Metal Industry Guidelines for Safe Work 1

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2 introduction Metal manufacturing can be a hazardous business. From the use of machinery, working at heights and handling heavy materials to exposure to dust, noise and chemicals, potentially harmful events can happen at any time. These events can affect a person s health, for example cause them to suffer hearing loss or respiratory disease. They can cause injury such as loss of fingers, broken bones or even death. For employers, workplace accidents can mean: downtime dealing with an emergency and investigating the cause of the accident costly repairs to damaged machinery and equipment paying overtime or finding replacement workers to cover for injured or ill staff. For workers, workplace injury and illness often cause pain and suffering. They may also mean being unable to live life to the fullest, and having financial difficulty if time off work is needed and pay is reduced. Having safe and healthy work practices helps everyone to avoid these costs. By law, employers are required to take all practicable steps to provide a safe workplace for their staff. But safety is not just an employer s problem. Workers need to be actively involved in identifying hazards and using safe work procedures to reduce the risk of an accident or illness. The information in these guidelines is based on practical experience and hard-earned knowledge from past accidents and incidents. This booklet has been put together by members of the metals industry to give guidance on safe practices for both large and small workshops. Everyone in the workshop is encouraged to use it as a reference tool to make sure that work processes and procedures are both safe and efficient. These guidelines cannot contain all the answers to every hazard or danger. It is recognised that many workshops have their own unique issues, so there are no easy one size fits all answers. The intention is for employers, supervisors, tradespeople and all other workers in the metals industry to use this material as a starting point and guide for working safely. There are references throughout the booklet to further detailed information on complex or technical hazards. The guidelines are a living document and will need updating and amendment from time to time. To assist with future developments we are seeking feedback and suggestions from any metals industry participants. Please any comments to: metal@acc.co.nz. 2

3 contents INTRODUCTION and Key to Using the Guide...6 SECTION 1 MANAGING HEALTH AND SAFETY The Health and Safety in Employment Act Hazard management...13 Identify hazards...13 Assess and prioritise hazards...16 Control hazards...17 Review work practices...19 Accident recording, reporting and investigation Training and supervision Contractors and subcontractors Public Employee participation Regulations and Codes of Practice Workplace self-check...29 SECTION 2 WORKING ENVIRONMENT Safe access Heat dehydration Wet or cold Dust Vapours and gases Chemicals and other hazardous substances Noise Off-site work Safety equipment and clothing...61 SECTION 3 HIGH-RISK ACTIVITIES Working at heights Confined spaces

4 contents SECTION 4 LIFTING AND MOVING Lifting with cranes, overhead gantries and hoists Rigging Forklift safety Manual handling and lifting Discomfort, pain and injury SECTION 5 MACHINE GUARDING AND LOCKOUT Machinery guards and interlocks Lockout systems Emergency stops SECTION 6 ELECTRICAL, HYDRAULIC, PNEUMATIC AND REFRIGERATION SYSTEMS Electrical systems Portable electrical equipment and leads Compressed air Hydraulics Water blasting and steam cleaning Refrigeration systems SECTION 7 MACHINING SECTION 8 WELDING Welding hazards and safe practices Hot work on tanks and drums Hot work permits Hot work in confined spaces SECTION 9 FABRICATION Metal cutting safety Metal forming Metal grinding Plate rollers and pipe benders

5 SECTION 10 METAL CASTING Heat Dust and fumes Metal splashes and water explosions Refractory failure Fettling Material handling Electrical Safety General Safety SECTION 11 EMERGENCY MANAGEMENT Fire Earthquake Storm, flood and tsunami SECTION 12 FIRST AID CPR cardio pulmonary resuscitation Hypothermia Burns Shock Stroke Heart attack Poisons Cuts and scratches Electric shock appendix self-check list

6 introduction a key to using the guide: The following symbols appear throughout the Guidelines to help users quickly locate the information they need. action points action points: Provides practical advice on safe work practice and controlling common hazards. hazards hazards: Identifies common hazards associated with work activities there may be additional hazards in your workplace that also need to be controlled. more information: Provides a list of additional resources with further information on the work activity. 6

7 ! employer s responsibilities: Provides a guide to the legal responsibilities of employers. worker s responsibilities: Provides a guide to the legal responsibilities of workers. the law: Provides reference to the specific legal requirements for the work activities. 7

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9 section 1 1 managing health and safety 9

