SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY · · 2017-06-16Manual handling chemicals in the automotive industry can also expose employees ... damage to chemical

SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY1ST EDITIONOCTOBER 2006

MANUFACTURING

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 https://www.worksafe.vic.gov.au/__data/assets/pdf_file/0011/207659/ISBN-

OHS-regulations-summary-of-changes-2017-04.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 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

Why has this guide been produced? . . . . . . . . . . . . . . . . 1

Injuries and health effects – exposure to hazardousmanual handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Injuries and health effects – exposure to chemicals . . . 2

Manual handling of chemicals . . . . . . . . . . . . . . . . . . . . . 3

Consulting employees and health and safetyrepresentatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Information and training. . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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 andputting 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

Packages and containers . . . . . . . . . . . . . . . . . . . . . . 29

Examples of problems with packages and containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Identifying and fixing problems with packages andcontainers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Container and package health & safety checklist . . . . . 32

Fixing container and packaging problems . . . . . . . . . . . 34

Adding handles to bags and sacks . . . . . . . . . . . . . . . . . 34

Effective closures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Protective clothing and equipment . . . . . . . . . . . . . 36

Risks of using protective clothing and equipment. . . . . 36

Steps to follow before using protective clothing andequipment as a risk control. . . . . . . . . . . . . . . . . . . . . . . 38

Further information and guidance. . . . . . . . . . . . . . 42

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Legislation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Publications and further information available from WorkSafe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Acknowledgements. . . . . . . . . . . . . . . . . . . . . . . . . . . 44

The information presented in Safe Manual Handling of Chemicals in the AutomotiveIndustry is intended for general use only. It should not be viewed as a definitive guideto the law, and should be read in conjunction with the Occupational Health and SafetyAct 2004. Whilst every effort has been made to ensure the accuracy and completenessof this guide, the advice contained herein may not apply in every circumstance.Accordingly, the Victorian WorkCover Authority cannot be held responsible, andextends 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 AutomotiveIndustry is protected by copyright. The Victorian WorkCover Authority hereby grants a non-exclusive licence in this publication to the recipient of this publication on thecondition that it is not disseminated for profit. The Victorian WorkCover Authorityencourages the free transfer, copying and printing of the information in this publicationif such activities support the purposes and intent for which the publication wasdeveloped.

WorkSafe Victoria is a division of the Victorian WorkCover Authority.

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 1

INTRODUCTION

WHY HAS THIS GUIDE BEEN PRODUCED? Many tasks undertaken in the automotive industry involve the manual handling ofchemicals, placing employees at risk of injuries and adverse health effects due tomanual handling and/or exposure to chemicals.

This guide will help workplaces control risks and reduce injuries and adversehealth 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 ofthis guide. The work areas, jobs and tasks covered have been identified by theindustry as the primary areas that need to be addressed. Risk control solutionshave 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 chemicalsare handled.

This guide is provided in accordance with section 7(1)(f) of the OccupationalHealth 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 manualhandling of chemicals, while also referring to controlling employee exposureto chemicals and associated areas.

However, it is not intended to and should not be read as providing guidanceon the management of hazardous substances and dangerous goods and therisks 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 aremanually handled in the workplace.

For further information see page 42.

INTRODUCTION

INJURIES AND HEALTH EFFECTS – EXPOSURE TO HAZARDOUSMANUAL HANDLINGTasks such as unloading containers from pallets, transporting them to storageareas, moving 205 litre (44 gallon) drums, carrying containers to work areas,cleaning components, cleaning leaks and spills, emptying bags and sacks anddecanting 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 followingcharacteristics:• 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 employeesto chemicals that may affect employees’ health immediately or take months, oreven 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 hazardoussubstances. They may be solids, powders, liquids or gases, pure chemicals ormixtures. 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 andhow 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).

2 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

Muscle sprains and strains

Injuries to muscles, ligaments, spinal discs and other structures in the back

Injuries to soft tissues such as nerves, ligaments and tendons in the wrists, arms, shoulders, neck or legs

Abdominal hernias

Poisoning

Chemical burns and irritation of the skin, eyes, etc.

Diseases of certain organs such as the skin, lungs, liver, kidneys and nervous system

Cancer, birth defects

Ingestion

Skin absorption

Inhalation

Musculoskeletal disorders frommanual handling

Exposure to substances

Routes of exposure

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 asdangerous goods, classified on the basis of immediate physical or chemical effectssuch as fire, explosion, corrosion and poisoning, affecting property, theenvironment 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, therequirements of both pieces of legislation apply in these cases. As there may beoverlaps, each legislation complements the other, ensuring the effective control of all risks.

