Start With Safety!
Employee Safety Manual
A Guide to Safety Policies & Procedures to Support
a Safety-Conscious Work Environment
a Safety-Conscious Work Environment
Employee Safety Handbook
Preface
Our Company recognizes that our people drive the business. As the most critical resource, employees will be safeguarded through training, provision of appropriate work surroundings, and procedures that foster protection of health and safety. All work conducted by our employees will take into account the intent of this policy. No duty, no matter what its perceived result, will be deemed more important than employee health and safety. Our Company is firmly committed to the safety of our employees. We will do everything possible to prevent workplace accidents and we are committed to providing a safe working environment for all employees. We value our employees not only as employees but also as human beings critical to the success of their family, the local community, and this Company. Employees are encouraged to report any unsafe work practices or safety hazards encountered on the job.
All accidents/incidents (no matter how slight) are to be immediately reported to the supervisor on duty. A key factor in implementing this policy will be the strict compliance to all applicable federal, state, local, and company policies and procedures. Failure to comply with these policies may result in disciplinary actions. Respecting this, we will make every reasonable effort to provide a safe and healthful workplace that is free from any recognized or known potential hazards. Additionally, our Company subscribes to these principles:
1. All accidents are preventable through implementation of effective Safety and Health Control policies and programs.
2. Safety and Health controls are a major part of our work every day.
3. Accident prevention is good business. It minimizes human suffering, promotes better working conditions for everyone, holds our Company in higher regard with customers, and increases productivity. This is why we will comply with all safety and health regulations which apply to the course and scope of operations.
4. Management is responsible for providing the safest possible workplace for Employees. Consequently, management is committed to allocating and providing all of the resources needed to promote and effectively implement this safety policy.
5. Employees are responsible for following safe work practices and company rules, and for preventing accidents and injuries. Management will establish lines of communication to solicit and receive comments, information, suggestions and assistance from employees where safety and health are concerned.
6. Management and supervisors will set an exemplary example with good attitudes and strong commitment to safety and health in the workplace. Toward this end, Management must monitor company safety and health performance, working environment and conditions to ensure that program objectives are achieved.
7. Our safety program applies to all employees and persons affected or associated in any way by the scope of this business. Everyone’s goal must be to constantly improve safety awareness and to prevent accidents and injuries. Everyone at this Company must be involved and committed to safety. This must be a team effort. Together, we can prevent accidents and injuries. Together, we can keep each other safe and healthy in the work that provides our livelihood.
President Risk Manager
President Risk Manager
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Breathing Easy in Paint Mixing Rooms in Auto Refinishing Shops |
Auto refinishers use many potentially harmful chemicals when painting vehicles and auto parts. In particular, auto shops use solvents, isocyanates, pigments and other additives in paints and coatings that can present serious risks to your employee’s health and the environment as well. In conjunction with the Environmental Protection Agency’s (EPA) Design for the Environment (DfE) Program, the agency launched the Auto Refinish Project to provide health and safety recommendations for reducing employee injuries and illnesses in auto body shops around the U.S. This program was created partially because workers tend to overlook their safety when mixing paint and during cleanup tasks. In fact, many workers perform paint mixing and cleanup duties in small, enclosed rooms with little or no ventilation or with ventilation that works improperly. This often increases their exposure to dangerous chemicals.
However, a properly installed ventilation system will remove harmful vapors from the air and will provide a healthy working environment for employees.
TYPES OF VENTILATION SYSTEMS
General Exhaust Systems:
• Typically consist of an exhaust fan, mounted in a ceiling or wall that pulls air out of the workroom and discharges it outdoors.
• Replacement air is brought into the work area by either natural means (windows or vents) or by a more sophisticated setup that includes a separate make-up air fan, duct work and air registers that provide clean air to the work space.
• Systems are not recommended as the sole source of ventilation when hazardous vapors are present because they do not immediately remove vapors from the work space. Local Exhaust Ventilation Systems:
• Remove chemicals and other contaminants at their source.
• Systems are recommended for controlling hazardous vapors because they remove vapors before workers are exposed to them. • Systems consist of the following: a hood installed close to where the work is performed to capture vapors, ductwork to transport vapors from the hood to the outdoors and a fan located downstream of the hood to draw air away from the work area. Combination Systems: The most effective means of ventilating your paint mixing room is to use both local and general exhaust ventilation systems together. A local exhaust system installed at the work bench as close to the mixing operation as possible will capture most hazardous vapors before they can escape into the air. General ventilation systems, on the other hand, for rooms with floor level exhaust vents, will remove low-lying vapors that are not captured by the local exhaust system or are generated from other sources of vapor in the room.
