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Paint stripping using methylene chloride in a
tank
There have been several
workplace deaths in Australia and overseas associated with
using methylene chloride, also known as dichloromethane, in
open tanks for stripping paint from furniture. In these
fatalities the bodies were found slumped over the tank
indicating that the operators had been overcome by vapours
when leaning into or over the tank.
This guidance note describes the measures
needed to prevent fatalities and serious injuries from
exposure to methylene chloride when it is used during paint
stripping operations in an open
tank.
Use of methylene
chloride in the paint stripping
industry
Methylene
chloride is a volatile solvent used to strip paint from
timber. The process typically involves immersing the item in
methylene chloride in an open tank, leaving it to soak for
several hours or overnight and then washing it using high
pressure water. Manual scrubbing and scraping is often carried
out to remove paint after soaking.
Some large and bulky items such as
wardrobes cannot be fully immersed in the tank, either because
of their size, the size of the tank or the depth of solvent.
In these circumstances workers lean over or into the tank to
scoop and pour methylene chloride over the items and scrape or
scrub them for prolonged periods of time. Business or
commercial pressure for a quick turnaround on jobs may also
contribute to a shorter period of soaking and therefore more
manual scrubbing and scraping of the items while still in the
tank.
Workplace
deaths
Inhalation
of methylene chloride vapour can cause dizziness, impaired
coordination and central nervous system depression which can
lead to unconsciousness and death.
Investigations conducted by WorkSafe
Victoria indicate that methylene chloride vapour levels that
are immediately dangerous to life build up within stripping
tanks. The work practice of leaning over or into a stripping
tank to scrub or manoeuvre items is likely to expose workers
to these dangerously high vapour levels. As a result, workers
risk being overcome by vapours and falling forward into the
tank.
Methylene
chloride also has other health effects. The vapour can cause
headache and irritation to the respiratory tract and eyes.
Splashes to the skin and eyes can be painful, while prolonged
skin exposure can lead to dry skin and dermatitis. It is also
assigned as a category 3 carcinogen (i.e. a substance
suspected of having cancer producing potential) by the
National Occupational Health & Safety Commission
(NOHSC).
In the
fatality cases the deceased workers were not wearing any
respiratory protection and few safety measures were in
place.
Practical steps
to prevent a fatality
The employer has a duty to eliminate or reduce as far
as practicable risks to employees using methylene chloride.
Risks can be reduced by:
Using a less hazardous product or
different method of stripping paint Don't use methylene chloride if you don't
have to. Use a less hazardous product or less hazardous
technique if possible. For example, using water-based products
or a brush-on paste rather than liquid methylene chloride may
be practicable in some instances and can reduce the risk from
exposure to vapours.
Preventing employees from working over or
leaning into the tank
If it is not
practicable to eliminate or substitute methylene
chloride, the key to
preventing a fatality is to eliminate the practice or
possibility of leaning over and into the
tank. Where
operators lean over a tank, they are likely to fall
forward into the tank if overcome by vapours. Employers
can prevent this by:
- Raising the tank
height
By
raising the tank off the floor using legs (shown in
Figure 1), employees can work upright without the need
to lean over and into the tank. Furthermore, if
workers are overcome by vapours, the raised tank
should prevent them from falling forward into the
tank.
- Using tanks of
different size and shape
The design of the tanks should be
tailored to suit the items to be handled. Large deep
tanks should be used for large items such as wardrobes
whereas long narrow tanks can be used for skirting
boards (shown in Figure 2). This reduces employee
exposure because the surface area of solvent is
reduced and there is also less space in the tank for
vapours to accumulate. The need to manually scrub the
items can also be reduced by fully immersing them and
allowing them to soak.
- Increasing the depth
of solvent in tank
If the depth of solvent in the tank is
increased, the items can be fully immersed and left to
soak. The need to manually pour solvent over the items
and scrub them is eliminated or reduced. There is also
less space in the tank for vapours to
accumulate.
- Soaking the items for
longer
If items
are left to soak for longer periods the exposure of
employees to vapours is reduced because the need to
manually scrub items is reduced or eliminated.
- Conducting manual
tasks outside of the tank
Where practicable, manual tasks
such as scrubbing and scraping should be done away
from the tank. A suitable area may be the wash down
area where the item can be pressure sprayed with
water. If the paint hasn't been completely removed,
the item can be placed back into the tank to soak for
longer.
- Use mechanical lifting
devices to manoeuvre items
Mechanical lifting devices such as
small hoists (often roof mounted) enable the operators
to distance themselves from vapours and any splashes
that may occur when moving items. The use of such
devices also eliminates or reduces the need to lean
into the tank to move items. |
Figure
1 – a
raised shallow tank can help operators to work upright
and reduces the space where vapour can build
up.
Figure 2 – long narrow tank is
suitable for skirting boards, etc. |
|
Ensuring employees do not work
alone In
addition to implementing practicable control measures to
prevent employees from leaning over or into the tank,
employers must provide adequate supervision to ensure
employees work in a safe manner and use the control
measures provided. As far as possible they should not
work alone when stripping paint with methylene chloride,
particularly if they are likely to lean into the
tank.
