Document 851gxOvYkKmxamG4JznjvV4j5

"iSS^NTlON MANUAL for Industrial Operations edition NATIONAL SAFETY COUNCIL Chicago, Illinois 60611 (\SC(o\ SCIENCE & INDUSTRY COPYRIGHT 1964 NATIONAL SAFETY COUNCIL All Rights Reserved No portion of this book may be reproduced by any pro cess without written permission of the National Safety Council, 425 North Michigan Avenue, Chicago, 111. 60611 Library of Congress Catalog Card Number: 64-24124 25M106463 Printed In U.S.A. Stock No. 121.35 CONTENTS For detailed contents of any chapter, consult the title page of that chapter. Chapter The Industrial Safety Movement.............................................................................................1 Safety Organization and Safety Inspection............................................................................. 2 Safety Committees......................................................................................................................3 Removing the Hazard From the Job....................................................................................... 4 Human Behavior and Industrial Safety.................................................................................. 5 Safety Training........................................................................................................................... 6 Maintaining Interest in Safety................................................................................................. 7 Publicizing Safety......................................................................................................................8 Accident Records and Injury Rates....................................................................................... 9 Accident Investigation, Analysis, and Costs............................................................................10 Workmen's Compensation Insurance......................................................................................11 Sources of Help for the Safety Man......................................................................................12 Audio-Visual Aids.................................................................................................................... 13 Industrial Buildings and Plant Layout......................................................................................14 Building Construction and Maintenance.................................................................................15 Boilers and Unfired Pressure Vessels......................................................................................16 Manual Handling and Storage of Materials............................................................................17 Hoisting Apparatus and Conveyors...................................................................... Elevators and Plant Railways................................... 18 19 Power Trucks.........................................................................................................................20 Ropes, Chains, and Slings..........................................................................................................21 Principles of Guarding and Transmission Guards................................................................. 22 Cold Forming of Metals..........................................................................................................23 Machine Tools . .................................................................................................................... 24 Woodworking Machinery..........................................................................................................25 Cuarding Equipment in Selected Industries............................................................................26 Hot Working of Metals..........................................................................................................27 Local Exhaust Systems, General and Comfort Ventilation.................................................. 28 Welding and Cutting . .......................................................................................................... 29 Hand and Portable Power Tools...........................................................................................30 Electrical Hazards....................................................................................................................31 Flammable and Combustible Liquids..................................................................................... 32 Fire Protection......................................................................................................................... 