10 section 1 managing health and safety There are lots of good reasons to manage health and safety well in your workplace. A healthy and safe workplace is better to work in and more productive. Both employers and workers benefit. Think about the losses that can be caused by workplace injuries or illnesses: Loss of productivity. Loss of workers. Loss of income for worker s family. Cost of extra overtime to make up lost time. Loss due to the employment of unfamiliar temporary staff. Fines, and legal and investigation costs. Loss of goodwill. A downturn in staff morale. Pain and suffering. Good management will make health and safety a priority! By having a good health and safety management system you can reduce or eliminate these losses. the law: Legal requirements This section covers the requirements of: Health and Safety in Employment Act 1992 consolidated version of the Act, ammendments and fact sheets available from Health and Safety in Employment Regulations 1995 available from A Guide to the Health and Safety in Employment Act available from 10

11 1.1 The Health and Safety in Employment Act (HSE Act) 1 The purpose of the HSE Act is to make work activities and places where work is carried out safe and healthy for everyone. The HSE Act covers everyone that is at, in or in the vicinity of, any place of work, including employers, employees, contractors, visitors and the public. The HSE Act reinforces that employers, or other people responsible for the work, have the primary responsibility for health and safety at work. It gives specific responsibilities to employers.! employer s responsibilities: Employers need to Take all practicable steps to ensure the safety and health of workers and other people while at work. Note: All practicable steps means you are expected to take all actions that are reasonable and practical. This does not mean that you have to do everything that is humanly possible; you only have to do what a reasonable and prudent person would do in the situation Key responsibilities are to: identify all hazards in the workplace then assess and control significant hazards to ensure workers are not exposed to them provide appropriate training and supervision involve employees in the development of health and safety procedures record and investigate accidents and notify the Department of Labour (DOL) of any serious harm injuries. Be aware that these guidelines cannot contain all the answers to every hazard or danger in each workplace and cannot identify all the practicable steps that can be taken. It is up to each employer to determine what actions are needed to keep their workplace safe. 11

12 section 1 managing health and safety The HSE Act clearly states that employees also have a responsibility for health and safety at work. Under the HSE Act a worker is also able to refuse to do work that they believe is likely to cause them serious harm. Workers need to: worker s responsibilities: Take all practicable steps to ensure: you remain safe at work, for example by using the correct protective clothing and equipment, and following the correct procedures that any action or non-action (something you don t do) by you does not harm any other person. The HSE Act also recognises that everyone within a workplace has responsibilities to themselves and others. Effective health and safety in the workplace requires the cooperation of everyone involved. 12

13 1.2 hazard management 1 Hazard management involves the four steps shown here: identify hazards review work practices assess and prioritise hazards control hazards step 1 identify hazards Hazard identification means working out all the hazards in your workplace and making sure all workers are aware of them. It is strongly recommended that every workplace has a written list of all hazards. The list is normally called a hazard register. The hazard register should be: kept in the workplace reviewed regularly as part of the health and safety system put in place shown to all new workers or other people involved in the workplace for the first time if the hazards are not covered in other induction material. Hazards don t have to be identified only at set times! Everyone should be looking out for hazards at all times and making sure that employers, supervisors, Health and Safety Representatives and other workers are made aware of them. 13

14 section 1 managing health and safety hazards A hazard is any activity, situation or substance that can cause harm. Hazards can be: actual or potential physical (e.g. moving machinery, electrical, burning, rotating, environmental and ergonomic conditions) chemical (e.g. inhaling dust or poisonous vapours, touching toxic chemicals or products) behavioural (e.g. temporary conditions caused by stress, fatigue, shock, alcohol or drugs) biological (e.g. infectious organisms, body fluids). significant hazard A significant hazard is one that is an actual or potential cause or source of one or more of 1. Serious harm The definition of serious harm is as follows: Any of the following conditions that amounts to or results in permanent loss of bodily function, or temporary severe loss of bodily function: respiratory disease, noise-induced hearing loss, neurological disease, cancer, dermatological disease, communicable disease, musculoskeletal disease, illness caused by exposure to infected material, decompression sickness, poisoning, vision impairment, chemical or hot-metal burn of eye, penetrating wound of eye, bone fracture, laceration, crushing. Amputation of a body part. Burns requiring referral to a specialist registered medical practitioner or specialist outpatient clinic. Loss of consciousness from a lack of oxygen. 14

15 Loss of consciousness, or acute illness requiring treatment by a registered medical practitioner, from absorption, inhalation or ingestion of any substance. Any harm that causes the person harmed to be hospitalised for a period of 48 hours or more commencing within 7 days of the harm s occurrence. Note: the definition of serious harm is under review and may change during Refer to to make sure that this information is current Harm that depends on how often or how long a person is exposed to the hazard This harm must be more than trivial and includes such things as noise-induced hearing loss (industrial deafness). 3. Harm that cannot be detected until a significant time after exposure This includes diseases caused by exposure to hazardous substances, such as asbestosis, neurotoxicity, emphysema, and other occupational diseases. Ways of identifying hazards It is up to the employer to assess if a hazard is significant. As part of the assessing process the employer should discuss the hazards with the workers, contractors and any others in the workplace. In some cases, employers may need to ask for specialist advice. Going around and inspecting the workplace and equipment. Analysing the work that needs to be done in the workplace and how it s being done. Reviewing previous accidents (including near misses) and looking at what happened and why (see also Step 4). 15

