 205 litre containers from pallets is hazardous. Materials are supplied in pallet bulk bags and the contents are fed directly into the process automatically. Use a forklift with a drum moving attachment. Forklift drum attachments eliminate the need to physically handle 205 litre containers of substances on and off pallets. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 15

19 2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE MOVING CHEMICALS AND STORING IN WORK AREAS HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION POTENTIAL SOURCE OF RISK Use mechanical aids such as trolleys to move containers. Change to a bulk distribution system. Carrying a load. Bending the back more than 20 degrees or twisting. Lifting or lowering and repetitive grasping: Manually carrying chemical containers to work areas. Size, shape and weight of container. Use vacuum lifters to move containers. Use motorised stock chasers to move containers. more than twice a minute; more than 30 seconds at a time; or with long duration (more than 30 minutes at a time or more than 2 hours over a shift). High force Lifting, lowering and carrying heavy loads. Lifting heavy loads in an awkward posture. Exerting high force while in an awkward posture. Change container, e.g. transfer chemicals from bulk storage containers (hoppers, pallet containers) to wheelie bins which are then wheeled to work areas. Wheelie bins provide a means to manually move materials from one process to another. Care must be taken to ensure bin weights are kept low. Reduce weight of container. Change design to allow easier handling. 16 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

20 2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE MOVING CHEMICALS AND STORING IN WORK AREAS HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION POTENTIAL SOURCE OF RISK Alter the layout of the work area to allow easy access to storage. Change to a bulk distribution system. Carrying a load. Bending the back more than 20 degrees or twisting. Lifting or lowering and repetitive grasping: more than twice a minute; more than 30 seconds at a time; or with long duration (more than 30 minutes at a time or more than 2 hours over a shift). Crowded and congested work areas and poor local storage facilities increase the amount (e.g. double handling) and difficulty of manual handling, and prevent trolley access and other handling aids. Containers stored on the ground, stacked behind other containers or on top of each other. Store heavier items between knee and shoulder height. Provide sufficient shelving, racking and cradles that fit containers in use. See WorkSafe s A Guide to Manual Order Picking 2004 for further information. High force Lifting, lowering and carrying heavy loads. Lifting heavy loads in an awkward posture. Exerting high force while in an awkward posture Manual handling gas bottles in congested work areas is hazardous. Messy and congested storage areas are hazardous. Manually lifting heavy loads, especially above shoulder height, is extremely hazardous. Moving chemicals and storing in work areas exposure to chemicals Poor practices in moving chemicals to work areas and storing them locally may damage containers and cause spills. Poor local storage may mean chemicals are not properly separated and cross contamination may occur. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 17

21 2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE EMPTYING, DECANTING, MEASURING AND MIXING CHEMICALS HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION Bending the back forward more than 20 degrees or twisting. Lifting, lowering and carrying a heavy load with repetitive grasping. Excessive bending of the wrist: more than twice a minute; more than 30 seconds at a time; or with long duration (more than 30 minutes at a time or more than 2 hours over a shift). High force Lifting, lowering and carrying heavy loads. Lifting heavy loads in an awkward posture. Exerting force while in an awkward posture. POTENTIAL SOURCE OF RISK Emptying heavy bags and sacks. Chemical bags are hand-lifted from a pallet on the ground and the bag is held well above or below waist height, slit open and emptied into a hopper, chute or similar. No shelf or bench at waste height on which to rest bag while being opened and emptied. Weight, size and shape of bag. Build chutes with benches at waist height that feed into a hopper. Change the bag or container and work process. Supply chemicals in bulk hoppers or palcons and transfer to wheelie bins that are then wheeled to the take up area and connected to suction hoses to suck up contents and feed them into the process. Make the bags smaller. Change the design of the container to allow easier handling. Change to a bulk distribution system. Supply contents in bulk and transfer directly into process. A purpose designed sack tipping station with a vacuum lifter minimises handling and exposure to dust by sucking powder away. 18 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

