safe manual handling of chemicals in the

Transcription

SAFE MANUAL HANDLING
OF CHEMICALS IN THE
AUTOMOTIVE INDUSTRY
1ST EDITION
OCTOBER 2006
MANUFACTURING
* 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 2012. 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
CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Packages and containers . . . . . . . . . . . . . . . . . . . . . . 29
Why has this guide been produced? . . . . . . . . . . . . . . . . 1
Examples of problems with packages
and containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Injuries and health effects – exposure to hazardous
manual handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Injuries and health effects – exposure to chemicals . . . 2
Identifying and fixing problems with packages and
containers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Manual handling of chemicals . . . . . . . . . . . . . . . . . . . . . 3
Container and package health & safety checklist . . . . . 32
Consulting employees and health and safety
representatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fixing container and packaging problems . . . . . . . . . . . 34
Information and training. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Effective closures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
The legal status of this guide . . . . . . . . . . . . . . . . . . . . . . 4
How to use this guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. Manual handling chemicals during delivery,
unloading and storage . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Unloading containers and bags from pallets and
putting them into storage . . . . . . . . . . . . . . . . . . . . . . 8
Unloading shipping containers and enclosed
trailers – manual handling . . . . . . . . . . . . . . . . . . . . . 13
Manual handling of gas bottles . . . . . . . . . . . . . . . . 14
2. Manual handling chemicals in the workplace . . . . . . 15
Adding handles to bags and sacks . . . . . . . . . . . . . . . . . 34
Protective clothing and equipment . . . . . . . . . . . . . 36
Risks of using protective clothing and equipment. . . . . 36
Steps to follow before using protective clothing and
equipment as a risk control. . . . . . . . . . . . . . . . . . . . . . . 38
Further information and guidance. . . . . . . . . . . . . . 42
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Legislation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Publications and further information available
from WorkSafe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Acknowledgements. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Moving chemicals and storing in work areas . . . . . 15
Emptying, decanting, measuring and
mixing chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3. Cleaning components and parts. . . . . . . . . . . . . . . . . 25
4. Dipping components . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5. Disposing of waste chemicals . . . . . . . . . . . . . . . . . . 27
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 2004. 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.
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
INTRODUCTION
Musculoskeletal disorders from
manual handling
INJURIES AND HEALTH EFFECTS – EXPOSURE TO HAZARDOUS
MANUAL HANDLING
Muscle
sprains
and strains
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.
Injuries to
muscles,
ligaments,
spinal discs
and other
structures
in the back
These tasks may cause injuries, such as musculoskeletal disorders (MSDs).
However, it is important to note that not all manual handling is hazardous.
Abdominal
hernias
Injuries to
soft tissues
such as
nerves,
ligaments
and tendons
in the wrists,
arms,
shoulders,
neck or legs
Exposure to substances
Chemical
burns and
irritation of
the skin,
eyes, etc.
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
Poisoning
Diseases
of certain
organs such
as the skin,
lungs, liver,
kidneys and
nervous
system
Cancer,
birth defects
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.
Routes of exposure
Inhalation
Ingestion
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
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.
3
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.
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.
Before: Dry sweeping can create
airborne dust in the breathing zone.
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 2004. 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
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
YES
Are any solutions
from the green column
reasonably practicable
for the workplace?
(Undertake
practicability test)
Implement a solution
from the green,
low risk solution,
column
NO
Implement solutions
from the amber,
reduced-risk, 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 www.worksafe.vic.gov.au or contact the WorkSafe
Advisory Service on 1800 136 089.
5
TASKS
1. Manual handling chemicals during delivery,
unloading and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Unloading containers and bags from pallets and putting
them into storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unloading shipping containers and enclosed trailers –
manual handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Manual handling of gas bottles . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2. Manual handling chemicals in the workplace . . . . . . . . . . . . . . . . . 15
Moving chemicals and storing in work areas . . . . . . . . . . . . . . . 15
Emptying, decanting, measuring and mixing chemicals . . . . . . . 18
3. Cleaning components and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4. Dipping components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5. Disposing of waste chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6
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 2000.
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.
7
UNLOADING CONTAINERS AND BAGS FROM PALLETS AND PUTTING THEM INTO STORAGE
HIGH RISK
ACTION
POTENTIAL SOURCE
OF RISK
Exerting force while in
an awkward posture.