16 section 1 managing health and safety step 2 assess and prioritise hazards Hazards need to be assessed to determine whether or not they are significant. They can then be prioritised and addressed in order of importance. The diagram below shows things to consider when assessing the risk. Employers should consult workers when doing this risk assessment. Many companies set up a health and safety group to actively involve workers in the risk assessment process. Likelihood of hazard being present + Time exposed to hazard + Result of accident = Overall RISK Almost certain All the time Death High Likely to happen Daily Major longterm illness or disability Reasonably high Is a realistic chance it may happen Weekly Monthly Injuries or illness that needs medical attention Moderate Unlikely Yearly Minor cuts, infections, bruises Low Almost impossible Never No injuries Very low deal with highest-risk hazards first! 16

17 Step 3 control hazards Once significant hazards have been identified and prioritised it is necessary to eliminate, isolate or minimise them. 1 eliminate This must always be your preferred choice! isolate Consider this ONLY if it is impracticable to eliminate the hazard! minimise If it is impracticable to eliminate or isolate the hazard then steps must be taken to minimise the risk! Eliminate This means to remove a hazard completely. You must always do this if it can be done practicably! Examples include: Remove the hazardous machinery or upgrade it to a completely safe model. Replace a hazardous substance with a safe, non-toxic alternative. Stop making a hazardous product. Stop carrying out a particular hazardous task. Isolate This means to separate the hazard from workers. This should only be considered if the hazard cannot practicably be eliminated. Examples include: Cover the noisy machinery with a soundproof enclosure. Enclose the hazardous part of the machinery by use of guards and interlocks. 17

18 section 1 managing health and safety Minimise This means to reduce the risk to workers and is the last choice. This action must be taken if it is impracticable to eliminate or isolate the hazard. Actions include: Put procedures in place that take account of the hazard. Provide appropriate protective clothing and insist that people wear it. Minimise and control the use of hazardous substances. Monitor exposure to the hazard, ensuring unsafe levels are not exceeded. Conduct specific training that covers the hazards.! employer s responsibilities: Employers need to: Take steps to control hazards in the following order: Elimination (removal) of the hazard must always be your first option. If it can practicably be done, you must take this option. You have then removed that hazard and you won t have to worry about it any more. If you can t eliminate the hazard then your next choice must be to isolate it. Only if it is impracticable to eliminate or isolate the hazard can you consider minimising the hazards. Remember that if the isolate or minimise option is taken there will always be ongoing costs in monitoring the hazards, supervising workers, and maintaining personal protective equipment (PPE) etc. 18

19 Step 4 review work practices This step has two parts: Continual review and Accident investigation. 1 Continual review Hazard management is not a once-in- a-lifetime event. We don t simply list the hazards we find, do something about them and then forget about them! the law: Legal requirements: The HSE Act requires employers to review hazards regularly and to ensure that suitable controls are in place. We need to repeatedly re-examine the workplace to check things like: Have standards dropped? Are new substances used hazardous? Have new hazards been introduced with new technology? Have some of the previous hazards gone away because old equipment has been replaced? Is our training up to standard? Are people following our procedures? Are our procedures practical? 19

20 section 1 managing health and safety! employer s responsibilities: Employers need to: have set times to review the hazard management systems you have in place (this can be included in a planned maintenance programme) make sure specific times are scheduled to review existing hazards (in your register) and look for new hazards put in place a system that allows hazards to be identified at any time put in place procedures that ensure hazard identification is undertaken before any new tool, plant or equipment is put into operation encourage workers to be involved with the identification, control and monitoring of hazards make sure workers are made aware of the hazards in the workplace. Accident investigation If an accident happens it is important that we all learn from it so we can identify what went wrong and how to prevent it recurring in the future. It is important to note that there will also be near misses that we can learn from. Near misses should be investigated as if they were an accident. The Department of Labour (DOL) investigates serious accidents so they can issue accident alerts, identify trends or common causes and develop appropriate prevention programmes. 20