33 Fire Extinguishment and Control...........................................................................................34 Emergency Action Plans..........................................................................................................35 Personal Protective Equipment................................................................................................36 Industrial Sanitation and Personnel Facilities...................................................................... 37 Occupational Health Services................................................................................................38 Industrial Hygiene....................................................................................................................39 Elements of Industrial Toxicology.......................................................................................... 40 Table of Chemical Hazards.....................................................................................................41 Ionizing Radiation.................................................................................................................... 42 Industrial Noise......................................................................................................................... 43 Motorized Equipment...............................................................................................................44 Safety Engineering Tables....................................................................................................45 Alphabetical Index v INDUSTRIAL HYGIENE Free silica is uncombined silicon dioxide (SiO.). Silicates contain silicon and oxy gen combined with other elements in more complex molecules. The SiOt reported in chemical analyses for mineral and geological reports is the total of the silicon dioxide present, both the free silica (if present), and the silica combined in the mineral. Such analyses are not reliable indications of the silicosis potential of the material, because it is the uncombined or free silica that is most important in industrial dust exposure. So that an exposure can be properly evaluated, the percentage of uncombined silica must be determined by petrographic analysis using a polarizing microscope or, preferably, by X-ray diffraction analyses and special ana lytical chemical procedures. There has been some experimental evi dence that some dusts may tend to inhibit the action of silica on the body, but this in hibiting action is so slight and uncertain that it must be discounted in practice. In fact, there is also evidence that the nonsiliceous components of a dust mixture containing free silica may provoke a disabling condition more severe than that caused by the silica acting alone. With the exception of asbestos and some talcs, the silicate dusts do not ordinarily cause a serious disabling lung condition such as Is produced by free silica. Much higher levels of silicate dusts than of free silica dust can be tolerated. In many industries, men have worked with silicate dusts that con tainer! no free silica without development of disability or of nodulation in the lungs. The X-ray may show shadows indicating dust deposits in the lungs, but the pneumoconiosis is essentially harmless. However, partially disabling pneumoconioses have been reported where men have worked for long periods of time in very high concentrations of certain silicate dusts. Disabling pneumoconioses from exposure to abnormally high concen trations of mica, tremolite talc, and kaolin dusts have been described in the literature. The clinical signs are not the same for these silicate dusts as for free silica, but the symp toms can be marked. The fine airborne fibers of asbestos can pass through the upper respiratory tract to the lower parts of the lungs to cause irrita tion and to form "asbestos bodies" where the fibers are encapsulated. This diffuse fibrosis probably begins as a "collar" about the terminal bronchioles. There is evidence that other minerals having a fibrous charac ter (except glass fiber) can produce a reac tion similar to that of asbestos. Following a study by the U.S. Public Health Service of the asbestos textile indus try,* it was recommended that the dust con centration be kept at less than 5 mppcf to prevent asbestosis. Evaluation of an expo sure to asbestos dust is based on the total amount of dust, since the concentration of infurious fibers will be kept within safe limits if the fine dust is kept below the suggested threshold limit. Miscellaneous pneumoconioses. Even though a dust is classified as harmless, amounts above the TLV can lead to trouble by causing a pneumoconiosis, mechanically instating the walls of the respiratory system, or interfering with ordinary lung processes. Mica dust and kaolin dust are two good ex amples of dusts that ordinarily are consid ered benign but amounts above the TLV can cause a troublesome pneumoconiosis. Mica pneumoconiosis has been observed in grind ing operations where mica dust, but no free silica was present. There were marked changes in the X-ray pictures of the lungs and some disability. The cases occurred where the dust exposures were massive over many years. / Toxic dusts and fumes jI Systemic reactions are caused by toxic dusts and fumes of various elements and their compounds and by certain organic com pounds. All metallic fumes arc irritating, - ; ; pecially when freshly generated. Industrially j important metals and their compounds that can have a toxic effect when the dust or .