22 2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE EMPTYING, DECANTING, MEASURING AND MIXING CHEMICALS HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION Bending the back forward more than 20 degrees or twisting. POTENTIAL SOURCE OF RISK Lifting containers from below knee height. Use handling aids such as an overhead crane, forklift with drum attachment or drum handler. Use a bulk decanting facility with closed systems and integrated automatic feed and pumping systems for supply and mixing. Lifting, lowering and carrying a heavy load with repetitive grasping. Excessive bending of the wrist: more than twice a minute; more than 30 seconds at a time; or with long duration (more than 30 minutes at a time or more than 2 hours over a shift). High force Lifting, lowering and carrying heavy loads. Lifting heavy loads in an awkward posture. Exerting force while in an awkward posture. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 19

23 2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE EMPTYING, DECANTING, MEASURING AND MIXING CHEMICALS HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION Gripping and working with the fingers close together and/or wide apart. Twisting or turning actions with the hands or arms. Exerting force with one hand or one side of the body. Awkward wrist postures when holding or supporting. Twisting, turning, grabbing, picking or wringing actions with the fingers, hands or arms: more than twice a minute; more than 30 seconds at a time; or with long duration (more than 30 minutes at a time or more than 2 hours over a shift). POTENTIAL SOURCE OF RISK Holding and tipping containers to decant, dispense or mix liquids. Provide racks, shelves, holders or cradles that hold containers. Supply pre-mixed or pre-diluted chemicals in pre-measured amounts to eliminate mixing and decanting. It may be necessary to change the batch size to enable this. Purpose built stand for decanting with supporting stand for the container. Ensure the container receiving the liquid is close enough to prevent splashing. The photos above demonstrate examples of hazardous manual decanting of chemicals. Fit pumps, taps, bungs, siphons or spigots onto main container. 20 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

24 2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE EMPTYING, DECANTING, MEASURING AND MIXING CHEMICALS HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION Gripping and working with the fingers close together and/or wide apart. Twisting or turning actions with the hands or arms. Exerting force with one hand or one side of the body. Awkward wrist postures when holding or supporting. Twisting, turning, grabbing, picking or wringing actions with the fingers, hands or arms: more than twice a minute; more than 30 seconds at a time; or with long duration (more than 30 minutes at a time or more than 2 hours over a shift). POTENTIAL SOURCE OF RISK Decanting or mixing in cramped and congested work areas makes the task more difficult. Install a fixed dosing pump that moves the liquid from the container to the process eliminating lifting, holding and tipping. Use process rooms or mix rooms and then pump the substance to the process area. Wheels on cradles enable them to be moved around and help ease crowding and congestion of the work area. Drums fitted with pumps make dispensing easier and dollies help ease crowding and congestion of the work area. Change the layout of the work area to make more space available and improve access to dispensers, etc. Reduce local storage space needed for chemicals by using a just-in-time delivery program. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 21

25 2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE EMPTYING, DECANTING, MEASURING AND MIXING CHEMICALS HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION Gripping and working with the fingers close together and/or wide apart. POTENTIAL SOURCE OF RISK Size, shape and weight of containers. Use smaller containers. Reduce the container s weight. Change container design to improve grip. Increase the size of the container so it must be handled with a mechanical aid. Twisting or turning actions with the hands or arms. Exerting force with one hand or one side of the body. Awkward wrist postures when holding or supporting. Large container size requires higher force during decanting. Twisting, turning, grabbing, picking or wringing actions with the fingers, hands or arms: more than twice a minute; more than 30 seconds at a time; or with long duration (more than 30 minutes at a time or more than 2 hours over a shift). 22 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