Requirements for managing hazardous substances and dangerous good risks arespecified in the Dangerous Goods Act, Regulations and Codes of Practice and the Hazardous Substances Regulations.

WorkSafe publications that provide information and guidance about hazardoussubstances and dangerous goods are listed on page 42.

MANUAL HANDLING OF CHEMICALS

Manual handling of chemicals can create extra risks compared to othermanual handling jobs and tasks. Employees manually handling containers of chemicals may adopt awkwardpostures 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 risksby restricting movement, limiting grip, increasing the physical effort required to dothe job and increasing heat stress.

Sometimes when completing manual handling tasks, protective clothing andequipment may be used incorrectly, increasing exposure to chemicals. Measuresto reduce or eliminate the need to use protective clothing and equipment canreduce manual handling risks.

Reducing manual handling risks associated with protective clothing and equipmentcan 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 preventingdamage 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 manualhandling risks and exposure to chemicals.


INTRODUCTION

Implementing risk controls to reduce exposure to chemicals can also reducemanual handling risks For example, using a vacuum cleaner fitted with HEPA (High Efficiency ParticulateAir) filters to clean spilt powders and dusts improves manual handling as there isless bending, less repetitive forceful movements and less physical effort requiredcompared to sweeping.

Caution needs to be taken to ensure a vacuum cleaner is not used onchemical spills unless specifically designed to do so.

CONSULTING EMPLOYEES AND HEALTH AND SAFETYREPRESENTATIVES When identifying, assessing and controlling health and safety risks posed by themanual handling of chemicals, consultation with affected employees and their HSRis essential.

Everyone has a role to play in workplace health and safety.

Healthier and safer work environments and improved productivity can be moreeasily achieved when employers and employees discuss risks and problems andwork together to find solutions.

Consultation is required under sections 35 and 36 of the Occupational Health andSafety Act 2004. It must involve the sharing of information, giving employees theopportunity to express their views, valuing their views and taking them intoaccount when making decisions.

Labour hire employees, employees of contractors and their supervisors andmanagers must be included in any workplace consultation.

INFORMATION AND TRAININGWhere necessary, training and support must be provided to employees,supervisors and managers to ensure they can effectively identify, assess andcontrol risk and meet all legal duties and responsibilities.


Before: Dry sweeping can create airborne dust in the breathing zone.

After: Use a mobile vacuum cleaner fittedwith a HEPA filter.

INTRODUCTION


HOW TO USE THIS GUIDEThe red, amber and green or ‘traffic light’ format will help identify high-risk activities and assist workplaces in implementingsafer 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 inbreach 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 ofMSD 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 beingundertaken 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 maybe effective. If this is not reasonably practicable, consider putting in place the comparable practice in the amber column asan interim solution.

Generally, the manual handling solutions in the amber and green sections provide different options as the tasks, and therisks, will vary according to the specifics at each workplace. It is important any controls implemented address the riskfactors in the task.

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 providesinterim solutions.

However, if you are able to demonstrate an appropriate risk assessment process has been undertaken and are able toverify that the ‘reasonably practicable’ test has been applied to the controls you implement, then amber (interim) controlmeasures may be reasonably practicable. The interim solutions should be reviewed as green (higher order) solutionsbecome more reasonably practicable.

For more information identifying and controlling potential risks visit www.worksafe.vic.gov.au or contact the WorkSafeAdvisory Service on 1800 136 089.

RED (HIGH RISK) AMBER SOLUTION GREEN SOLUTIONThe practices in the red column shouldnot be used in workplaces; anemployer who allows these practicesto be used is likely to be in breach ofOHS legislation.

The solutions in the amber column areless effective in reducing risk thanthose in the green column, and shouldbe regularly reviewed with the aim tomove towards higher order solutions(green).

The solutions in the green column arethe most effective at reducing risk andshould be regarded as the target for allworkplaces.

Implement a solution from the green, low risk solution, 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)

Red, high risk, column

Implement solutions from the amber, reduced-risk, column

NO

YES


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

1. MANUAL HANDLING CHEMICALS DURING DELIVERY, UNLOADING AND STORAGE

The delivery, unloading and storage of chemicals can potentially exposeemployees to chemicals and a range of manual handling risks.