21 ! employer s responsibilities: 1 Employers need to: keep a register of all accidents that occur in the workplace report all serious harm accidents to DOL as soon as possible make sure the serious harm accident scene is not disturbed until DOL gives approval to restart work forward an Accident Investigation Form for all serious harm accidents to DOL within seven days of the accident. Note: you should investigate near misses as if they were accidents. You can get valuable information from this that can prevent future accidents. Recording accidents Accidents are investigated using the form shown on page 24. This example can be photocopied but is also available from the local Department of Labour office, or templates can be downloaded from their website These forms must be kept in a folder in your workplace. This folder must be reviewed regularly to ensure the hazards that caused these accidents are being controlled. Reporting serious harm accidents Employers are required to report serious harm accidents that happen in the workplace to DOL as soon as possible, that is, once you are no longer required to tend to the injured person(s) or the prevention of further injury. This report can be made by phone 24 hours a day, seven days a week to If you are unsure if the accident should be reported, err on the side of caution and contact your local DOL office. remember do not disturb the scene. (except to save life, assist the injured or prevent further loss). After the initial report you have seven days to send the completed accident register form to DOL. This should include a copy of your accident investigation report. 21

22 section 1 managing health and safety Investigating accidents and incidents An employer is required to investigate all accidents. It is a good practice to also investigate near misses which could have resulted in an injury. This is so you can see if there is something you can do to prevent further accidents happening. Start the investigation as soon as possible! This is so events are still fresh in everyone s mind and evidence is still available. When you carry out an investigation it is very important you have an open mind. Health and Safety Representatives are usually trained in accident investigation techniques so their involvement would be valuable. Workers can be used to assist with investigating an accident to help cover all aspects. It is important to remember that there is usually more than one cause of an accident. Often it is a chain of events that happen in such a way as to give rise to an accident. The drawings below show that if certain things happen at one time they can all contribute to an accident. 22

23 The sequence to follow for an investigation is shown below: Assist the injured The first priority is to ensure an injured person gets the assistance he/she requires and that the risk of further damage or injury is averted. 1 Secure the scene Rope off the area where the accident occurred and any machinery that was involved. Ensure nothing is moved. Make sure witnesses remain available for interviews. Start an investigation as soon as possible Interview witnesses Interview each witness at the scene in relative privacy. Read back any notes to ensure you have understood correctly. Interview key witnesses first. Get written statements wherever possible. Remain aware that witnesses may be traumatised. Stay positive! Take immediate corrective action If there are obvious causes that can be rectified straight away implement the changes required immediately. Complete the report and send it to DOL The accident register form should be treated as the minimum. Your report should include: events leading up to the incident background, training and skills of those involved names of those involved practices and procedures being, or not being, followed at the time a timeline of events leading up to, and occurring at, the time of the incident out-of-the-ordinary circumstances conclusions recommendations. take corrective action as soon as possible! 23

24 section 1 managing health and safety Form of register or notification of circumstances of accident or serious harm Required for section 25(1), (1A), (1B), and (3)(b) of the Health and Safety in Employment Act 1992 For non-injury accident, complete questions 1, 2, 3, 9, 10, 11, 14 and 15 as applicable 1 Particulars of employer, self-employed person or principal: (business name, postal address and telephone number) 2 The person reporting is: an employer a principal a self-employed person 3 Location of place of work: (shop, shed, unit nos., floor, building, street nos. and names, locality/suburb, or details of vehicle, ship or aircraft) 4 Personal data of injured person: Name Residential address Date of birth 5 Occupation or job title of injured person: (employees and self-employed persons only) Sex (M/F) 6 The injured person is: an employee a contractor (self-employed person) self other 7 Period of employment of injured person: (employees only) 1 st week 1 st month 1-6 months 6 months-1 year 1-5 years Over 5 years non-employee 11 Agency of accident/ serious harm: machinery or (mainly) fixed plant mobile plant or transport powered equipment, tool, or appliance non-powered handtool, appliance, or equipment chemical or chemical product material or substance environmental exposure (e.g. dust, gas) animal, human or biological agency (other than bacteria or virus) bacteria or virus 12 Body part: head neck trunk upper limb lower limb multiple locations systemic internal organs 13 Nature of injury or disease: fatal (specify all) fracture of spine puncture wound other fracture poisoning or toxic effects dislocation multiple injuries sprain or strain damage to artificial aid head injury disease, nervous system internal injury of trunk disease, musculoskeletal system amputation, including eye disease, skin open wound disease, digestive system superficial injury disease, infectious or parasitic bruising or crushing disease, respiratory system foreign body disease, circulatory system burns tumour (malignant or benign) nerves or spinal chord mental disorder 14 Where and how did the accident/serious harm happen? (If not enough room attach separate sheet or sheets.) 8 Treatment of injury: None Doctor but no hospitalisation First aid only Hospitalisation 9 Time and date of accident/ serious harm: Time am/pm Date Shift Day Afternoon Night Hours worked since arrival at work (employees and self-employed persons only) 10 Mechanism of accident/ serious harm: fall, trip or slip hitting objects with part of the body sound or pressure being hit by moving objects body stressing heat, radiation or energy biological factors chemicals or other substances mental stress 15 If notification is from an employer: (a) Has an investigation been carried out? yes no (b) Was a significant hazard involved? yes no Signature and date Name and position (capitals) / / 24