Unloading heavy
containers and
packages from pallets
by hand, then carrying
and putting them into
storage areas.
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).
High force
Lifting, carrying and
lowering heavy loads.
REDUCED-RISK SOLUTION
LOW RISK
– 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.
– Increase space in unloading and
storage areas to allow forklift
access.
– 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.
Repetitive bending below
the knees and use of high
force to de-palletise bags
of material.
Crowded and
congested unloading
and storage areas.
– Provide sufficient pallet racking
that follows the 2005 WorkSafe
Pallet Racking Guidance Note.
Unload pallets with a forklift and
store on pallet racking.
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
HIGH RISK
ACTION
POTENTIAL SOURCE
OF RISK
an awkward posture.
Pallet is located on
the ground.
LOW RISK
– 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.
an awkward posture.
Bending the back
load:
• more than twice
a minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than
2 hours over a shift).
– Provide a pallet stand.
High force
– 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.
9
HIGH RISK
ACTION
POTENTIAL SOURCE
OF RISK
High force
Weight of containers
or bags.
LOW RISK
– 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 Unloading 20 litre tins
an awkward posture.
from pallets on the
ground, carrying them
to storage areas and
stacking them on
an awkward posture.
shelves.
Bending the back
load:
• more than twice
a minute;
• more than
30 seconds at a
time; or
(more than 30
minutes at a time
or more than 2
hours over a shift).
– Provide a height adjustable
trolley that can be set at the
same height as the bottom of
the tins.
– Supply in bulk containers so
paint must be handled
mechanically.
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.
High force
Paint tins are mechanically loaded into
custom made racks fitted with rollers.
10
HIGH RISK
ACTION
POTENTIAL SOURCE
OF RISK
High force
• Exerting force from
an awkward
posture.
• Applying sudden
forces.
• Applying uneven,
fast or jerky forces
during pushing and
pulling.
• Pushing or pulling
hard to move
objects.
Containers ‘stuck’
together during
transport to stabilise
the pallet load.
exerting force while
in an awkward
posture.
Crowded and
congested unloading
and storage areas may
cause pallets to be
stacked on top of each
other.
Bending the back
or twisting.
Working with one or
both hands above
shoulder height:
• more than twice a
minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
LOW RISK
– Use stretch-wrap and banding
to stabilise the loads on pallets
during transport.
– Provide a stable platform/steps
to raise employee and eliminate
reaching above shoulder height.
Containers are difficult
to separate from each
other.
– 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.
Operator forced to
manually unload pallets
above shoulder height
using high force.
High force
Lifting heavy loads in
an awkward posture.
Exerting force while
in an awkward
posture.
11
HIGH RISK
LOW RISK
– Arrange with supplier to reduce
height of pallets.
ACTION
POTENTIAL SOURCE
OF RISK
an awkward posture.
Pallet is stacked above – Provide a stable platform/steps
to raise employee and eliminate
shoulder height.
reaching above shoulder height.
Bending the back
or twisting.
– 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.
Working with one or
both hands above
shoulder height:
• more than twice
a minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
This pallet is over stacked
and well above shoulder
height.
High force
an awkward posture.
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
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, 2003.
• WorkSafe Guidance Note: Slip-sheets or Pallets Ease Packing and Unpacking
of Shipping Containers, 2005.
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, 2005.
Safely loading and unloading shipping
containers can be challenging.
13
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 2002.
Dangerous goods and hazardous substances
Gas cylinders contain dangerous goods and hazardous substances and are subject
to regulatory control.
Gas cylinders are not designed to be
manually handled safely.
14
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 4332–2004: The Storage and Handling of Gases in Cylinders.
2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE
MOVING CHEMICALS AND STORING IN WORK AREAS
HIGH RISK
ACTION
POTENTIAL SOURCE
OF RISK
High force
• Pushing and pulling
objects that are
hard to move or
stop.
• Lifting or lowering
heavy loads.
• Exerting high force
while in an
awkward posture.
Requirement to
manually move 205
litre (44 gallon) drums.
LOW RISK
– 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.
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.
15
HIGH RISK
ACTION
POTENTIAL SOURCE
OF RISK
Carrying a load.
Manually carrying
chemical containers to
work areas.