> fumes are inhaled include arsenic, antimony, jii: cadmium, chromium, lead, manganese, mer- cury, selenium, tellurium, thallium, uranium, 'jf and a few others. V| \ Asbestosis. Several minerals having a ) fibrous character are classed as "asbestos"-- J hydrated silicates of magnesium with vari] able amounts of iron, calcium, sodium, potasI sium, and aluminum present as impurities. 39-8 *U.S. 'Public health Service, Washington, D.C. "A Study of Asbestosis in the Asbestos i-. Textile Industry." Bulletin No. 241. 1938. fi f - I v| Industrial chemicals: th e ir source and th e ir effect upon the body. Courtesy "A ir Engineering" Megezine ELEMENTS OF INDUSTRIAL TOXICOLOGY TABLE 40-B. THRESHOLD LIMIT VALUES FOR 1963 (Continued) Minehal, Dusts, Tentative Values, and Appendix A Mineral Dusts Substance mppcfl SILICA Crystalline Quartz, Threshold Limit coleu- ,,,, 250 loted from the formula................ %Siot +5 Cristobolite " Amorphous, including natural diatomaceous earth................... 20 SILICATKS (less than 1% crystalline silica) iMh-Asbestos..................................... v* Mica ........................................... Soapstone................................... Tale............................................. Portland Cement....................... 5 20 20 20 50 Miscellaneous (less than 1 % crystalline silica) ....................... 50 Conversion factors mppcf X 35,3 = million particles per cubic meter = particles per c.c. Tentative Values Substance ppm* C tert. Butyl chromate (as CrO>--Skin ... Calcium oxide ....... Camphor....................... Copper Fume............... Dusts & Mists ...... DDVP (0,0-Dlmethyl- 2.2-dlch lorovlnyl phosphate) ........... -- -- -- -- -- -- mg/cu m** O.t 5 2 0.1 1.0 1 Tentative Values Substance ppm* Demeton (R) (Systox) -- Endrin (1,2,3,4,10, 10,-hexachloro-o, 7-epoxy-l ,4,4a, 5,6,7,8,8a-octa hydro l,4-endo-5, 8-dimethanonap- thalene--Skin .... -- Epichlorhydrin........... 5 Ethanolamine........... 3 Graphite................... -- Hafnium................... -- Heptachlar (1,4,5,6, 7,8,8o-h#ptoehloro- 3a, 4,7,7a-tetra- hydro-4,7-meth- anoindene).......... -- Methylamine .......... 25 Methyl Methacrylate 100 Methylene bis pheny- 1 isocyanate......... 0.02 Mineral Wool (Fiberglas)........... -- Napthalene.............. Oil (mineral) to B-Propioloctone .... Silver......................... Tantalum ................. 1,1,1,2,-Tetrachloro2,2,-difluoroathane 1000 1,1,2,2-Te trochloro1,2-difluoroethane 500 Tetraethyl lead--Skin Tin (Inorganic compounds) ... (organic compounds as Sr>--Skin........... mg/cu m** 0.1 0.1 19 6 15 mppcf 0.5 0.5 31 410 0.2 2 50 5 A-5 0.05 5 8340 4170 0.075 0.1 Nave: The word "Skfn'* following a substance Indicate* that the aubetenee can penetrate the skin to contribute to the exposure and TLV should be reduced accordingly. Parts of vapor or gas per million parts of air by volume at 26 C and 760 mm Hg pressure, Approximate mg of particulate per eu m of air. 9Millions of particles per eu ft of air. baaed on impinger samples counted by Hght-SeM technics. JThe percentage of crystalline silica in the formula is the amount determined from airborne samples, except in those Instances In which other methods have besn shown to bt applicable. A numbers, ace epeclfle number in Appendix A. O substances, sea Appendix C. Appendix A A-1 Benzidine. Because of high Incidence of btodder tumors in man, any exposure. Including skin, Is extremely hazardous. A-2 p-Naphtbyiamlne. Because of the ex tremely high incidence of bladder tu mors In workers handling this compound, and tha Inability to control exposures. 0-naphthylamlne has been prohibited from manufacture, use and other activi ties that Involve human contact by the State of Pennsylvania. A-9 N-NMresodlmefhylamlite. Because of ex tremely high toxicity and presumed car cinogenic potential of this compound. contact by any route should not be per mitted. i-4 Teflen decomposition products. At least one Identified component of Teflon de composition products is extrsmely toxic, but in the absence of more complete toxicity information and suitable analy tic methods, a definite threshold limit value Is not recommended at this time: but air concentrations should be minimal. k-5 p-Preplolactone. Because of high acute toxicity and demonstrated skin tumor production In animals, contact by any route should be avoided. 