Transcript Health and Safety for users of Brunel 007

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, Bob Mann, Richard Kenyon
 researchers
 Omar Sheikh (RampCo research assistant)
 and research degree candidates
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
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
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
Styrene odour and
time weighted average
occupational exposure levels (OEL)
Condition
Odour threshold
Level (ppm)
0.08 - 0.32
OEL for new build facilities in Sweden
10
Styrene Producers Association recommendation
20
Current UK voluntary code/legal OEL
50/100
NIOSH (National Institute for Occupational Safety and Health)
IDLH (Immediately Dangerous to Life or Health) level
700
Geometric mean for 15 minutes for glue wipe workers with
air purifying respirators inside a wind turbine blade
970
Explosive limits (1.1-8.0%)
11000-80000
** see for Lecture C4 webpage for sources **
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
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 water
and 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
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
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
Health and Safety:
Unsaturated PolyEster resin (UPE)
never, never, never
directly mix
catalyst (initiator)
with accelerator:
they will form an
explosive mixture
Health & Safety:
Epoxy resin (Ep)
 Base resin
 mild to moderate primary skin irritants
 irritation potential increased by prolonged skin contact
 epoxy sensitisation
 skin reddens in close proximity to uncured resin
 end of career in high-performance composites
 For all curing agents
 wear protective clothing and goggles
 ventilation is essential
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
Health & Safety: thermoplastics
 generally chemically inert
 need to be processed at high temp.
 beware of molten polymer (hot!)
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 for man-made mineral fibre
 disposal
 all man-made fibres are a notifiable waste
and must be disposed of into the bagged bins provided
Health & Safety:
ancillary materials
you are also likely to use ....
 solvents
 release agents
 etcetera
 read the
Material Safety Data Sheet (MSDS)
then compile a risk assessment
specific to the task before you start work
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
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
Health & safety: summary

remember to:
 read and follow the 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 for
your safety and that of your colleagues
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
and if in doubt ...
ask !!
Please …
… in the interests of everyone’s safety,
e-mail me (in confidence)
if you have issues which might
compromise laboratory activity, e.g.
 a.., b..,
 chemical allergies
 diabetes
 epilepsy
 f.., g.. …..y.., z.. !
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
Risk assessment

probability
order
1 = unlikely
1:1000000
2 = possible
1:10000
3 = probable
1:100
 http://www.tech.plym.ac.uk/sme/mats324/risk.htm
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
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
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-phoneas-a-light