25 1.3 training and supervision 1 People must be trained and/or supervised to the appropriate level to ensure they can carry out all work safely. Employers must be satisfied that workers are properly trained before they are allowed to work unsupervised.! employer s responsibilities: Employers need to: ensure all people in the workplace are aware of the hazards they may come across, or create during their time at work make sure that workers have knowledge and experience of relevant similar workplaces, work, equipment or substances, or that they are supervised by someone who has that knowledge and experience ensure that workers and contractors are adequately trained in using the types of objects, substances and equipment that they are required to work with. Workers need to: worker s responsibilities: STOP work and inform your supervisor if you are asked to do a job that you have not been trained for, or you do not feel safe doing. 25

26 section 1 managing health and safety 1.4 Contractors and subcontractors When an employer hires a contractor or subcontractor at a workplace or site you must take all practicable steps to ensure that they, and their workers, are not harmed while at work. You must also check their health and safety systems to ensure that any work conducted by them will not harm others. You must make them aware of any unusual or site specific hazards in your workplace before they start work as well as practices and procedures designed to prevent harm. If a contractor or subcontractor employs others to work on your contract, they have all the responsibilities of an employer. This means they are responsible for carrying out work in a way that will not endanger others or themselves and you are responsible for monitoring their health and safety performance. 1.5 Public An employer must make sure that the work activities of their workers don t harm any other people (including customers, visitors, neighbours, bystanders or other members of the public). You might include actions such as warning them about site hazards, restricting their access to the workshop or placing barriers around off-site work. 1.6 Employee participation Employee participation is an important part of developing and implementing health and safety practices in the workplace. Everyone needs to work cooperatively and in good faith to establish an effective health and safety system. Good faith requires being open and honest, and understanding that all involved have a legitimate interest in a safe and healthy workplace. An effective health and safety participation system will cover: identification of hazards assessment and control of significant hazards provision of information. People who carry out work in an area or on a particular machine are in a good position to identify actual or potential hazards that arise in the course of that work and suggest ways those hazards could be managed. 26

27 ! employer s responsibilities: 1 Employers need to: provide reasonable opportunities for your workers to participate effectively in processes for improving health and safety at work work with your workers to develop an employee participation system that suits your workplace. the law: Legal requirements: All employers must provide reasonable opportunities for their workers to participate in health and safety issues. This will depend on the circumstances of the work and the workplace and the existing work arrangements. An employee participation system is required if the employer has 30 or more workers, or if there are less than 30 workers but one or more people (or the union representing them) requests a system. Employers and workers are free to develop and agree on a participation system that suits their requirements. If they cannot agree on a system within six months then the default system described in the HSE Act will apply. This will involve holding an election in the workplace to select Health and Safety Representative/s to be members of a health and safety committee. The Health and Safety Representative will have received training so he or she can: play a key role in hazard identification foster positive health and safety management practices consult with inspectors on health and safety issues promote the interests of employees regarding health and safety. Note: Employment contracts can be used to establish legally binding commitments to health and safety by both the employer and the worker 27

28 section 1 managing health and safety 1.7 Regulations and Codes of Practice This shows the hierarchy of documentation produced to ensure minimum health and safety standards are met in workplaces Health and Safety in Employment Act Legislation governing health and safety standards in New Zealand workplaces. Regulations These are rules or standards that must be complied with. Codes of Practice These present codes of practice that are recommended to NZ workplaces to meet the legal obligations of the HSE Act. Normally compiled by DOL and industry bodies. Available from DOL Standards NZS = NZ Standard AS/NZS = Australia/NZ Standard BS = British Standard These present minimum standards that are recommended to ensure NZ workplaces meet the legal obligations of the HSE Act. Guidelines These guidelines present best practice (at the time). They may be used to establish practicable steps that are available and considered reasonable. 28

29 1.8 Workplace self-check 1 Any system that is put in place needs to be regularly reviewed to make sure it is effective and that it is fully meeting the requirements of the law to have a safe and healthy workplace. This should be done in a systematic way perhaps have a list of the parts of the system and review one each month. You need to write down the details and results of the review, and any action you take because of the review. Employers should remind workers that they have responsibilities under the HSE Act. Workers must tell their immediate supervisor about any issues in their workplace that might affect health and safety. The self-check list on page 206 can be used to check how you are performing. Further information: more information: A Guide to the Health and Safety in Employment Act available from Involving Employees in Safety at Work:Developing an approach that suits your workplace available from The Role of Health and Safety Representatives fact sheet available from Forms available from Accident Register Form Accident Investigation Form First Aid Register Hazard Identification Form Notification of Particular Hazardous Work. 29

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31 section 2 2 working environment In this section you will find information about the work environment and how this can affect health and safety. It includes information on: safe access heat and dehydration wet and cold dust vapours and gases chemicals noise off-site work safety equipment and clothing. 31