40-8 ELEMENTS OF INDUSTRIAL TOXICOLOGY TABLE 40-B. THRESHOLD L IM IT VALUES FOR 1963 ei i iof u .1 s:i 8 g I 3-a 8 i\2 8 3jss-af-jasl id J* .2525 Ills'll R|*|os's S-tJ-l S|*(5f o|`Sjg sl-lUl '?1'S ^"llfSl-Sill'! I js a>'ft'<3 s `a * 8 * -I s tj2o 22 mm aH 0> 0 s| > &bpOO= 'OV oZis -uC8 OB >11 j l| l|Sy|a=.s| ;**!jou-a dmI>3 fill*2 3 Rg o S s8 SU iS'?S<*0<) <** ii sail E 8 *O 3-8 ** S ss a ?Jfi *S.-Sa l, legIS.. -`SSl^!w8lSs5-s^aUiJ.ls>a 8S| -8S 1||.<j <s9 gd -3<^u o pi .Sc .gi gi .so M _ O M .sljI'jJIt il^oStfl-S88 gSg Bl-J-f.fi JS*a Sj-a gfi *f a || |>Ilb S00o-Oa 52? 8 2*3S *>< *3 #> S a s S 'S`8.|'S. * js ? E P-4 * U9 W 45 f 5 5-sS-JaoS c 3 ei-s^-s 8 8*1 ts S ,, O *J U3 S'5 3 i jjlJ^ I .Tws'!ilrl 8 g g 15 y-9 S SO |MIlfair'flsl Qt v O 3 cu JS S 8 **3'S f-oi f 2 oH.S "illlilll^lll! I'i i% iil AWAJ ii 1 S| iltl SJJ| biS-'s<"iS*s3.->3 sf-*a * 3S s3 *= jao - ' ^ ~n r. * ' m-i 'O JS 3*339 _H * _ u -g s s'* * il g J g|ij|ii&!i 8"*p8rp"l'S^ J21g-1a P5 J'i-lf i8-2S 8=2a .>a3>*52- 'i3s a5a 33 Su3 'x-SSPsc3.SB0 .Ba2 i f T*- ELEMENTS OF INDUSTRIAL TOXICOLOGY TABLE 40-C. MAXIMAL ACCEPTABLE CONCENTRATIONS Meaning4 It is generally recognized that there are levels of concentration of atmospheric contaminants to which a person may be exposed without known ill effects or dis comfort. Since it is not practical to main tain completely uncontaminnted air in most industrial situations, it is necessary to establish maximal acceptable concen trations of atmospheric contaminants en countered in industrial operations. These concentrations in themselves do not rep resent a scale of relative toxicity; they represent the concentrations of contami nants below which ill effects are unlikely to be experienced by any but hypersusceptible individuals. These concentrations are usually based upon data obtained by one or more of the following procedures: (1) Laboratory tests on animals (2) Laboratory tests using human sub jects (3) Environmental and medical investi gations in plants. A common feature of these procedures is that the experimental exposure shall correspond to the normal work pattern. This would be taken into consideration also in the application of maximal accept able concentration vnlues. Three criteria have governed the es tablishment of these concentrations: (1) Organic or other tissue changes (2) Functional reactions that have no discernible untoward effects on health but cause impairments, such as in-coordinations and increased proneness to accidents (3) Discomfort or adverse sensory effects. In those cases in which the concen trations have been established on the bads of organic changes, it is logical to assume that repeated exposure to con centrations significantly in excess of the acceptable concentration probably would proauce injury. When the level has been established on the basis of a functional change or discomfort, it is logical to as sume1 that exposure to concentrations not greatly exceeding the acceptable concen tration would not produce materially in jurious effects. Hence it is important to understand the criteria upon which any such maximal acceptable concentration hns been established. Though the purpose of the acceptable concentration is to minimize health haz ards, its immediate use is for guidance in establishing engineering procedures to prevent objectionable concentrations of toxic or noxious materials from being present in the air of work places. Com parison of the results of air analyses with maximal acceptable concentrations indi cates acceptable conditions or otherwise the need, extent, and urgency of control measures. Sampling and analysis should be performed by competent personnel using an acceptable method that will pro vide a reliable measure of actual expo sure. Air analyses in conjunction with ac ceptable concentrations of such atmos pheric contaminants as are encountered in industrial operations serve as a mea sure of exposure, but not as a means of diagnosis of occupational disease. Diag nosis should be based on a consideration of all factors, including results from clinical and physical examination, as well as from air analyses, from means of as sessing amounts of materials in the body, and a knowledge of toxicological effects of the materials under consideration. In the application of the standards, it should be kept in mind that: (1) The acceptable concentrations serve as standards for good industrial hy giene practice. (2) They serve as engineering guides. Design and operation should aim at maintaining aft concentrations below the acceptable maximum. (3) They should be applied and inter preted by competent individuals with a full understanding of the basis and limitations of the informa tion from which the standard has been developed. (4) It is advised that these standards are considered to be guides townrd good industrial hygiene and are not in tended as legal requirements. (5) The levels are applicable only for exposure to a single substance. In the case of exposure to mixtures, the effect may be increased or decreased, and controls should be based on the specific situation. From American Standard Z37.Z3-1S62. 