26 2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE EMPTYING, DECANTING, MEASURING AND MIXING CHEMICALS HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION High force Applying high force with the hands and arms, hitting, exerting force with the non-preferred hand, applying uneven, fast or jerky forces. POTENTIAL SOURCE OF RISK Buckets and drums that are difficult to open. Hands, screwdrivers, claw hammers, etc. used to open buckets. Use a purpose designed opening tool. Increase the size of the container so it must be handled with a mechanical aid. The container is then connected to the process once, to avoid the need to continually open and close the containers. Emptying, decanting, measuring and mixing chemicals exposure to chemicals Employees may be exposed to hazardous chemicals when emptying, decanting, measuring and mixing. Some of the solutions identified above may also reduce exposure to chemicals. Risk controls to reduce exposure to chemicals may also improve manual handling. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 23

27 2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE EMPTYING, DECANTING, MEASURING AND MIXING CHEMICALS DECANTING EXAMPLE AUTOMOTIVE PAINT KITCHEN Potential source of risk: Lifting containers off the floor and then holding and tipping them to decant, dispense or mix liquids. Example of low risk solution: Increase the size of the container so it must be handled with a mechanical aid. A parts manufacturer has an automated line to paint and coat automotive panel components. These are piped to the line from vats in a paint kitchen. Containers were manually filled from 20 litre drums, lifted from a trolley and then poured into vats. After emptying, the drums were carried from the paint kitchen, stacked on the ground, and lifted into a waste bin. Risk Control Some coatings and paints, such as clear finishes, were used in higher volumes than others and, as such, were supplied in 205 litre drums. The drums are delivered to the paint kitchen by forklift and moved inside and put in place using an overhead crane. The 205 litre drum is directly connected to the paint supply system. Once empty, the drum is placed outside the kitchen by the crane and then removed by a forklift. Benefits Hazardous manual handling of 20 litre drums of high use coatings has been completely eliminated. There have also been productivity and financial gains due to changes in buying in bulk, delivery, storage, transport within the plant and disposal. 205 litre drums are moved inside the paint kitchen using the overhead tracked crane. 24 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

28 3. CLEANING COMPONENTS AND PARTS Components and parts are often cleaned by hand, requiring repetitive manual handling tasks, awkward postures and high force, especially to the hands and arms. HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION Gripping and working with the fingers close together and/or wide apart. Twisting or turning actions with the hands or arms. Exerting force with one hand. Awkward wrist postures. Holding or supporting components and parts. Twisting, turning, grabbing, picking or wringing actions with the fingers, hands or arms. Bending the back more than 20 degrees or twisting. Reaching more than 30cm from the body: more than twice a minute; more than 30 seconds at a time; or with long duration (more than 30 minutes at a time or more than 2 hours over a shift). POTENTIAL SOURCE OF RISK Cleaning components by hand. Change the set up of work area to bring components closer to the body and raise them to waist height. Change upstream process to minimise cleaning. Some cleaning, e.g. degreasing, may be unnecessary and the task can be eliminated. Change the cleaning process by using an ultrasonic bath to clean components in batches. This bath uses water and vibration to clean. Use mechanical handling aids to handle crated batches of components in and out of the bath. Manual workstations for degreasing or cleaning parts can be hazardous. Ultrasonic cleaning baths eliminate hazardous manual handling and chemical exposure associated with part degreasing or cleaning. High force Applying high force with the hands and arms, exerting force with the non-preferred hand, applying uneven, fast or jerky forces. Cleaning components and parts exposure to chemicals Manual cleaning of components and parts can expose employees to chemicals. The low risk solution listed above may help reduce or eliminate this exposure. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 25

29 4. DIPPING COMPONENTS Components and parts are often dipped by hand involving lengthy and repetitive manual handling tasks and awkward postures and the application of high force, especially by the hands and arms. HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION Gripping and working with the fingers close together and/or wide apart. Twisting or turning actions with the hands or arms. POTENTIAL SOURCE OF RISK Manually dipping components. The shape, size and weight of components. Change set up of workstation to bring components closer to the body and raise them to waist height. Use a chain conveyor or similar. Automate the task using robots or similar. Awkward wrist postures. Holding or supporting dipping components. Twisting, turning, grabbing or picking actions with the fingers and hands. Bending the back more than 20 degrees or twisting. Reaching more than 30cm from the body: more than twice a minute; or, more than 30 seconds at a time; or, with long duration (more than 30 minutes at a time or more than 2 hours over a shift). High force Applying high force with the hands and arms, exerting force with the non-preferred hand, applying uneven, fast or jerky forces. Dipping components exposure to chemicals Manual dipping of components and parts can expose employees to chemicals. The low risk solution listed above may help reduce or eliminate this exposure. 26 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