Working
alone was an important contributing factor in all the
fatalities that have occurred with use of methylene
chloride in tanks. While it is an additional safety
measure to always have more than one person on site,
using the above control measures first to prevent
operators falling into the tank is essential and is far
more effective in preventing a fatality. |
Important
note
on local exhaust
ventilation Local exhaust ventilation (such as extraction
fans or hoods) may be useful in reducing overall
exposure in cases where employees do not lean into the tank.
However, where the nature of the
work is such that employees might lean into the tank,
the use of local exhaust ventilation fitted to the
tank rim or over the tank is not
considered to be an effective
solution.
In
this case solvent vapours are likely to be drawn
through the operators breathing
zone. | Using an airline
respirator The
levels of methylene chloride vapour present in a large tank
have been tested and found to be immediately dangerous to
life. Where the nature of the paint stripping requires the
worker to lean into the tank, an airline respirator
supplying clean air is the most appropriate form of
respiratory protection. An airline respirator comprises a face
mask and an airline attached to a filtered compressed air
supply.
Note: Half
face organic vapour cartridge respirators are generally not
suitable for exposure to high levels of methylene chloride
vapour as the solvent can readily break through the charcoal
filter.
Additional
measures to minimise exposure to methylene
chloride
In
addition to the control measures already mentioned, exposure
to methylene chloride can be further minimised by taking the
following actions:
- Ensure that there is good
general ventilation in the workplace by keeping doors
and windows open.
- Provide and use covers
for tanks when they are not in use.
- If practicable, add a
layer of water, wax or suitable medium such as wooden
balls to the surface of the solvent to reduce
evaporation and the build up of vapour in the
tank.
- Reduce the duration of
worker's exposure to methylene chloride by rotating
them through various tasks in the workplace.
- Provide information,
instruction and training to ensure that personal
protective equipment is worn and safe work practices
are
followed.
| Legal requirements
The Occupational Health and Safety (Hazardous Substances)
Regulations 1999 place
duties on employers who use chemicals such as methylene
chloride (see in particular Regulations 302 to 321). These
regulations require the employer to:
- Obtain material safety
data sheets (MSDS) for the chemicals that employees
use and make sure they have access to them.
- Set up a hazardous
substances register (i.e. a list of chemicals used in
the workplace and a copy of each MSDS).
- Make sure containers,
drums and tanks are labelled.
- Assess the risks of
methylene chloride taking into account how it is used
and the information on the MSDS and product
label.
- Ensure that exposure of
employees does not exceed the exposure standard (see
Note below).
- Make sure that control
measures are being properly used and
maintained.
- Provide information,
instruction and training.
- Conduct air monitoring if
necessary.
| (Note: The Exposure Standard for methylene
chloride, as specified by NOHSC, is an 8 hour average of 50ppm
(parts per million) in air.)
In addition, where any risk assessment is to be
undertaken or risk control measures are to be implemented, the
employer is to consult with the health and safety
representative(s) in the workplace. If there isn't a health
and safety representative elected, employers are recommended
to consult with employees.
The WorkSafe Victoria Code of Practice for Hazardous
Substances provides practical guidance on complying with the
regulations.
Further
information
Act & Regulations
- Occupational Health and Safety
Act 1985
- Occupational Health and Safety
(Hazardous Substances) Regulations 1999
Acts and regulations are available from
Information Victoria on 1300 366 356 or order online at
www.bookshop.vic.gov.au.
If you only
want to view the legislation you can use the Parliament of
Victoria web site; go to www.dms.dpc.vic.gov.au, click on "Victorian Law Today" and scroll
down to the "Search" window.
WorkSafe
Victoria
- Code of Practice for Hazardous
Substances – June 2000
Copies of publications, including codes of practice,
can be obtained by contacting WorkSafe Victoria on 03 9641
1555, or your local WorkSafe Victoria
office.
Other useful
health and safety information is available on WorkSafe
Victoria's web site; go to www.workcover.vic.gov.au and click on the WorkSafe Victoria
logo.
Other
The National Occupational Health and Safety Commission
(NOHSC) web site provides access to technical data and
occupational health and safety information; go to www.nohsc.gov.au/OHSLegalObligations.
If
you can't find guidance material that gives the solutions or
advice you're after, try the national database of guidance
material on the NOHSC web page; go to www.natindex.nohsc.gov.au.
Suppliers of methylene chloride are a source of
information on use, chemical properties and health effects of
this substance.
Note: This guidance
material has been prepared using the best information
available to WorkSafe Victoria. Any information about
legislative obligations or responsibilities included in this
material is only applicable to the circumstances described in
the material. You should always check the legislation referred
to in this material and make your own judgement about what
action you may need to take to ensure you have complied with
the law. Accordingly, the Victorian WorkCover Authority
extends no warranties as to the suitability of the information
for your specific circumstances.
Alert 03/2003July |
This
document may be freely copied or reprinted. |
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