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 andtime weighted average occupational exposure levels (OEL)Condition Level (ppm)

Odour threshold 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 ventilationwith 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 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

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 mmHgFlash Point: 129.7 °CHazard Symbols: O; CRisk Codes: 20/22-34-7Safety: 26-36/37/39-45-3/7-14 Transport Information: UN 3105 5.2

per

oxid

e

>

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, neverdirectly 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 microstructureand may fibrillate into particles of <3 μm

(respirable?)

all reinforcements should be regarded asa 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 ....solventsrelease agentsetcetera

read the Material Safety Data Sheet (MSDS)then compile a risk assessmentspecific 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 arecuts 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 materialsto soak up spillage

and if in doubt ...

ask !!

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 riskRF cannot be 5, 7 or 8

http://www.tech.plym.ac.uk/sme/mats324/risk.htm

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