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Health and Safety & Risk Assessment for users of Brunel 007 (W7) - Composites Manufacturing Laboratory

Health and Safety & Risk Assessment for users of Brunel 007 (W7) - Composites Manufacturing Laboratory. Staff associated with composite modules in W7. academic Stephen Grove John Summerscales technicians Richard Cullen, Greg Nash, Richard Kenyon researchers

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Health and Safety & Risk Assessment for users of Brunel 007 (W7) - Composites Manufacturing Laboratory

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  1. Health and Safety& Risk Assessment for users of Brunel 007 (W7) - Composites Manufacturing Laboratory

  2. Staff associated with composite modules in W7 • academic • Stephen Grove • John Summerscales • technicians • Richard Cullen, Greg Nash, Richard Kenyon • researchers • post-doc and research degree candidates

  3. Principal material groups • Resins • unsaturated polyester (UPE) • epoxide/epoxy (Ep) • phenolic • Thermoplastics • polypropylene (PP) • nylon (PA: polyamide) • polyester (PET: polyethylene terephthalate) • poly ether ether ketone (PEEK) • Fibres • aramid (Kevlar, Twaron) • carbon • glass (usually E-glass) • Solvents, release agents, etc

  4. Health and Safety • Control of Substances Hazardous to Health (COSHH) • can you substitute a safer material • can you use an engineering solution • are you using appropriate personal protection • Environmental Protection Act • you must dispose of materials in the correct manner • A clean and tidy workplace is a safer workplace • if you are not using it put it away • if you must leave anything out, make sure it is clearly labelled

  5. Health and Safety: Unsaturated PolyEster resin (UPE) • base resin: polymer chains with reactive sites (50%) • styrene: reactive diluent (50%) • volatile • flammable: • flash point 31 degrees Centigrade, explosive limits 1.1-8.0% • NO SMOKING, no naked flames • toxic: • (inhalation) ODOUR threshold 25 ppm (Scandinavian Occupational Exposure Limit) • little inhalation irritation <210 ppm (UK OEL is 100 ppm 8h TWA) • irritating to nose and throat above 500 ppm • NIOSH IDLH (Immediately Dangerous to Life or Health) at 700 ppm • (ingestion) IRRITATING to mouth, throat and stomach • may lead to vomiting and dizziness • harmful effects at >4 g/kg of body weight • (skin contact) IRRITATING: evident as itching and redness • frequent or prolonged contact leads to dermatitis • degreases skin • (eye contact) IRRITATION may last several hours

  6. Styrene odour andtime weighted average occupational exposure levels (OEL) ** see for Lecture C4 webpage for sources **

  7. Health and Safety: Unsaturated PolyEster resin (UPE) • COSHH • substitution: resin without styrene (eg epoxy) or low styrene emission resin • Engineering controls • general ventilation to reduce background level • local exhaust ventilation with flow away from operator • use shielded rollers to reduce droplet cloud • protection:lab coat, barrier cream, gloves, goggles • Disposal to waste solvent bottle if resin uncured

  8. Health and Safety: Unsaturated PolyEster resin (UPE) • Peroxide Initiator (usually added as 1-2%) • acetyl acetone peroxide (AAP), benzoyl peroxide (BzO2),hydrogen peroxide (H2O2), methyl ethyl ketone peroxide (MEKP) • SEVERE IRRITANTS to skin • CAUSE BURNS: wash immediately for 15 minutes with waterand obtain doctors attention • CORROSIVE to moist tissue (eyes, nose, throat, airways to lungs) • Irreversible damage may be caused to eyes by prolonged contact • avoid contact between MEKP and rust • BzO2: EXTREME RISK OF EXPLOSION by shock, friction, fire or ignition • COSHH • substitution: different resin system? • engineering controls: use as a dilute solution if practicable • protection: protective clothing, face/eye protection • Handle and open container with care • Ignition: contact with combustible material may cause fire • do not mop up with e.g. paper cloths • Disposal do not empty into drains

  9. acetyl acetone peroxide (AAP) • 2,4-pentanedione peroxide solution • CAS 37187-22-7 a.k.a. Luperox 224 • Formula: C10H14O6 • Density: 1.177 g/cm3 • Melting Point: ≥60 °C (SADT) • Boiling Point: 301.9 °C at 760 mmHg • Flash Point: 129.7 °C • Hazard Symbols: O; C • Risk Codes: 20/22-34-7 • Safety: 26-36/37/39-45-3/7-14 • Transport Information: UN 3105 5.2 peroxide >