Bending the back
or twisting.
Lifting or lowering and
repetitive grasping:
minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
LOW RISK
– Use mechanical aids such as
trolleys to move containers.
– Change to a bulk distribution
system.
– Use vacuum lifters to move
containers.
– Use motorised stock chasers to
move containers.
Size, shape and
weight of container.
High force
carrying heavy loads.
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
HIGH RISK
LOW RISK
system.
ACTION
POTENTIAL SOURCE
OF RISK
– Alter the layout of the work area
to allow easy access to storage.
Carrying a load.
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.
– 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.
Bending the back
or twisting.
Lifting or lowering and
repetitive grasping:
minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
High force
an awkward posture.
Exerting high force
while in an awkward
posture
Containers stored on
the ground, stacked
behind other
containers or on top
of each other.
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.
17
EMPTYING, DECANTING, MEASURING AND MIXING CHEMICALS
HIGH RISK
ACTION
POTENTIAL SOURCE
OF RISK
Bending the back
forward more than 20
degrees or twisting.
Emptying heavy bags
and sacks.
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
(more than 30
minutes at a time
or more than 2
High force
an awkward posture.
an awkward posture.
18
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.
LOW RISK
– Build chutes with benches at
waist height that feed into a
hopper.
system.
– Change the bag or container and
work process.
– Supply contents in bulk and
transfer directly into 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.
No shelf or bench at
waste height on which
to rest bag while
being opened and
emptied.
Weight, size and
shape of bag.
– Make the bags smaller.
– Change the design of the
container to allow easier
handling.
– A purpose designed sack tipping
station with a vacuum lifter
minimises handling and
exposure to dust by sucking
powder away.
HIGH RISK
ACTION
POTENTIAL SOURCE
OF RISK
Bending the back
forward more than 20
degrees or twisting.
Lifting containers from
below knee height.
LOW RISK
– 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.
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
(more than 30
minutes at a time
or more than 2
High force
an awkward posture.
an awkward posture.
19
HIGH RISK
ACTION
POTENTIAL SOURCE
OF RISK
Gripping and working
with the fingers close
together and/or wide
apart.
Holding and tipping
containers to decant,
dispense or mix
liquids.
LOW RISK
– 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.
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.
– Purpose built stand for
decanting with supporting stand
for the container. Ensure the
container receiving the liquid is
close enough to prevent
splashing.
Twisting, turning,
grabbing, picking or
wringing actions with
the fingers, hands or
arms:
minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
The photos above
demonstrate examples
of hazardous manual
decanting of chemicals.
20
– Fit pumps, taps, bungs, siphons
or spigots onto main container.
HIGH RISK
ACTION
POTENTIAL SOURCE
OF RISK
apart.
Decanting or mixing in
cramped and
congested work areas
makes the task more
difficult.
Twisting or turning
or arms.
LOW RISK
– 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.
Exerting force with
of the body.
Awkward wrist
postures when
Twisting, turning,
arms:
minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
– 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.
21
HIGH RISK
ACTION
apart.
LOW RISK
POTENTIAL SOURCE
OF RISK
– Use smaller containers.
– Increase the size of the
container so it must be handled
with a mechanical aid.
Size, shape and
weight of containers.
– Change container design to
improve grip.
– Reduce the container’s weight.
Twisting or turning
actions with the
hands or arms.
Exerting force with
of the body.
Awkward wrist
postures when
Large container size
requires higher force
during decanting.
Twisting, turning,
arms:
minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
22
HIGH RISK
ACTION
POTENTIAL SOURCE
OF RISK
High force
Buckets and drums
that are difficult to
open.
Applying high force
with the hands and
arms, hitting, exerting
force with the
non-preferred hand,
applying uneven,
fast or jerky forces.
LOW RISK
– 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.
Hands, screwdrivers,
claw hammers, etc.
used to open buckets.
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.
23
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
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
ACTION
POTENTIAL SOURCE
OF RISK
apart.
Cleaning components
by hand.
LOW RISK
– 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.
Twisting or turning
or arms.
Exerting force with
one hand.
Awkward wrist
postures.
Holding or supporting
components and
parts.
Twisting, turning,
arms.
Bending the back
or twisting.
Reaching more than
30cm from the body:
minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
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.
25
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
ACTION
POTENTIAL SOURCE
OF RISK
apart.