Low risk control solution: bulk delivery, unloading and storage of chemicalsWhen large amounts of chemicals are used, the low risk control solution isbulk supply, storage and handling of chemicals whenever reasonablypracticable. This eliminates or reduces manual handling and employees being exposed to hazardous substances during handling. Bulk refers to supply in largequantities and in containers such as pallet bags or palcons that must behandled mechanically. It does not mean bulk as defined in the DangerousGoods (Storage and Handling) Regulations 2000.Any proposed changeover to bulk supply and handling of chemicals must beassessed in consideration of the Dangerous Goods Act, Regulations andCode of Practice and the Hazardous Substances Regulations.

Examples of bulk delivery, unloading and storage at an automotivemanufacturing site Most major ingredients are supplied in pallet bulk bags that are unloaded into thestorage area and then moved to the inside of the plant by forklift. Otheringredients may be delivered by truck and pumped directly into silos before beingpumped into the plant.In both of these cases, hazardous manual handling has been eliminated, whileproductivity and financial gains have also been achieved. Suppliers will often meetsome of the costs associated with implementing the new infrastructure requiredfor bulk handling.


Bulk bags or boxes holding up to 1000kg or more of material.

Bulk silo storage.

Liquid chemicals can be supplied in bulkstackable containers.


UNLOADING CONTAINERS AND BAGS FROM PALLETS AND PUTTING THEM INTO STORAGE


HIGH RISK REDUCED-RISK SOLUTION LOW RISK

ACTION POTENTIAL SOURCEOF RISK

– Ensure there is enough space in unloading and storage areas,which allows pallets to beunloaded as near as possible tostorage areas and reduces thedistances containers must becarried. It also allows the use of mechanical handling aids.

– Increase space in unloading andstorage areas to allow forkliftaccess.

– Provide sufficient pallet rackingthat follows the 2005 WorkSafePallet Racking Guidance Note.Unload pallets with a forklift andstore on pallet racking.

– Bulk supply and storage.

– Increase available unloading andstorage space by reducing therange of chemicals used andhaving a just-in-time system forordering and stocking to avoidoverstocking. Refer to WorkSafeVictoria’s Guidance NoteProduction Flow Fluctuations –Managing Risks to Health andSafety.

– Storage areas should be wellmaintained and regularlyinspected, providing enoughroom as well as easy forklift andpallet jack access.

Sufficient, easy access pallet rackingused to store materials.

Exerting force while inan awkward posture.

Lifting, lowering andexerting force while inan awkward posture.

Bending the backmore than 20 degreesor twisting. Carrying aload:• more than twice

a minute; • more than 30

seconds at a time;or

• with long duration(more than 30minutes at a time or more than 2 hours over a shift).

High forceLifting, carrying andlowering heavy loads.

Unloading heavycontainers andpackages from palletsby hand, then carryingand putting them intostorage areas.

Repetitive bending belowthe knees and use of highforce to de-palletise bagsof material.

Crowded andcongested unloadingand storage areas.

Crowded storage area.Lifting and lowering aboveshoulder height.






– Use height adjustable palletlifters to lower, raise and rotatepallets.

– Provide a pallet stand.

– Use mechanical aids such asheight adjustable trolleys to move containers from unloadingto storage areas.

– Use vacuum lifters to movecontainers off pallets and ontostorage racks and shelves.

Vacuum lifters can be used for all typesof packages.




a minute; • more than 30


• with long duration(more than 30minutes at a time or more than 2 hours over a shift).


Pallet is located on the ground.






– Order chemicals in smallercontainers and bags. Cautionshould be taken to ensurerepetitive manual handling ofsmaller containers or bags isassessed.

– Increase size of container (e.g.palcons) so materials must behandled mechanically.

Bulk supply eliminates the need tophysically handle chemicals.


Weight of containersor bags.




a minute;• more than

30 seconds at atime; or

• with long duration(more than 30minutes at a timeor more than 2hours over a shift).


Unloading 20 litre tinsfrom pallets on theground, carrying themto storage areas andstacking them onshelves.

– Provide a height adjustabletrolley that can be set at thesame height as the bottom ofthe tins.

Tins are loaded onto the trolleyand moved to storage racks.

Storage racks are fitted withrollers and tins are slid from the trolley onto the racks thenpushed to back of racks andretrieved with push sticks/picksticks.

Paint tins are mechanically loaded intocustom made racks fitted with rollers.

– Supply in bulk containers sopaint must be handledmechanically.






– Use stretch-wrap and banding to stabilise the loads on palletsduring transport.