40-13 ELEMENTS OF INDUSTRIAL TOXICOLOGY in the handling of wet dross from a light metals plant, in the cleaning of tank cars which have held sulfuric and hydrochloric acids, in the cleaning of pipes with an acid contaminated with arsenic, in the precipita tion of cadmium with metallic zinc, and in other operations. Arsine rapidly destroys the red cells. After it has been inhaled, the first signs are those of lack of oxygen. After some time the body begins to excrete the damaged red cells, which appear as a dark or bloody urine. The kidneys may then become too clogged to operate at all. Arsine, in very small amounts, is also capable of producing a chronic type of poisoning, but it is more typically a source of acute episodes. The possibility of arsine formation should always be considered when there is freshly formed hydrogen around ores of the heavy metals, since arsenic is widely distributed in small amounts and only a trace of it is re quired to produce enough arsine to be trou blesome. One of the more common sources of arsine incidents in recent years has been the han dling of dross from the aluminum refining of metals. Probably the most significant ob servation about these cases, aside from die fact that the moisture in the-atmosphere is enough to form arsine, is the fact -that the people involved in them have not been aware of the garlic-like odor which is supposed to be a warning of the presence of arsine. See Hygienic Guide. Asbestos is a hydrated magnesium silicate found in die minerals chrysotile, amianthus, actinolite, and tremolite. Practically all the commercial asbestos is either chrysotile or amianthus, and about 90 per cent of that used in this country is chrysotile. It Is used almost exclusively for beat insulation or for textiles which must resist high temperature, such as heat-resistant clothing and brake linings. Inhalation of excessive quantities of as bestos fiber can produce a fibrosis in the lungs similar to that found in silicosis but somewhat milder and usually not so rapidly progressive. Like silicosis, the condition de velops and advances slowly and is equally resistant to treatment. There is also good evidence that inhaled asbestos causes lung cancer. See Hygienic Guide. Barium, in the form of its soluble salts, is toxic on both ingestion and inhalation and highly caustic when applied to the skin. The carbonate and sulfide are suiRciendy soluble to be toxic, although not very caustic. The sulfate, which is used as a contrast medium in X-ray work, is too insoluble to show any toxicity, and soluble sulfates are specific antidotes for ingested barium salts. Since these salts produce violent stimula tion of all muscle, upon ingestion they pro duce severe disturbances of the digestive system. After absorption, the barium salts increase blood pressure by constriction of the arterial muscle, slow down heart beat by an action similar to that of digitalis, and first excite and then paralyze the central nervous system. In spite of the high inher ent toxicity, there are few cases of indus trial poisoning with barium. Barium is a heavy metal, and the dust of the insoluble salts will -collect in the lungs and give rise to the condition known as baritosis. Its nodular appearance on X-ray film may be mistaken for that of silicosis. Men showing the sign of baritosis are apparendy not disabled or inconvenienced in any way. See Hygienic Guide. Benzene (benzol) is a colorless, flamma ble/ volatile liquid with a rather pleasant aromatic odor. Its fire hazard is between ethyl alcohol and ethyl ether. The greatest hazard is that of chronic poisoning by in halation of comparatively small amounts over a long period of time. It is one of the two or three most dangerous organic sol vents in commercial use, and acts primarily on the blood-forming organs, producing se vere anemia, bleeding under the skin, and great reduction in the ability of the blood to clot. The most convenient measurement of damage is given by a blood count. PcopU who may be exposed to benzene vapor should have blood counts at regular into* vals and significant changes in the count should be closely investigated. j Headaches, dizziness, fatigue, loss of ap petite, irritability, nervousness, nosebleed, and other signs of abnormalities of tbs blood may or may not be present in chronic poisoning. A single heavy exposure to benzene vapor may produce a serious acute effect, similar 40-18 mm