Make Wise Decisions
An improperly designed system will do little to improve your current workplace conditions and will not protect your workers from hazards. For this very reason, it is important to make sure your system is designed and installed by properly trained individuals, such as a qualified ventilation contractor or an industrial hygienist. As an alternative, prefabricated paint mixing rooms are currently on the market and typically provide spill protection, explosion-proof electrical installation and general ventilation.
Design Considerations
Regardless of what type of ventilation system that you choose, keep in mind that vapors produced in paint mixing rooms are extremely flammable and can produce explosive environments. For this reason, all electrical equipment that you place or install in this room (including ventilation fans, wiring and switches) must be specifically designed and approved for use in explosive atmospheres. Ventilation equipment manufacturers should also be able to tell you what types of environments their equipment can be used in properly. Beyond that, it is wise to contact your local Fire Marshall to learn more about applicable electrical requirements. Keeping your workers safe is not only your obligation, it is the law. Visit www.epa.gov/dfe/projects/auto for more information on how you can protect your auto body workers from the occupational hazards they encounter each and every day.
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SPRAY PAINTING HAZARDS Safety Recommendations for Employers |
Spray painting in the auto body industry refers to the process by which liquid coating is converted into mist or aerosol to apply a coating onto a surface or object. Workers performing this task are at risk of several occupational dangers such as the exposure to hazardous substances contained in paints, fire, explosions, excess noise from machinery and manual handling dangers. Workers can be exposed to paint via vapor inhalation, injection and substance contact with the skin. Consequently, short- and long-term illnesses may result.
§ Hazardous Substanceso Exposure due to poor ventilation, faulty equipment, poorly designed spray zones or use in a confined space.o Short-term effects: nausea, skin irritation and rashes.o Long-term effects: occupational asthma, lung cancer and sensitization (developing an allergy to the paint).
§ Fire and Explosiono Mists containing flammable substances can ignite from heat sources such as sparks from electronic equipment or hot surfaces.o Injuries: shocks, burns, loss of consciousness and death.
§ Electricityo Worker exposure to electrical currents when undertaking wet work.o Injuries: shocks, burns, loss of consciousness and death.
§ Plant Hazardso Ventilation malfunctions and electrical shocks causing injuries.o Injuries: respiratory disease, burns and electrocution.
§ Manual Handlingo Holding heavy spray painting equipment for an extended period of time, awkward twisting or bending, moving items being sprayed and handling large paint drums can cause injuries.o Injuries: sprains, strains and fractures.§ Noiseo Noise from pumps, motors and air compressors.o Injuries: hearing loss and fatigue. To assess the potential for danger in your workplace, inspect your establishment for hazards such as solvents, two-pack paints, resins and ignition sources; determine which employees may be in danger based on their job duties and eliminate and control hazards by making the necessary changes. Use the following checklist to protect the health and safety of your employees:
ASSESSING HEALTH AND SAFETY RISKS |
YES | NO | NA |
| Carefully read the Material Safety Data Sheets (MSDS) for all substances used in your workplace. Manufacturers and suppliers must present you with this information, and you then you must pass it on to your employees. | ¨ | ¨ | ¨ |
| Keep MSDS information up-to-date. | ¨ | ¨ | ¨ |
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Conduct a preparation assessment before allowing employees to use new substances. Take the following factors into account: § The way substances can enter the body – via inhalation, injection by high pressure equipment and skin contact. § Health effects of the substance, both short- and long-term. § Other hazards related to using the substance – using flammable substances produce a risk of fire and explosion. Dust from sanding or grinding may create respiratory problems. § Exposure to hazardous substances needs to be considered during every step of the working process. § Number of employees potentially exposed to hazards. § How long and how often workers are exposed to hazards. |
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Conduct an assessment of use and work practices of hazardous substances. Take the following factors into account: § The nature of the object being sprayed – consider the size and shape of the object, ease of moving it, location of the object in relation to the painter and direction of the stream of ventilation. § The nature and effectiveness of booths used to isolate against spray hazards. § Type of ventilation used to minimize exposure to hazardous substances. § Type of spray painting – techniques vary according to the job and type of coating used. § Using personal protective equipment (PPE) – poorly chosen and improper use of PPE contribute to greater exposure to hazardous substances. Also, over-reliance on PPE without taking other necessary precautions increases the risk of hazards. |