High force• Exerting force from

an awkwardposture.

• Applying suddenforces.

• Applying uneven,fast or jerky forcesduring pushing andpulling.

• Pushing or pullinghard to moveobjects.

Containers ‘stuck’together duringtransport to stabilisethe pallet load.

Containers are difficultto separate from eachother.

Lifting, lowering andexerting force whilein an awkwardposture.

Bending the backmore than 20 degreesor twisting.

Working with one orboth hands aboveshoulder height: • more than twice a

minute;• more than 30



High forceLifting heavy loads inan awkward posture.Exerting force whilein an awkwardposture.

Crowded andcongested unloadingand storage areas maycause pallets to bestacked on top of eachother.

Operator forced tomanually unload palletsabove shoulder heightusing high force.

– Provide a stable platform/steps to raise employee and eliminatereaching above shoulder height.

– Provide a stable raised surface(e.g. scissor lift) at the sameheight as containers on the toplayer and move containers ontothis surface.

– Ensure there is enough room inunloading areas so pallets arenot stacked unnecessarily.

– Implement work systems sothat pallets are not stackedduring the unpacking process.







– Arrange with supplier to reduceheight of pallets.

– Provide a stable platform/stepsto raise employee and eliminatereaching above shoulder height.

– Provide a stable raised surface(e.g. scissor lift) at the sameheight as containers on the toplayer and move containers ontothis surface.




Working with one orboth hands aboveshoulder height: • more than twice

a minute;• more than 30



High forceLifting heavy loads inan awkward posture. Exerting force while inan awkward posture.

Pallet is stacked aboveshoulder height.

This pallet is over stackedand well above shoulderheight.

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 chemicalsstored 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 alsoreduces employees’ exposure to hazardous chemicals, reducing clean ups and waste disposal.


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 andmusculoskeletal 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 tochemicals Employees may be exposed to hazardous chemicals when imported shippingcontainers 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: FumigatedShipping Containers: Safe Transport and Unloading, 2005.


Safely loading and unloading shippingcontainers can be challenging.


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 arisk of MSD occurring.

For information and guidance on safe manual handling of gas bottles see theWorkSafe publication Delivering Large Gas Cylinders 2002.

Dangerous goods and hazardous substances Gas cylinders contain dangerous goods and hazardous substances and are subjectto regulatory control.

Cylinders should be stored in an area that allows air movement to prevent anybuild 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.


Gas cylinders are not designed to bemanually handled safely.

2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE


MOVING CHEMICALS AND STORING IN WORK AREAS



– Use a mechanical aid such as adrum mover or overhead crane.

– Bulk distribution system.

Example: In an engine castingplant two-part resins are deliveredin bulk (pallet containers),unloaded by forklift and directlyconnected by hose to the castingprocess.

– Materials are supplied in palletbulk bags and the contents are fed directly into the processautomatically.

– Use a forklift with a drummoving attachment.

Forklift drum attachments eliminate the need to physically handle 205 litrecontainers of substances on and off pallets.

High force• Pushing and pulling

objects that arehard to move orstop.

• Lifting or loweringheavy loads.

• Exerting high forcewhile in anawkward posture.

Requirement tomanually move 205litre (44 gallon) drums.

Manually moving 205 litrecontainers from pallets ishazardous.






– Use mechanical aids such astrolleys to move containers.

– Change container, e.g. transferchemicals from bulk storagecontainers (hoppers, palletcontainers) to wheelie binswhich are then wheeled to workareas.

Wheelie bins provide a means tomanually move materials from oneprocess to another. Care must be takento ensure bin weights are kept low.

– Reduce weight of container.

– Change design to allow easierhandling.

– Change to a bulk distributionsystem.

– Use vacuum lifters to movecontainers.

– Use motorised stock chasers tomove containers.

Carrying a load.


Lifting or lowering andrepetitive grasping:• more than twice a

minute; • more than 30



High forceLifting, lowering andcarrying heavy loads.Lifting heavy loads inan awkward posture.Exerting high forcewhile in an awkwardposture.

Manually carryingchemical containers towork areas.

Size, shape andweight of container.






– Alter the layout of the work areato allow easy access to storage.

– Store heavier items betweenknee and shoulder height.Provide sufficient shelving,racking and cradles that fitcontainers in use. SeeWorkSafe’s A Guide to ManualOrder Picking 2004 for furtherinformation.


Carrying a load.