32 section 2 working environment 2.1 Safe access Access ways include doors, passages, walkways and other spaces that allow people to move around the workplace. At any worksite there are access ways for maintenance, escape or simply enabling safe passage. We need to keep at least two access ways clear to allow people to get out in an emergency. Things can happen extremely quickly and often a work area will have to be evacuated fast. Fire and smoke make it even harder to get out. It is very important that further obstacles are not put in the way of the person escaping, whether it is a physical obstruction, or the person s lack of knowledge about their work area. Keep all access ways clear and mark emergency exits with visible signs. There is more information on specialist access using ladders and scaffolding in section 3.1 Working at heights. action points Every stairway, passage, ladder and door should be treated as an escape route. Regularly open and close alternative escape doors to ensure they are unlocked, with all handles and hinges working freely from the inside. Exits must be clearly marked. Keep all openings, ladders, passageways and stairs clear at all times. When they arrive on-site, show all employees and contractors the location of alternative escape routes from all work areas. 32

33 action points 2 Keep markings and signs well maintained. Make sure they are kept clean and clear. Everyone should use the correct access ways don t take shortcuts. Keep guard rails secure. Keep walkway gratings and floor plates in good order, secure and clean of grease and oils. Non-skid surfaces must also be kept in good order. Ensure that steps on ladders and stairs have good tread. 33

34 section 2 working environment 2.2 Heat dehydration Everyone working in hot conditions is at risk of dehydration. Hot conditions can be due to working in the direct sun, working near heat-producing processes or from the actual work you are doing. Working in hot conditions can result in a wide range of physical and mental effects for workers. These range from mild discomfort through to life-threatening heatstroke. Sweating is the body s main means of trying to cool itself and this can quickly lead to dehydration for people working in hot conditions. Workers who are dehydrated may become fatigued quickly, have difficulty completing skilled tasks and are at higher risk of making mistakes or having an accident. Understanding dehydration Your body needs a certain amount of fluid each day to maintain the various body systems within. The fluid you drink replaces body fluids lost through sweat and urine. You become dehydrated when you are not drinking enough fluid to replace lost body fluid. On average, people need about eight glasses of water per day to replace lost fluid. People in metal manufacturing often work in very hot environments. In a hot environment, you need to drink more than eight glasses to replace the larger amount of fluid that you will lose. Signs of dehydration include: headaches muscle cramps dizziness or fainting mood changes or confusion changes in heart rate and breathing patterns. In the most severe cases it may lead to heatstroke, with workers suffering convulsions, dilated pupils or coma. Call an ambulance immediately if you see someone with these signs! 34

35 action points 2 Schedule work to avoid (or at least limit) prolonged exposure to extreme heat if possible. Drink plenty of water during the day. Water is the best thing you can drink to avoid dehydration. Limit drinks of tea, coffee and soft drinks the caffeine and sugar in these drinks make them less hydrating than water. Wear lightweight clothes where it is safe to do so. Wear the correct PPE to ensure you are protected against heat. But be aware that such PPE can at times increase the risk of dehydration. Work in the shade as much as possible. Wear sun hats and sun screen where appropriate. Ensure there is adequate air flow (ventilation) to keep the temperature down. 35

36 section 2 working environment Checking for dehydration Urine is a good indicator. This chart helps you analyse your level of hydration.! employer s responsibilities: Employers need to: ensure workers and contractors have access to cool and clean drinking water make sure you are aware of the conditions your workers are working in. If they are in environments where dehydration may be a problem (e.g. in tanks, in direct sunlight, in foundries), you must make sure they have access to the necessary equipment such as shades and ventilation fans. Further information: more information: What You Need to Know about Temperature in Places of Work available from Guidelines for the Management of Work in Extremes of Temperature available from 36

37 2.3 Wet or cold People working in wet and cold conditions are more likely to slip or fall. Extreme cold reduces muscle strength and stiffens joints this increases the chance of accidents occurring. 2 People working in these conditions are also more likely to get coughs, colds and other similar illnesses. In very wet and cold situations, there is the risk of hypothermia (also known as exposure ). Hypothermia happens when your body temperature starts to drop. A person suffering hypothermia may not realise what is happening to them. It is very serious and you must act quickly if you think someone is showing signs of hypothermia. Signs of hypothermia include: uncontrollable shivering gradual slowing, both physically and mentally increased clumsiness poor judgement developing into mental confusion in severe cases, increased drowsiness, progressing to a coma or death. What to do: Move the person to a dry place. Replace their wet clothes with warm coverings wrap in blankets, or anything warm and dry. Once the person has warm, dry coverings, warm them up with mild exercise. Offer food and warm drinks. If the person goes into a coma, call an ambulance immediately! 37