Manually dipping
components.
Twisting or turning
or arms.
The shape, size
and weight of
components.
LOW RISK
– Change set up of workstation to
bring components closer to the
body and raise them to waist
height.
– Automate the task using robots
or similar.
– Use a chain conveyor or similar.
Awkward wrist
postures.
Holding or supporting
dipping components.
Twisting, turning,
grabbing or picking
actions with the
fingers and hands.
Bending the back
or twisting.
Reaching more than
30cm from the body:
minute; or,
• more than 30
seconds at a time;
or,
(more than 30
minutes at a time
or more than 2
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
5. DISPOSING OF WASTE CHEMICALS
HIGH RISK
ACTION
POTENTIAL SOURCE
OF RISK
High force
• Pushing and pulling
objects that are
hard to move or
stop.
• Lifting or lowering
heavy loads.
Manually moving
205 litre (44 gallon)
drums of waste
liquids.
LOW RISK
– 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.
Weight, size and
position of drum.
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.
27
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
ACTION
POTENTIAL SOURCE
OF RISK
High force
Untying heavy bags of
waste dust, powder,
granules, etc.
collected from a chute
and dragging them to
a disposal point.
Pulling hard to move
objects.
an awkward posture.
LOW RISK
– Extend the chute into a closed
wheelie bin and change the bin
before it fills. Wheel the bin to
disposal point.
– Extend the chute into a closed
drum and move the drum using
mechanical aids.
The weight, size and
shape of the bag.
After
Flexible
connector
to bin
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
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, 2000.
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.
29
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.
These containers have poor handholds requiring a grip that is too
narrow or too wide.
The contents of bags and sacks can move,
unbalancing them and making them difficult
to hold.
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
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
Discuss and
consult with
manufacturers,
suppliers and
transporters
Information from Job
Safety Analysis (JSA),
routine safety
inspections, etc.
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.
31
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
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?
33
FIXING CONTAINER AND PACKAGING PROBLEMS
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
Chemicals supplied in convenient
pre-measured sealed bags.
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
EFFECTIVE CLOSURES
The closures on these containers are reusable, easy to use and provide an effective seal.
35
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
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.
37
STEPS TO FOLLOW BEFORE USING PROTECTIVE CLOTHING AND
EQUIPMENT AS A RISK CONTROL
Step 1
A risk assessment, as required by the Hazardous Substances Regulations, should
be completed prior to using protective clothing and equipment. Consultation with
employees exposed to the chemicals and their HSRs is required.
Step 2
If the risk assessment shows risk controls are needed, the following must be
considered when consulting employees exposed to the chemicals:
• eliminating the hazardous chemicals;
• using less hazardous substances, or substances in less hazardous forms;
• isolating employees from the chemicals;
• engineering controls that reduce employee exposure to chemicals; and
• changing the systems of work to reduce or eliminate employee exposure.
If these risk controls are not reasonably practicable in the short term then
protective clothing and equipment may be suitable as a temporary risk control.
Can you eliminate the hazard/risk?
YES
NO
Can the hazard/risk be replaced with something less hazardous?
NO
YES
Does this control the hazard?
YES
NO
Can you isolate the hazard/risk from people?
NO
YES
YES
Protective
clothing and
equipment
not required
NO
Can engineering controls be used to control the hazard/risk?
NO
YES
YES
NO
Can administrative changes control the hazard/risk?
NO
YES
GO TO STEP 3
38
YES
NO
Step 3
This checklist will help determine if protective clothing and equipment is a suitable risk control.
It identifies factors that may need to be addressed when using protective clothing and equipment as a risk control.
Answers in a red box indicate that protective clothing and equipment may not be a suitable primary risk control.
YES
NO
Are employees potentially exposed to chemicals and have they and their HSRs been consulted about
the use of protective clothing and equipment?
Is there protective clothing and equipment that will effectively protect employees from the
chemicals?
Is this protective clothing and equipment readily available?
Will the protective clothing and equipment interfere with vision and communication?
Will any exposed employees be unable to use the protective clothing and equipment due to physical,
psychological or medical factors?
Will the protective clothing and equipment interfere with the job or task?
Will using protective clothing and equipment create other risks, e.g. manual handling risks or heat
stress?