Lifting or lowering andrepetitive grasping:• more than twice a

minute; • more than 30



High forceLifting, lowering andcarrying heavy loads.Lifting heavy loads inan awkward posture.Exerting high forcewhile in an awkwardposture

Crowded andcongested work areasand poor local storagefacilities increase theamount (e.g. doublehandling) and difficultyof manual handling,and prevent trolleyaccess and otherhandling aids.

Containers stored onthe ground, stackedbehind othercontainers or on top of each other.

Manual handling gasbottles in congested workareas is hazardous.

Messy and congestedstorage areas arehazardous.

Manually lifting heavyloads, especially aboveshoulder height, isextremely hazardous.

Moving chemicals and storing in work areas – exposure to chemicalsPoor 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.



EMPTYING, DECANTING, MEASURING AND MIXING CHEMICALS



– Build chutes with benches atwaist height that feed into ahopper.

– Change the bag or container andwork process.

– Supply chemicals in bulkhoppers or palcons and transferto wheelie bins that are thenwheeled to the take up area andconnected to suction hoses tosuck up contents and feed theminto the process.

– Make the bags smaller.

– Change the design of thecontainer to allow easierhandling.


– Supply contents in bulk andtransfer directly into process.

– A purpose designed sack tippingstation with a vacuum lifterminimises handling andexposure to dust by suckingpowder away.

Bending the backforward more than 20degrees or twisting.

Lifting, lowering andcarrying a heavy loadwith repetitivegrasping.

Excessive bending ofthe wrist:• more than twice




High forceLifting, lowering andcarrying heavy loads.Lifting heavy loads inan awkward posture.Exerting force while inan awkward posture.

Emptying heavy bagsand sacks.

Chemical bags arehand-lifted from apallet on the groundand the bag is heldwell above or belowwaist height, slit openand emptied into ahopper, chute orsimilar.

No shelf or bench atwaste height on whichto rest bag whilebeing opened andemptied.

Weight, size andshape of bag.






– Use handling aids such as anoverhead crane, forklift withdrum attachment or drumhandler.

– Use a bulk decanting facilitywith closed systems andintegrated automatic feed andpumping systems for supply and mixing.

Bending the backforward more than 20degrees or twisting.

Lifting, lowering andcarrying a heavy loadwith repetitivegrasping.

Excessive bending ofthe wrist:• more than twice




High forceLifting, lowering andcarrying heavy loads.Lifting heavy loads inan awkward posture.Exerting force while inan awkward posture.

Lifting containers frombelow knee height.






– Provide racks, shelves, holdersor cradles that hold containers.

– Purpose built stand fordecanting with supporting standfor the container. Ensure thecontainer receiving the liquid isclose enough to preventsplashing.

– Fit pumps, taps, bungs, siphonsor spigots onto main container.

– Supply pre-mixed or pre-dilutedchemicals in pre-measuredamounts to eliminate mixing anddecanting. It may be necessaryto change the batch size toenable this.

Gripping and workingwith the fingers closetogether and/or wideapart.

Twisting or turningactions with the handsor arms.

Exerting force withone hand or one sideof the body.

Awkward wristpostures whenholding or supporting.

Twisting, turning,grabbing, picking orwringing actions withthe fingers, hands orarms:• more than twice a




Holding and tippingcontainers to decant,dispense or mixliquids.

The photos abovedemonstrate examples of hazardous manualdecanting of chemicals.






– Install a fixed dosing pump thatmoves the liquid from thecontainer to the process –eliminating lifting, holding andtipping.

– Wheels on cradles enable themto be moved around and helpease crowding and congestionof the work area.

– Drums fitted with pumps makedispensing easier and dollieshelp ease crowding andcongestion of the work area.

– Change the layout of the workarea to make more spaceavailable and improve access to dispensers, etc.

– Reduce local storage spaceneeded for chemicals by using a just-in-time delivery program.

– Use ‘process rooms’ or ’mixrooms’ and then pump thesubstance to the process area.









Decanting or mixing incramped andcongested work areasmakes the task moredifficult.






– Use smaller containers.

– Reduce the container’s weight.

– Change container design toimprove grip.

– Increase the size of thecontainer so it must be handledwith a mechanical aid.


Twisting or turningactions with thehands or arms.







Size, shape andweight of containers.

Large container sizerequires higher forceduring decanting.






– Use a purpose designedopening tool.

– Increase the size of thecontainer so it must be handledwith a mechanical aid. Thecontainer is then connected tothe process once, to avoid theneed to continually open andclose the containers.