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Conduct an assessment of your cleanup and maintenance operations. Take the following factors into account: § Labeling unused or surplus substances – when substances are moved from their original containers to other containers, they must be labeled. Labeling should include the product name and the risk and safety phrases as outlined by the MSDS. § Storage of spray painting supplies – keep only minimal supplies in the spray zone. All other supplies should be kept in a storage area. § Cleaning and maintenance operations for spray booths and equipment – spray guns must be cleaned according to the manufacturer’s recommendations. Service hoses and lines regularly as well. Assure that employees are protected during cleaning and maintenance operations. § Personal cleaning processes – Assure that employees use the appropriate cleansers when cleaning up after spray painting. Saturated cleaning rags must also be properly disposed of in lidded wet bins to minimize inhalation and fire risks. |
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| PREVENTIVE TECHNIQUES | YES | NO | NA |
| Develop emergency plans against leaks, spills and the uncontrolled release of hazardous substances. Also include fire protection plans and first aid training into your emergency preparations. | ¨ | ¨ | ¨ |
| Periodically review your health and safety techniques by ensuring that spray painting equipment (booths, exhaust ventilation, spray guns and compressors) are inspected and maintained regularly. | ¨ | ¨ | ¨ |
| Ensure that safety measures are kept up-to-date when changing the type and formulation of paint. | ¨ | ¨ | ¨ |
| Review preventive measures against hazards when work practices are modified or new practices are introduced. | ¨ | ¨ | ¨ |
| Review safety procedures after injuries, illness or near-miss accidents and make the necessary changes to avoid these in the future. | ¨ | ¨ | ¨ |
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Supplied Air Respirators: Useful Options for Auto Refinishers |
To stay healthy on the job, painters should wear a supplied-air respirator when spraying paints containing highly toxic chemicals. In fact, the Environmental Protection Agency (EPA) claims that painters should wear supplied-air respirators when spraying isocyanate-containing paints to ensure their health and safety. Although some painters complain that conventional supplied-air respirators lack comfort, visibility or convenience, newer models succeed in protecting workers and are also user-friendly.
TYPES OF RESPIRATORS
Loose-Fitting Hood Supplied-Air Respirators
• Respirators are lightweight, low maintenance (most are equipped with disposable visor covers) and offer a wide field of vision. • Painters do not need a fit test to use the hood model and can have a beard and wear glasses.
• Provide the greatest cooling effect for workers.
Tight-Fitting Full Face-Piece Respirators
• Typically provide the highest level of protection of all supplied-air respirators.
• Many designs have the breathing tube and air line attach in back, away from the work zone. This helps prevent the air line from accidentally ruining the paint job.
• Painters need a fit test for this unit and cannot have a beard or other facial hair to ensure a tight seal. Eyeglass mounts are available on most models.
Loose-Fitting Face-Piece Respirators
• Respirator has a flip-up visor, which allows the painter to get a better view of the finish without removing the unit.
• Models do not require fit testing and can accommodate eyeglasses and moderate facial hair.
• Painters must remember to lift the visor only after the ventilation system has exhausted all of the paint overspray from the spray booth.
Considerations for Supplied-Air Respirators
Shop owners must decide what type of breathing air system will work best for their facility and their supplied-air respirators. There are two common options: In-Line Air Filtration Units
• Units convert your shop’s existing high-pressure compressed air to clean, breathable air. • Use replaceable filters to remove contaminants from the compressed air stream.
• To meet the Occupational Health and Safety Administration (OSHA) requirements for breathing air, the filtration units should be equipped with a carbon monoxide monitor.
• Filters need periodic changes, which increase their cost over time.
• Some systems come equipped with air-conditioned or heated air features. Low-Pressure Ambient Air Pumps• Differ from air filtration units in that they are electronically driven, oil-free compressors and are usually placed in locations with fresh air away from work areas.
• Typically do not require filters (other than a small inlet filter) or high-temperature alarms, if installed in a contaminant-free area.
• System can be used when the shop’s air compressor lacks the capability to feed equipment and respirators.