Step 4
Take action to address any problems identified in Step 3, indicated by ticks in any of the red boxes.
39
Step 5
Implement an effective personal protective clothing and equipment program.
When protective clothing and equipment are used as a temporary risk control, a protective clothing and equipment
program should be in place and reviewed regularly.
This checklist contains the essential requirements of an effective program and can be used to evaluate an existing
program. Answers in a green box indicate the requirement has been satisfied.
REQUIREMENT
YES
NO
N/A
Did the employer establish the program?
Did the employer consult employees and HSRs when establishing the program?
Are employees and HSRs active participants in the program, involved in its planning,
implementation, monitoring and evaluation?
Is someone designated to be responsible for the program?
Does that person have the full support of employees and the employer?
Is there an effective procedure for dealing with situations where clothing and equipment
are not being used as required?
Does the procedure for selecting protective clothing and equipment include consultation?
Are the following considerations met when selecting protective clothing and equipment:
• Is it comfortable, a good fit?
• Does it not interfere with the job?
• Does it provide employees with choice?
• Does it cater for differences between employees?
• Does it provide adequate levels of protection?
• Can it be used together with other clothing and equipment?
Is there medical screening of each employee assigned to wear respirators?
Are employees and supervisors (including labour hire and contractors) appropriately
trained in:
• the program;
• why the program is the only reasonably practicable risk control solution at present;
• future risk controls which may replace the use of protective clothing and equipment;
• proper use and fitting;
• how to test the equipment (e.g. respirators);
• cleaning, storage, maintenance and replacement;
• the limitations of the equipment and clothing;
• the risks, dangers, and need for protection;
• when, where and how the clothing and equipment is to be used; and
• how any problems/issues with the equipment and its use are to be reported and fixed.
Is clothing and equipment supplied to each employee for their use?
Do employees get a copy of the operator’s manual for the clothing and equipment
provided?
Is there proper fitting and testing of clothing and equipment?
Is there regular cleaning/disinfecting of clothing and equipment?
Is proper storage for the clothing and equipment available?
Is there periodic inspection and maintenance of the equipment and/or replacement as
required and as per manufacturer’s/supplier’s instructions?
Is there adequate employee time allocated for training, fitting, cleaning and rest breaks
(if necessary) when using some equipment?
Are there procedures for non-routine situations such as spills and leaks?
Is there regular assessment of the program to ensure procedures are being followed and
employees are being properly protected?
40
Step 6
Protective clothing and equipment is a temporary measure, a last resort, to
be used when other risk controls do not control exposure or are not reasonably
practicable and steps 1-5 have been completed.
If protective clothing and equipment is being used for extended periods in a
workplace, then alternative risk controls may not have been properly considered.
It is the employer’s responsibility to provide protective clothing and equipment for
employees, including labour hire employees.
Step 7
A continuous improvement approach is essential. This includes yearly reviews of:
• changes in knowledge about the effects of the substance on health;
• existing, and any new, risks due to changes in chemicals used and work
processes;
• changes in technology and state of knowledge about risk control measures
including elimination, substitution, engineering and changing systems of work
or work practices;
• changes in technology and state of knowledge about protective clothing and
equipment; and
• the workplace’s protective clothing and equipment program.
The basis for these reviews can be steps 1, 2 and 3 and the checklist on page 40.
41
FURTHER INFORMATION
AND GUIDANCE
GENERAL
• Employees can contact their union.
• Employers can contact their industry association.
• WorkSafe publications can be obtained by phoning WorkSafe on toll free
1800 136 089 or emailing [email protected]
• Visit www.worksafe.vic.gov.au
LEGISLATION
•
•
•
•
•
•
•
•
•
Occupational Health and Safety Act 2004
Road Transport (Dangerous Goods) Act 1995
Road Transport Reform (Dangerous Goods) Act 1995 (Commonwealth)
Dangerous Goods Act 1985
Manual Handling Regulations 1999
Dangerous Goods (HCDG) Regulations 2005
Dangerous Goods (Storage and Handling) Regulations 2000
Occupational Health and Safety (Hazardous Substances) Regulations 1999
Occupational Health and Safety (Confined Spaces) Regulations 1996
For copies of the above Acts and Regulations go to www.dms.dpc.vic.gov.au or
phone Information Victoria on 1300 366 356.