High force

Applying high forcewith the hands andarms, hitting, exertingforce with the non-preferred hand,applying uneven, fast or jerky forces.

Buckets and drumsthat are difficult toopen.

Hands, screwdrivers,claw hammers, etc.used to open buckets.

Emptying, decanting, measuring and mixing chemicals – exposure to chemicalsEmployees may be exposed to hazardous chemicals when emptying, decanting, measuring and mixing. Some of thesolutions identified above may also reduce exposure to chemicals.

Risk controls to reduce exposure to chemicals may also improve manual handling.




205 litre drums are moved inside the paint kitchen using the overhead tracked crane.

DECANTING EXAMPLE – AUTOMOTIVE PAINT KITCHEN Potential source of risk: Lifting containers off the floor and then holding and tipping them to decant, dispenseor 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 theline 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, weresupplied 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.

BenefitsHazardous manual handling of 20 litre drums of high use coatings has been completely eliminated. There have alsobeen productivity and financial gains due to changes in buying in bulk, delivery, storage, transport within the plant anddisposal.

3. CLEANING COMPONENTS AND PARTS


Components and parts are often cleaned by hand, requiring repetitive manual handling tasks, awkward postures and highforce, especially to the hands and arms.



– Change the set up of work areato bring components closer tothe body and raise them towaist height.

– Change upstream process tominimise cleaning.

– Some cleaning, e.g. degreasing,may be unnecessary and thetask can be eliminated.

– Change the cleaning process byusing an ultrasonic bath to cleancomponents in batches. Thisbath uses water and vibration to clean. Use mechanicalhandling aids to handle cratedbatches of components in andout of the bath.

Ultrasonic cleaning baths eliminatehazardous manual handling andchemical exposure associated with part degreasing or cleaning.



Exerting force withone hand.

Awkward wristpostures.

Holding or supportingcomponents andparts.

Twisting, turning,grabbing, picking orwringing actions withthe fingers, hands orarms.


Reaching more than30cm from the body:• more than twice a




High forceApplying high forcewith the hands andarms, exerting forcewith the non-preferredhand, applyinguneven, fast or jerkyforces.

Cleaning componentsby hand.

Manual workstations fordegreasing or cleaningparts can be hazardous.

Cleaning components and parts – exposure to chemicalsManual cleaning of components and parts can expose employees to chemicals. The low risk solution listed above may helpreduce or eliminate this exposure.

4. DIPPING COMPONENTS


Components and parts are often dipped by hand involving lengthy and repetitive manual handling tasks and awkwardpostures and the application of high force, especially by the hands and arms.



– Change set up of workstation tobring components closer to thebody and raise them to waistheight.

– Use a chain conveyor or similar.

– Automate the task using robots or similar.



Awkward wristpostures.

Holding or supportingdipping components.

Twisting, turning,grabbing or pickingactions with thefingers and hands.


Reaching more than30cm from the body:• more than twice a

minute; or, • more than 30

seconds at a time;or,


High forceApplying high forcewith the hands andarms, exerting forcewith the non-preferredhand, applyinguneven, fast or jerkyforces.

Manually dippingcomponents.

The shape, size and weight ofcomponents.

Dipping components – exposure to chemicals Manual dipping of components and parts can expose employees to chemicals. The low risk solution listed above may helpreduce or eliminate this exposure.

5. DISPOSING OF WASTE CHEMICALS




– Reduce the weight of the drum by replacing it before it fills upwith waste.

– Use a closed system, withintegrated automatic feed andpumping that automaticallycollects liquid waste andtransfers it to collection orrecycling stations.

High force• Pushing and pulling

objects that arehard to move orstop.

• Lifting or loweringheavy loads.

Manually moving 205 litre (44 gallon)drums of wasteliquids.

Weight, size andposition of drum.

Manual handling 205 litredrums on and off pallets is hazardous.

WASTE DISPOSAL EXAMPLEWaste solvent from a spray painting line is automatically pumped along a line to a sealed and labelled drum on apallet in a cabinet.

At regular intervals the drum is disconnected, sealed and removed from the cabinet, and a forklift is used to replacethe 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.

5. DISPOSING OF WASTE CHEMICALS


WASTE RECYCLING EXAMPLEWaste 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 andreused. 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 eventof 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.



– Extend the chute into a closedwheelie bin and change the binbefore it fills. Wheel the bin todisposal point.

AfterFlexible connector to bin

– Extend the chute into a closeddrum and move the drum usingmechanical aids.