  10. Health and Safety: unsaturated polyester resin • accelerators (1-2%) • cobalt-based solutions in styrene (cobalt naphthenate or cobalt-octoate) • amine-based 25% solution in styrene • toxic if swallowed, inhaled or allowed to remain in contact with the skin • fumes from burning accelerators contain toxic materials

  11. Health and Safety: Unsaturated PolyEster resin (UPE) never, never, nevermix catalyst (initiator)directly with accelerator: they will form an explosive mixture

  12. Health & Safety: Epoxy resin (Ep) • Base resin • mild to moderate primary skin irritants • irritation potential increased by prolonged skin contact • EPOXY SENSITIZATION: • skin reddens in close proximity to uncured resin • For all curing agents • wear protective clothing and goggles • ventilation is essential

  13. Health & Safety: epoxy resin curing agents • aliphatic amines • alkaline caustic materials • cause burns and severe tissue damage to skin, mucous membranes and eyes • ALL contact should be avoided • solid aromatic amines • less caustic, less irritating and less sensitising than aliphatic amines • diaminodiphenylmethane (DAPM) is toxic/known to cause liver damage in humans • DAPM can be absorbed through the skin so all contact should be avoided • cycloaliphatic amines • variable in their irritation and sensitising effect • extremely irritating to the eyes • polyamides • skin irritants of varying sensitivity, but generally non-sensitising to the skin • extremely irritating to the eyes

  14. Health & Safety: thermoplastics • generally chemically inert • need to be processed at high temp. • beware of molten polymer (hot!)

  15. Health & Safety: Reinforcement Fibres • respirable dust is believed to have a particle size of <3 μm • for safety, 5 μm is assumed • reinforcement fibre diameters are in the range 6-15 μm • carbon and glass fibres are not expected to break into lengths shorter than the diameter • aramid (and polyethylene) fibres have a complex microstructure and may fibrillate into particles of <3 μm (respirable?) • all reinforcements should be regarded as a nuisance dust when cutting/machining • control limits are 10 mg/m3 total dust • 5 mg/m3 forman-made mineral fibre • disposal • all man-made fibres are a notifiable wasteand must be disposed of into the bagged bins provided

  16. Health & Safety: ancillary materials • you are also likely to use .... • solvents • release agents • etcetera • the Material Safety Data Sheet (MSDS)is there to be read, then you compilea risk assessment specific to the taskbefore you start work

  17. Health & Safety: sharps • you will be working with potentially dangerous chemicals • they need not be harmful if they are treated with respect • the most common entries in the Accident Book are cuts from knives or from sharp edges on demoulding

  18. First Aid at Work plus ... • The nominated First Aiders for Brunel are: • Steve Edmonds, 2.32536 Brunel W15 • Tony Tapp, 2.32539 Brunel W14 • heavy structures laboratory near Brunel south door • Cumberland Centre Minor Accident Unit  567999 • Royal Eye Infirmary (Derriford)  0845 155 8094 • In an emergency, call Security first on 33333,(Security can than expedite the services once on site)then ring for external services using 9.999

  19. Health & safety: summary • Remember to: • read and follow suppliers safety sheet and instructions for use • store and handle materials in the appropriate safe way • consider alternative materials and engineering controls • use ventilation and fume/dust control equipment properly • wear appropriate personal protection • good housekeeping is essential foryour safety and that of your colleagues

  20. Health & safety: summary • do not: • eat, drink (or smoke), in the laboratory or storage areas • mix peroxide initiator with accelerator • allow waste to accumulate • use solvents for cleaning skin • use combustible materials to soak up spillage

  21. and if in doubt ... ask !!

  22. Risk assessment • really, this is simple: • probability * severity = risk factor (RF) • if RF is high, then how can it be reduced? • http://www.tech.plym.ac.uk/sme/mats324/risk.htm

  23. Risk assessment • probability order 1 = unlikely 1:100 2 = possible 1:10000 3 = probable 1:100000 • http://www.tech.plym.ac.uk/sme/mats324/risk.htm

  24. Risk assessment • severity example 1 = minor pierced skin 2 = serious broken limb 3 = critical life-changing • http://www.tech.plym.ac.uk/sme/mats324/risk.htm

  25. Risk assessment • remember, risk factor is calculated • risk factor (RF) = probability * severity 1-3 = low risk 4 = medium risk 6 or 9 = high risk • RF cannot be 5, 7 or 8 • http://www.tech.plym.ac.uk/sme/mats324/risk.htm

  26. Some people do stupid things … • The winners of the competition: safety at work • Russian mechanics study airbag deployment • Construction workers • The Galway Car Recovery incident • DeWalt power tools • Petrol tanker in Paraguay and mobile-phone-as-a-light

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