38 section 2 working environment action points If it is possible, reschedule work or provide temporary cover to give shelter from wet or cold weather. Use suitable clothing: Wear a good set of waterproof gumboots if standing in water. Wear an over jacket where practical. Wear wind/water proof, wool or polar-fleece type clothes on colder days. Wear a hat and gloves on colder days. If you can t stay dry: wear polypropylene or similar quick drying warm garments. Don t wear cotton! a wide brimmed hat will protect you from both rain and sun dry yourself off as soon as you have finished your time in the wet conditions have a change of clothes (something warm) to put on have regular warm drinks.! employer s responsibilities: Employers need to: make sure you provide your workers with appropriate warm clothing if they are to work out in adverse weather conditions or in cold environments (e.g. refrigerated rooms). 38

39 more information: 2 Further information: What You Need to Know about Temperature in Places of Work available from Guidelines for the Management of Work in Extremes of Temperature available from Dust People working in metal manufacturing will breathe in dust in the work environment. You also get dust in your hair, on your clothing and on your skin. When you inhale or swallow, fine particles of dust can get through the body s filtering systems. If inhaled, dust particles will often stay in the lungs. Some types of particles are very dangerous and can cause life-threatening diseases such as cancers, silicosis and asbestosis. Dust is one of the most common causes of disease in workplaces around the world. Dusts from asbestos, silica and metals such as beryllium, chrome, tungsten, copper and lead are very dangerous and can cause lung disease, cancer or death. Dusts are also explosive and can be extremely dangerous! When materials are reduced to a very fine particle size they can explode. Often the source of dust is obvious as it is visible during cutting and casting operations. However, sometimes the sources are not obvious as the dusts are very fine or have settled. If there is dust sitting on shelves and surfaces in a workplace, there will be extremely fine particles of dust in the air. 39

40 section 2 working environment action points Keep the workshop as clean as possible. Wash down or vacuum dusty surfaces rather than sweeping them. Never use compressed air to remove dust from surfaces (this is a major cause of eye injuries!). Close containers of dusty materials. Wear appropriate personal protective equipment (PPE). Keep PPE clean. 40

41 action points 2 Wash your face as well as your hands before meal breaks. Remove your overalls before you go into lunch rooms. Take extreme care if you must do hot work in dusty environments. Be careful not to create dust around live electrical equipment. Turn equipment off, lock out and cover electrical equipment well before starting work. Ensure ventilation in work areas is working and turned on. Use dust extraction systems. Check and clean the filters in ventilation and exhaust systems regularly. Blocked and dirty filters in ducts are also often the cause of fires. 41

42 section 2 working environment! employer s responsibilities: Employers need to: make sure you refer to the Workplace Exposure Standards (WES) to find out what the safe exposure levels are if your workers are working in a dusty environment make sure you have a monitoring programme in place and personal monitors are worn where necessary, if your workplace has some dust present, or there is the risk of an increase in dust levels going unnoticed make sure you have ventilation and extraction systems that are fit for purpose keep all ventilation and extraction equipment well maintained. Further information: more information: Workplace Exposure Standards (WES) available from Dust Explosions in Factories precautions required with combustible dusts available from Guidelines for the Management and Removal of Asbestos available from Guidelines for the Management of Lead-based Paints available from 42

43 2.5 Vapours and gases Like dust, some vapours and gasses can be harmful when you breathe them in or if they come into contact with your skin. 2 You cannot see or smell many harmful vapours. Some vapours are very toxic and can get through the body s protection systems by being inhaled, ingested or absorbed through the skin. The chemicals find their way to the blood and may cause poisoning or disease. Depending on their toxicity and concentration, harmful vapours can: cause irritation and itchiness on your skin, and in your nose and eyes make you breathless and cause asphyxiation cause an allergic reaction or disease such as occupational asthma or metal fume fever (as detailed later in this section) make you drowsy or weak lead to loss of consciousness or death. Vapours or gases: may leak from gas bottles. The gas may be toxic, or explode or become poisonous when combined with other gases may escape from production processes (e.g. refrigeration plants) are given off from products used during cleaning and painting may be produced by operations such as welding, cutting and heating. 43

44 section 2 working environment action points Use non-toxic products wherever possible. Carry out work in an appropriate and safe area. For example, do the work away from other people or in special areas (e.g. in a spray booth). Always check the Material Safety Data Sheet (MSDS) for the product being used. This way you will know what the hazards are and how to control them. Wear appropriate protective equipment. This should include: the correct respiratory equipment gloves, aprons and coveralls to protect your skin safety goggles and a face shield to protect your face and eyes. Seek advice from your local safety product supplier or health and safety advisers on what safety gear is the best to use for the work you are doing. Make sure ventilation (temporary or permanent) is: in place turned on and working strong enough to dilute the concentration of toxic hazards to a safe level set up to draw vapours away from the breathing zone of the person working. 44