High force

Pulling hard to moveobjects.


Untying heavy bags ofwaste dust, powder,granules, etc.collected from a chuteand dragging them toa disposal point.

The weight, size andshape of the bag.

Before

Nylon bag

Disposing of waste chemicals – exposure to chemicalsManual handling during disposal can expose employees to chemicals. The low risk solutions above may help to reduce oreliminate this exposure.


PACKAGES ANDCONTAINERS

These tins have poor handholds makingthem difficult to handle and cause poorposture.

Pallets stretch-wrapped too tightly candamage containers resulting in spills andleaks.

These bags of sand used for spill clean upsare difficult to handle because of theirweight and lack of handholds.

Bottles, bags, sacks, tubs, cylinders, boxes, cans, drums, trays and buckets are allconsidered packages and containers.

This section applies to those packages and containers supplied to and used in theworkplace.

Problems with packages and containers may contribute to manual handling risksand increase the exposure of employees to chemicals.

The size, shape, weight and other features of packages and containers may be asource of manual handling risk.

Identifying a feature as a source of risk will depend on the particular circumstancesin which the package or container is handled and needs to be determined usingthe hazard identification and risk assessment processes described in the WorkSafeManual Handling Code of Practice, No. 25, 2000.

Other features of packages and containers can expose employees to chemicalsduring handling, depending on the way it is handled and used. Refer to theDangerous Goods Act, Regulations and Code of Practice and the HazardousSubstances Regulations.

EXAMPLES OF PROBLEMS WITH PACKAGES AND CONTAINERS

PACKAGES AND CONTAINERS


Containers that can’t be resealed properlyare more likely to cause leaks and spills.

The size, shape and weight of the containerand the handholds can cause hazardousmanual handling.

The contents of bags and sacks can move,unbalancing them and making them difficultto hold.

These containers have poor handholds requiring a grip that is toonarrow or too wide.

Using the wrong containers to collect liquid wastes can exposeemployees to fumes and cause spills.

Damaged containers are more likely tocause leaks and spills and can be difficultor impossible to handle with mechanicalaids.

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.

EXAMPLES OF PROBLEMS WITH 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 inthis process is the Container and Package Health & Safety Checklist over the page.

Information from injury, damage, accident and incident records

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.

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

Use the Container and Package Health & Safety Checklist, which can be completed in consultation with employees, etc.

Change packages and containers

Change tenders and supply specifications

The Container and Package Health & Safety Checklist can be used to specify what changes are required to control hazards

Discuss and consult with manufacturers, suppliers and transporters

Chemical manufacturers and suppliers meet their legislative duties

Step 1 Identify problems Step 2 Fix problems



FEATURE YES NO N/A

CONTAINER AND PACKAGE HEALTH & SAFETY CHECKLISTThis checklist can be used to assess containers and packages currently used or planned on being used. It is not for bulkcontainers. For each feature a tick in a red box may indicate a problem.

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?



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 andingredients?

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 usedduring 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 theHazardous 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?


ADDING HANDLES TO BAGS AND SACKSAdding handles to bags improves grip and ease of handling, decreasing the risk of injury.


Chemicals supplied in convenient pre-measured sealed bags.

FIXING CONTAINER AND PACKAGING PROBLEMS

Example: Working with employees, HSRs and suppliers to changepackaging to reduce hazardous manual handling and exposure tochemicals 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 dustand wear protective clothing and equipment. The task is done in a hot andhazardous area.

SolutionIn consultation with the HSR and the supplier, the substance was re-suppliedin pre-measured sealed bags that are added directly to the processunopened. The tasks of opening the bag, scooping and measuring wereeliminated along with exposure to the powder.



EFFECTIVE CLOSURESThe closures on these containers are reusable, easy to use and provide an effective seal.

The use of protective clothing and equipment is a common risk control foremployees exposed to chemicals. However, it is not a good idea to rely onprotective clothing and equipment to control risk as it may not properly protect allemployees from risks and can create new risks.

Controls other than the use of protective clothing and equipment should be usedto manage risks arising from the use of chemicals, so far as reasonably practicable.

Personal protective clothing and equipment should be used when recommendedin a Material Safety Data Sheet (MSDS) and when other controls do notadequately control exposure.

RISKS OF USING PROTECTIVE CLOTHING AND EQUIPMENTPersonal 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.