30 5. DISPOSING OF WASTE CHEMICALS HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION High force Pushing and pulling objects that are hard to move or stop. Lifting or lowering heavy loads. POTENTIAL SOURCE OF RISK Manually moving 205 litre (44 gallon) drums of waste liquids. Weight, size and position of drum. Reduce the weight of the drum by replacing it before it fills up with waste. Use a closed system, with integrated automatic feed and pumping that automatically collects liquid waste and transfers it to collection or recycling stations. Manual handling 205 litre drums on and off pallets is hazardous. WASTE DISPOSAL EXAMPLE Waste solvent from a spray painting line is automatically pumped along a line to a sealed and labelled drum on a pallet in a cabinet. At regular intervals the drum is disconnected, sealed and removed from the cabinet, and a forklift is used to replace the empty drum. The drum on the pallet is then picked up by a forklift and moved to a waste disposal contractor s depot on-site. Forklift tines enable direct access to the cabinet. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 27

31 5. DISPOSING OF WASTE CHEMICALS WASTE RECYCLING EXAMPLE Waste oil is piped automatically from an injection moulding production area and stored in a closed sump. An external contractor regularly brings a processing and recycling truck on-site and the waste oil is processed and reused. This reduces manual handling and exposure to contaminated oils is eliminated. Connections and hoses during recycling are well maintained and there are splash guards in place in the unlikely event of a hose break. Emergency stops should also be appropriately located and fitted. A mobile waste hydraulic oil refiner helps to reduce manual handling and exposure to oils. HIGH RISK REDUCED-RISK SOLUTION LOW RISK ACTION High force Pulling hard to move objects. Exerting force while in an awkward posture. POTENTIAL SOURCE OF RISK Untying heavy bags of waste dust, powder, granules, etc. collected from a chute and dragging them to a disposal point. The weight, size and shape of the bag. Extend the chute into a closed wheelie bin and change the bin before it fills. Wheel the bin to disposal point. After Flexible connector to bin Extend the chute into a closed drum and move the drum using mechanical aids. Before Nylon bag Disposing of waste chemicals exposure to chemicals Manual handling during disposal can expose employees to chemicals. The low risk solutions above may help to reduce or eliminate this exposure. 28 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

32 PACKAGES AND CONTAINERS Bottles, bags, sacks, tubs, cylinders, boxes, cans, drums, trays and buckets are all considered packages and containers. This section applies to those packages and containers supplied to and used in the workplace. Problems with packages and containers may contribute to manual handling risks and increase the exposure of employees to chemicals. The size, shape, weight and other features of packages and containers may be a source of manual handling risk. Identifying a feature as a source of risk will depend on the particular circumstances in which the package or container is handled and needs to be determined using the hazard identification and risk assessment processes described in the WorkSafe Manual Handling Code of Practice, No. 25, Other features of packages and containers can expose employees to chemicals during handling, depending on the way it is handled and used. Refer to the Dangerous Goods Act, Regulations and Code of Practice and the Hazardous Substances Regulations. EXAMPLES OF PROBLEMS WITH PACKAGES AND CONTAINERS These tins have poor handholds making them difficult to handle and cause poor posture. Pallets stretch-wrapped too tightly can damage containers resulting in spills and leaks. These bags of sand used for spill clean ups are difficult to handle because of their weight and lack of handholds. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 29