45 action points 2 Wear a monitor and repeatedly test the atmosphere for concentration levels. Dispose of contaminated material (e.g. solvent-soaked rags or used gloves) in sealed containers. Check with your local council or environment authority to find out how to dispose of hazardous substances. Keep respirators clean and in an airtight container when not in use. Wash your face, as well as your hands, before meal breaks. 45

46 section 2 working environment! employer s responsibilities: Employers need to: make sure you refer to the Workplace Exposure Standards (WES) to find out what the safe exposure levels are if your personnel are working in an environment where vapours and gases are present make sure you have ventilation and extraction systems that are fit for purpose keep all ventilation and extraction equipment well maintained make sure you provide your workers with the correct type of respiratory protection for the substances they are exposed to make sure you have a monitoring programme in place and personal monitors are worn where necessary. metal fume fever Cause Metal fume fever is a temporary tiredness and irritation of the respiratory tract, like influenza, with fever. It is caused by exposure to metal fume (e.g. zinc oxide, nickel fume, copper oxides) during operations such as welding, soldering and casting. Symptoms Symptoms are varied but are similar to those experienced when sick with the flu. These include feeling nauseous, experiencing headaches and muscle and joint pain, or having fevers or chills. Symptoms normally disappear within hours after exposure. Prevention Use information such as an MSDS to identify possible sources of fumes that may cause metal fume fever. Where necessary use effective ventilation. Treatment An historical treatment passed down through generations of welders was to drink milk, which supposedly absorbed the deposits that accumulated in the body. Current research shows there is no evidence to support this and it must be considered an old wives tale. Treatment consists of bed rest and the normal treatment for the symptom (e.g. aspirin for headaches). 46

47 occupational asthma Cause Occupational asthma is caused by substances (such as dust, vapour or gas) that your body regards as an invader. The asthma can trigger breathing difficulties and result in lung disease. Sufferers sometimes become sensitised to the airborne substance, which means that exposure to even a small dose could result in asthma. 2 Symptoms Wheezing or shortness of breath. Chest tightness or pain. Extreme fatigue. Prevention Make sure ventilation and extraction systems are effective where dust, vapour or gas is present. Clean up your workshop vacuum away dust, make sure there is good storage of hazardous substances and clear up spills quickly. Always use the correct respiratory protection and make sure it is well maintained. Limit the length of your exposure to dusts, vapours and gasses. Treatment Whenever possible, avoid exposure to substances that trigger an asthma attack. Medical treatment includes the use of inhaled steroids and anti-inflammatory medications. People with long-term or severe occupational asthma may need to consider changing to a different line of work. 47

48 section 2 working environment the law: Legal requirements: Management of Substances Hazardous to Health (Approved Code of Practice) available from Vapour Degreasing Operations (Approved Code of Practice) available from Further information: more information: Guidelines for the Use of Chemicals in Electroplating and Related Industries available from Acetylene Cylinders Safety Hints for Users available from Practical Guidelines for the Safe Use of Organic Solvents available from A Guide to Respiratory Protection available from Workplace Exposure Standards (WES) available from Dust Explosions in Factories Precautions Required with Combustible Dusts available from 48

49 2.6 Chemicals and other hazardous substances 2 Many chemicals and other substances used or produced in the workplace can be very damaging to health. People are exposed to these substances through breathing in the fumes or simply through skin contact. Hazardous substances include chemicals, poisons, explosives and flammable materials. These hazardous substances are present in products such as cleaners, coolants, lubricating fluids and paints. If exposure isn t prevented, or properly controlled, it can cause serious illness, including asthma, dermatitis or cancer, and sometimes even death. Recent research by the National Occupational Health and Safety Advisory Committee (NOHSAC) estimates that 700 to 1,000 people die in New Zealand each year from diseases caused by exposure to hazardous substances in their workplace. The Hazardous Substances and New Organisms Act (HSNO Act) covers the requirements for the use and storage of these substances. The HSNO Act requires every workplace to have a Person in Charge of hazardous substances. This person is responsible for ensuring that the hazardous substances under their control are correctly stored and used. Test certificates The Person in Charge must ensure necessary test certificates are obtained. Test certificates verify that the required controls for managing hazardous substances are met. They are required for the following: Locations where hazardous substances are held in excess of the specified limits a hazardous substance location must be established and a test certificate obtained. Approved Handlers where particularly hazardous substances are under the control of an Approved Handler or secured. Approved Fillers employees filling compressed gas containers must be Approved Fillers and know about the substance they are handling and the equipment. Stationary container or storage systems a test certificate is required for a stationary container system to confirm that it is designed, installed and maintained to the required standards. 49