42
FURTHER INFORMATION AND GUIDANCE
PUBLICATIONS AND FURTHER INFORMATION AVAILABLE FROM
WORKSAFE
Consultation
• There are many publications available including Talking Safety Together and
Consultation – A User’s Guide.
Manual Handling
•
•
•
•
•
•
•
•
•
•
Manual Handling Code of Practice, No. 25, 2000
Manual Handling in the Automotive Industry, March 2005
Manual Handling Risk – Assessing and Controlling, 2005
Production Flow Fluctuations – Managing Risks to Health and Safety,
October 2005
Delivering Large Gas Cylinders – A Guide to Manual Handling
A Guide to Handling Large, Bulky or Awkward Items, August 2005
A Guide to Manual Order Picking, March 2004
A Guide to Manual Handling in the Food Industry, April 2006
Guidance Note: Slip-sheets or Pallets Ease Packing and Unpacking of Shipping
Containers, 2005
Guide to Preventing Injury from Packing and Unpacking Shipping Containers and
Enclosed Trailers, 2003
Forklift safety
• Forklift Safety Reducing the Risk, February 2006
Pallet racking
• Guidance Note: WorkSafe Pallet Racking, 2005
Chemicals – Hazardous substances, dangerous goods, confined spaces
• Chemical Safety Self Assessment Tool, March 2006
• A Step by Step Guide for Manufacturers, Importers and Suppliers of Hazardous
Substances and Dangerous Goods, 2001
• Safe Handling of Industrial Waste, 2003
• Guidance Note: Fumigated Shipping Containers: Safe Transport and Unloading,
2005
• Hazardous Substances Code of Practice, No. 24, 2000
• Confined Spaces Code of Practice, No. 20, 1996
• Storage and Handling of Dangerous Goods Code of Practice .
Incident Reporting – Notifying WorkSafe Victoria
• Guide to incident notification – August 2005
43
ACKNOWLEDGEMENTS
This publication is part of the Safe Handling of Chemicals in the Automotive
Industry Project (SHOCAi). It has been funded by WorkSafe Victoria’s Safety
Development Fund.
The project’s steering group is the Motor Vehicle and Parts Manufacturing Health
and Safety Forum.
The following organisations are represented on the forum and WorkSafe would
like to thank them for their generous contributions to the guide’s development:
• Australian Industry Group
• Australian Manufacturing Workers Union – Vehicle Division
• Australian Manufacturing Workers Union – Metals Division
• Department of Industry Innovation and Regional Development
• Electrical Trades Union
• Liquor, Hospitality and Miscellaneous Union
• National Union of Workers
• Plastics and Chemical Industry Association
• Victorian Employers Chamber of Commerce and Industry
Thanks to all workplaces and individuals who participated in the Automotive and
Parts Industry Solutions Workshop in October 2005, those who provided images
for this publication, and Ross Armstrong of Global Ergonomics Pty Ltd.
44
WORKSAFE VICTORIA
Advisory Service
222 Exhibition Street
Melbourne VIC 3000
Phone . . . . . . . . . . . . . . 03 9641 1444
Toll-free . . . . . . . . . . . . . 1800 136 089
Email . . . . . [email protected]
Head Office
222 Exhibition Street
Melbourne VIC 3000
Phone . . . . . . . . . . . . . . 03 9641 1555
Toll-free . . . . . . . . . . . . . 1800 136 089
Website . . . www.worksafe.vic.gov.au
Local Offices
Ballarat . . . . . . . . . . . . . 03
Bendigo. . . . . . . . . . . . . 03
Dandenong . . . . . . . . . . 03
Geelong. . . . . . . . . . . . . 03
Melbourne
(628 Bourke Street). . . . 03
Mildura . . . . . . . . . . . . . 03
Mulgrave . . . . . . . . . . . . 03
Preston . . . . . . . . . . . . . 03
Shepparton . . . . . . . . . . 03
Traralgon . . . . . . . . . . . . 03
Wangaratta . . . . . . . . . . 03
Warrnambool . . . . . . . . 03
VWA1063/02/05.13
5338
5443
8792
5226
4444
8866
9000
1200
9941 0558
5021 4001
9565 9444
9485 4555
5831 8260
5174 8900
5721 8588
5564 3200

safe manual handling of chemicals in the

Transcription

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