33 PACKAGES AND CONTAINERS EXAMPLES OF PROBLEMS WITH PACKAGES AND CONTAINERS Containers that can t be resealed properly are more likely to cause leaks and spills. The size, shape and weight of the container and the handholds can cause hazardous manual handling. The contents of bags and sacks can move, unbalancing them and making them difficult to hold. These containers have poor handholds requiring a grip that is too narrow or too wide. Using the wrong containers to collect liquid wastes can expose employees to fumes and cause spills. Damaged containers are more likely to cause leaks and spills and can be difficult or impossible to handle with mechanical aids. Containers of decanted chemicals must be properly and legibly labelled or marked. Containers must be right for the chemical empty food containers should never be used. 30 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

34 PACKAGES AND CONTAINERS IDENTIFYING AND FIXING PROBLEMS WITH PACKAGES AND CONTAINERS The following flowchart outlines the process for identifying and fixing packaging and container problems. A useful tool in this process is the Container and Package Health & Safety Checklist over the page. Step 1 Identify problems Step 2 Fix problems Information from injury, damage, accident and incident records Change packages and containers Information from Job Safety Analysis (JSA), routine safety inspections, etc. Discuss and consult with manufacturers, suppliers and transporters High levels of use due to spills and leaks due to container and package problems Change tenders and supply specifications Use the Container and Package Health & Safety Checklist, which can be completed in consultation with employees, etc. The Container and Package Health & Safety Checklist can be used to specify what changes are required to control hazards Chemical manufacturers and suppliers meet their legislative duties At all stages consult with employees (including labour hire employees) who handle and work with containers and packages and their HSRs. Everyone involved in working with containers and packages needs to be properly informed of the risks to health and safety and what controls are in place to reduce these risks. Where determined, effective training should be provided to ensure risk control solutions are properly implemented, e.g. understanding labels on containers, understanding how to undertake new processes, and following standard operating procedures. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 31

35 PACKAGES AND CONTAINERS CONTAINER AND PACKAGE HEALTH & SAFETY CHECKLIST This checklist can be used to assess containers and packages currently used or planned on being used. It is not for bulk containers. For each feature a tick in a red box may indicate a problem. FEATURE YES NO N/A Size, shape and contents Weight: kg Is it heavier than it looks? Does it come in a pre-measured size or quantity that makes measuring, partial decanting or emptying unnecessary? Does the packaging allow for a pre-measured size or quantity to be directly added to the process without unwrapping? Does the size and shape allow for it to be easily handled by hand? Does the size and shape make it easy to handle with a mechanical aid? Is it less than 500mm wide measured across the body? Is it less than 300mm deep measured away from the body? Is it stable? Is it hard to knock or tip over? Does it block the worker s view when being handled? Are the contents stable during handling? Is the centre of gravity in the middle? Can it be moved with a mechanical handling aid? Handles and grips Are there good grips or handles? Are grips and handles located in good positions for manual handling? Do gloves need to be used during handling? Does it have any sharp edges or protrusions? Are there good grips or handles when wearing gloves? Other Is it slippery to hold? Does it have chemicals on the outside? Is it open during handling? Is it in good condition, not crushed, torn or leaking? Is it tough enough for all different workplace conditions? 32 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

36 PACKAGES AND CONTAINERS FEATURE YES NO N/A Opening, decanting, pouring, emptying Is it easy to open? For liquid containers that can have a high internal pressure, does the design of the lid, cap, bung, closure, etc. prevent liquid or fumes spraying the employee during opening? Is it easy to empty/pour? For decanting liquids, is a bung/tap fitted at the bottom, can a pump be inserted, or can a nozzle be used for decanting? Is it easy to use a scoop with? Does it minimise spills and leaks when emptying, is it fitted with anti-glug pouring? Can the lid, top or closure be removed easily? Can the lid, top or closure be put back on the container? Labelling Can the label be read after the package is removed from a pallet, stacked or shelved, or when it is being used or disposed of? Does the label clearly display the weight of the package? Does the label clearly show information about the contents, such as physical form and ingredients? Does the label clearly detail if the contents may have moved during handling? Does the label clearly show if there are any special manual handling requirements? Does the label clearly show if gloves or protective clothing or equipment should be used during handling? Does the label clearly show how to safely use the contents? Does the label identify any special storage or stacking requirements? Does the label detail what to do if there are spills or leaks? Does the label meet the requirements of the Dangerous Goods Act, Regulations and the Hazardous Substances Regulations? Can the label be understood by someone who can t read English? Is the label securely fixed to, or printed on, the container or package? Is the label long-lasting? Disposal Can it be easily rinsed/cleaned out before disposal/recycling? Can it be easily stacked or binned when empty? Other Does it fit in with how things are unloaded, stored, moved and used in the workplace? Does it fit in with the workplace s systems of work? WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 33