PROTECTIVE CLOTHINGAND EQUIPMENT

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 properlyused, e.g. gloves can prevent getting a good grip on tools, components andmaterials – this puts more physical stress on the hands, arms and shoulders;

• using non-powered respirators that can make breathing harder, worsened if thefilters need changing, making the job harder to do; and

• restricting movement and mobility if air-lines and air-hoses are used with airsupplied respirators, as this can make the job harder to do and creates trippingrisks.


Wearing personal protective clothing andequipment can increase heat stress, makethe job harder to do, affect grip and restrictpostures and movements.


STEPS TO FOLLOW BEFORE USING PROTECTIVE CLOTHING ANDEQUIPMENT AS A RISK CONTROL

Step 1A risk assessment, as required by the Hazardous Substances Regulations, shouldbe completed prior to using protective clothing and equipment. Consultation withemployees exposed to the chemicals and their HSRs is required.

Step 2If the risk assessment shows risk controls are needed, the following must beconsidered 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 thenprotective clothing and equipment may be suitable as a temporary risk control.


Can you eliminate the hazard/risk?

GO TO STEP 3

Can the hazard/risk be replaced with something less hazardous?

Does this control the hazard?

NO

Can you isolate the hazard/risk from people?

NO

NO

YES YES

Does this control the hazard?NO

NO

YES YES

Can engineering controls be used to control the hazard/risk?


NO

YES YES

Can administrative changes control the hazard/risk?


NO

YES YES

YES

Protective

clothing and

equipment

not required



YES NO

Are employees potentially exposed to chemicals and have they and their HSRs been consulted aboutthe use of protective clothing and equipment?

Is there protective clothing and equipment that will effectively protect employees from thechemicals?

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 heatstress?

Step 3This 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.

Step 4Take action to address any problems identified in Step 3, indicated by ticks in any of the red boxes.



Step 5Implement an effective personal protective clothing and equipment program.

When protective clothing and equipment are used as a temporary risk control, a protective clothing and equipmentprogram should be in place and reviewed regularly.

This checklist contains the essential requirements of an effective program and can be used to evaluate an existingprogram. 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 equipmentare 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 equipmentprovided?

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 asrequired 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 andemployees are being properly protected?


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 reasonablypracticable and steps 1-5 have been completed.

If protective clothing and equipment is being used for extended periods in aworkplace, then alternative risk controls may not have been properly considered.

It is the employer’s responsibility to provide protective clothing and equipment foremployees, including labour hire employees.

Step 7A 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 andequipment; 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.


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 orphone Information Victoria on 1300 366 356.


FURTHER INFORMATIONAND GUIDANCE

FURTHER INFORMATION AND GUIDANCE

PUBLICATIONS AND FURTHER INFORMATION AVAILABLE FROMWORKSAFE

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


This publication is part of the Safe Handling of Chemicals in the AutomotiveIndustry Project (SHOCAi). It has been funded by WorkSafe Victoria’s SafetyDevelopment Fund.

The project’s steering group is the Motor Vehicle and Parts Manufacturing Healthand Safety Forum.

The following organisations are represented on the forum and WorkSafe wouldlike 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 andParts Industry Solutions Workshop in October 2005, those who provided images for this publication, and Ross Armstrong of Global Ergonomics Pty Ltd.


ACKNOWLEDGEMENTS

WORKSAFE VICTORIA

Advisory Service222 Exhibition StreetMelbourne VIC 3000

Phone . . . . . . . . . . . . . . 03 9641 1444Toll-free . . . . . . . . . . . . . 1800 136 089Email . . . . . [email protected]

Head Office222 Exhibition StreetMelbourne VIC 3000

Phone . . . . . . . . . . . . . . 03 9641 1555Toll-free . . . . . . . . . . . . . 1800 136 089Website . . . www.worksafe.vic.gov.au

Local OfficesBallarat . . . . . . . . . . . . . 03 5338 4444Bendigo. . . . . . . . . . . . . 03 5443 8866Dandenong . . . . . . . . . . 03 8792 9000Geelong. . . . . . . . . . . . . 03 5226 1200Melbourne(628 Bourke Street). . . . 03 9941 0558Mildura . . . . . . . . . . . . . 03 5021 4001Mulgrave . . . . . . . . . . . . 03 9565 9444Preston . . . . . . . . . . . . . 03 9485 4555Shepparton . . . . . . . . . . 03 5831 8260Traralgon . . . . . . . . . . . . 03 5174 8900Wangaratta . . . . . . . . . . 03 5721 8588Warrnambool . . . . . . . . 03 5564 3200

VWA1063/02/05.13

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