OSHA Requirements
OSHA’s Respiratory Protection Standard (29 CFR 1910.134) requires that employers select only National Institute of Occupational Safety and Health (NIOSH)-certified respirators. This OSHA standard further states that employers may not modify the respirator system or change and mix components. To meet NIOSH certification, all respirator systems must be complete and properly assembled. For more information on supplied-air respirators, contact NIOSH at 1-800-35-NIOSH, visit www.cdc.gov/niosh or contact the OSHA office in your area via www.osha.gov.
Garage Keepers Liability Coverage Companies in the business of storing customer vehicles need to be protected. Picture this scenario: you are a tow truck driver who is called to tow a car in the middle of the night. Since the mechanic’s garage is closed at this time, you must store the car in your shop for the night. A few hours later, someone breaks into your shop and vandalizes the customer’s vehicle. Garage Keepers Liability coverage is designed to offer protection for business owners who offer towing services or operate service stations, similar to the scenario described above. This coverage protects customer vehicles while they are kept at the business location for parking, storage or to perform maintenance or services in the event of fire, theft, vandalism, explosion or lightning. There are two types of Garage Keepers Liability coverage that are available:1. Direct Primary Coverage – Coverage for a business, even if the loss is not the business’s fault nor are they legally liable.2. Excess Coverage – Additional coverage over the limit of coverage that the vehicle owner/customer has from his/her own insurance company. This will automatically pay if the customer does not have Automobile Insurance.
Garage Keepers Liability Coverage is Designed for:
• Automotive and motorcycle dealers
• Service stations
• Restaurants, hotels and special event operations with valet parking
• Private parking lots and structures and airport parking lots
• Car washes
• Other businesses that accept custody or control of vehicles belonging to others for a fee
Limits and Deductibles
• Determine coverage limits by considering the average value of vehicles in your care multiplied by the average number of vehicles in your care at any given time. For instance, if the average value of your customers’ vehicles is $30,000 and you tend to have 10 vehicles on hand, then you should select a limit of $300,000.
• You must select a per-vehicle deductible (generally $500) that is to be paid by you in case of a damaging incident. Then, the insurer covers the remaining amount, up to your limits. Exclusions
• Contractual obligations
• Theft by the insured
• Defective parts or faulty work
• Loss to sound reproducing equipment, unless it is permanently installed
• Loss of CDs and tapes
• Loss to sound receiving equipment (CBs, mobile radios and telephones), unless it is installed in the dash or console
• Radar detection equipment We understand that unfavorable incidents can occur. Garage Keepers Insurance assures that you are adequately protected. Contact us today for more details.
Spray Painting Safety in the Body Shop
Spray painting is a great way to protect and enhance parts, products and vehicles. Plus, this technique allows you to cover large areas with even coats of primer, paint, sealers and other coatings. Despite this, you must recognize and guard against potential hazards while doing spray painting tasks on the job. Why is protection necessary? Many paints, coatings, catalysts, sealers, hardeners and solvents contain hazardous chemicals that you can become exposed to during mixing, spraying, grinding and sanding tasks. In addition, surface preparation jobs and many cleanup tasks can pose dangers if you do not handle them properly. Since you can inhale chemical vapors when spraying, absorb chemicals in your skin or inject chemicals with high pressure spray painting equipment, you must be fully aware of what you are doing to avoid unnecessary exposure. It is also wise to look out for symptoms of overexposure, including: nausea, rash, asthma, lung cancer and sensitization (becoming allergic to the paint). Before beginning a new task, consult the Material Safety Data Sheets (MSDS) for the products used and wear the appropriate personal protective equipment (PPE) to protect against hazards.
Protection Recommendations:
· Use a spray booth to guard against spray paint vapors and debris within your breathing zone. Since many coatings contain flammable substances that are aerosolized when sprayed with powered equipment, these vapors can build up and create an explosion danger. A spray booth can provide maximum protection against these hazards, if it is regularly maintained and cleaned.
· Wear hearing protection when working with air powered tools. Also wear safety glasses and a dust mask or respirator to protect against dust particles that form when using grinding and sanding equipment.
· Since you may have to hold full paint pots while spraying, you must keep ergonomics in mind while on the job. Use balanced spray guns that fit in your hand or use a hoist and dolly to move materials instead of holding them. This will reduce your risk of accidents and injuries. Also, take frequent, short breaks throughout the workday to stretch to avoid unnecessary strains and sprains. Keeping safety in mind when working in and around spray painting operations will help you avoid dangerous hazards and keep you injury-free on the job.