37 PACKAGES AND CONTAINERS FIXING CONTAINER AND PACKAGING PROBLEMS Chemicals supplied in convenient pre-measured sealed bags. Example: Working with employees, HSRs and suppliers to change packaging to reduce hazardous manual handling and exposure to chemicals in an engine foundry Problem A hazardous substance was introduced to an engine foundry s melt area. Having been removed from its container with a scoop, it was measured and then added to the process. Employees are exposed to a hazardous dust and wear protective clothing and equipment. The task is done in a hot and hazardous area. Solution In consultation with the HSR and the supplier, the substance was re-supplied in pre-measured sealed bags that are added directly to the process unopened. The tasks of opening the bag, scooping and measuring were eliminated along with exposure to the powder. ADDING HANDLES TO BAGS AND SACKS Adding handles to bags improves grip and ease of handling, decreasing the risk of injury. 34 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

38 PACKAGES AND CONTAINERS EFFECTIVE CLOSURES The closures on these containers are reusable, easy to use and provide an effective seal. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 35

39 PROTECTIVE CLOTHING AND EQUIPMENT The use of protective clothing and equipment is a common risk control for employees exposed to chemicals. However, it is not a good idea to rely on protective clothing and equipment to control risk as it may not properly protect all employees from risks and can create new risks. Controls other than the use of protective clothing and equipment should be used to manage risks arising from the use of chemicals, so far as reasonably practicable. Personal protective clothing and equipment should be used when recommended in a Material Safety Data Sheet (MSDS) and when other controls do not adequately control exposure. RISKS OF USING PROTECTIVE CLOTHING AND EQUIPMENT Personal protective clothing and equipment is not a good risk control because it: does not eliminate or reduce the risks and dangers; may not be cost effective often the long-term monetary and employee time costs of using protective clothing and equipment are not taken into account. This includes the costs of: selection; storage; cleaning; fitting; medical examinations required before use; purchase; replacement; maintenance; training employees in use and maintenance; and monitoring use and extra supervision; only provides limited protection; will not protect employees if it is not properly selected, fitted, used, maintained and stored; is often less effective if more than one type of personal protective clothing and equipment is used at the same time; is not always used when it should be because it: interferes with doing the job; causes discomfort and/or pain; affects vision, e.g. safety goggles, full face respirators; interferes with hearing and talking, e.g. hearing protection, respirators; is not used by some employees for health, physical and psychological reasons; is difficult to use correctly if not properly supervised; or interferes with employee concentration; and could be contaminated if not stored properly. 36 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

40 PROTECTIVE CLOTHING AND EQUIPMENT Protective clothing and equipment can increase manual handling risks by: increasing heat stress in hot work areas, as this makes the work harder and increases tiredness and the risk of heat illness; restricting postures and movements, as this can make the job harder to do and increases the chances that protective clothing and equipment won t be properly used, e.g. gloves can prevent getting a good grip on tools, components and materials this puts more physical stress on the hands, arms and shoulders; using non-powered respirators that can make breathing harder, worsened if the filters need changing, making the job harder to do; and restricting movement and mobility if air-lines and air-hoses are used with air supplied respirators, as this can make the job harder to do and creates tripping risks. Wearing personal protective clothing and equipment can increase heat stress, make the job harder to do, affect grip and restrict postures and movements. WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 37