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Safety and health tips for your work and life—brought to you by the insurance and safety specialists.
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Selecting appropriate gloves in the auto body shop
Wearing the appropriate gloves can keep you protected against chemicals in paints that can pass through your skin and enter your body. Some of these chemicals can cause dangerous health problems, even if your exposure is only in small amounts. To protect yourself, it is important that you wear chemical-protective gloves every time you handle paint materials, especially during mixing, spraying and gun cleaning. In addition to protective gloves, you should also wear chemical-resistant clothing, eye protection and an appropriate respirator.
Solvent Dangers
Above all, the gloves you wear must provide a protective barrier between your skin and the toxic chemicals in the paints you use. Of primary concern are solvents, which typically have the fastest glove pass-through and pose serious health concerns. Solvents can damage your skin, consequently allowing dangerous poisons into your body. These chemicals can then cause allergic reactions to your skin and internal organs. However, gloves that protect against solvent exposure provide the necessary barrier that you need to remain safe.
Time Matters!In an auto body shop, you are exposed to many chemicals that pass through gloves at varying rates. The right glove must protect you from chemicals that penetrate your gloves the fastest. |
Selecting Gloves
All gloves do not provide the same level of protection. For instance, latex gloves offer little or no protection because they can rapidly degrade after being exposed to many chemicals found in paint materials. Nitrile gloves, on the other hand, provide a barrier against paints and organic solvents. These gloves are durable and are very cost-effective. However, nitrile gloves should not be used when working with methyl ethyl ketone (MEK), a chemical found in certain strong solvents and clean-up materials. These gloves should not be used when the gloves will be immersed in MEK products for longer than a few minutes. Instead, wear butyl rubber gloves, which provide a stronger barrier against MEK and similar chemicals.
Changing Your Gloves
It is important that you change your gloves often to remain thoroughly protected. When to change your gloves depends on the type, thickness and condition of use. Before any task, carefully inspect your gloves for cuts, tears or punctures. If you notice any of these signs of wear, change them immediately before starting a new task.Remembering these tips will keep your hands and the rest of your body protected against chemical dangers in the body shop!
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Safety and health tips for your work and life—brought to you by the insurance and safety specialists.
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Best practices for the auto body paint mixing room
In the body shop, the paint mixing room is a more dangerous place than you might expect because of all the toxic chemicals in the paints you are using. To avoid injuries and illnesses on the job, practice the following safety precautions. Put a Lid On It!
Get Automatic!When cleaning, use an automatic gun cleaner that will improve your health and safety. These devices will help get the most mileage out of your cleaning solvent, reduce waste and minimize your contact with hazardous solvents. |
Not only is an open container of paint or solvent a waste of money, it also contaminates the air. By putting a lid on it, you will keep harmful vapors out of the clean air that you and your coworkers breathe in. You will also save materials by not allowing expensive paints and coatings to evaporate or to become contaminated by air exposure.
Wear a Respirator
Vapor-generating materials and equipment permeate most paint mixing rooms. Despite this, wearing a respirator will decrease the amount of harmful vapors you breathe in from paints and solvents. When working in the mixing room, always wear an air-purifying respirator with an organic vapor cartridge. Some other things to consider:
· Make sure the respirator forms a tight seal on your face. You should also be clean-shaven where the mask touches your face for optimal protection.
· Change the cartridge on a regular basis, as outlined by the manufacturer.
Cover Up!
Your skin and eyes also need protection from hazardous paint materials. Many chemicals in coatings and solvents are not only strong irritants, they can also pass through your skin and can damage your internal organs. To avoid unnecessary problems, be aware of the variety of chemicals that you use in the mixing room and wear chemical-resistant gloves and a paint suit that offers adequate protection. Some other things to consider:· Wear nitrile or butyl rubber gloves (not latex) to protect your skin from chemicals. · Always follow the manufacturer’s recommendations regarding when to change your gloves to ensure that you are receiving optimal protection against chemicals. Also, if you notice a tear or puncture in your gloves, discard them right away.· Wear a full face-piece respirator to protect your eyes. If you are wearing a half-mask respirator, goggles or a face shield will provide adequate eye protection as well.
Reduce WasteShops that reduce waste do something good for the environment and their revenue. Therefore, mix only the amount of paints and coatings that you need. Also, store and reuse left-over primers and basecoats to avoid unnecessary waste .