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FILE NAME: National Safety Council (NSC) DATE: 1951 Aug DOC#: NSC119 DOCUMENT DESCRIPTION: NSC - Accident Prevention Manual for Industrial Operations i / A DENT PREVENTION MANUAL for INDUSTRIAL OPERATIONS This book was written by the staff o f the National Safety Council, with the close collaboration o f the Industrial Conference of the Council, particularly of its Manual Committee, under the chairmanship of William S. Smith, Director of Safety, Ford Motor Company. Appreciation is due the many consultants, especially the Executive Committees of the Council's Industrial Sections, who reviewed material perti nent to their own fields and whose advice contributed so much to the authority of the final result. E N G I N E E R S of the Industrial Department of the Council prepared the major portion of the book. G. G. Grieve wrote Section 1, permanent structure and plant LAYOUT; Robert L. Moore and George MacDonald Section 2, maintenance. Mr. MacDonald also wrote Section 15, electrical hazards. William N. Davis prepared the three Sections, boilers, pressure vessels and refrigerating equipment; Arthur S. Kelly Sections 6 to 10, inclusive, on guarding machinery. Lester W. Dutton wrote Sections 11 and 12 on materials handling; A. M. Baltzer, Section 13, hand and portable power tools. Floyd E. Frazier and Mr. Davis collaborated in the preparation of Section 14 on welding. Glenn F. Griffin and Mr. Frazier worked to gether on SAFETY ORGANIZATION AND TRAINING, Section 24. Roy G. Benson is the author of the three sections on flammable liquids and fire, and of Section 26, the safety man's resources. E. P. Marconi prepared Section 19, personal protective equipment; Floyd A. Van Atta Sections 21 through 23, industrial poisons, medical services, and industrial health engineering. H. Gene Miller, Director of the Statistical Division, is the author of the section on accident records; The Motor Transportation Bureau pre pared Section 20, motor transportation. Mrs. Mildred Grant of the National Safety Council Library did the alphabetical index. Kent W. Francis, Editor, Industrial Department, supervised the or ganizing, editing and production of the book. He was assisted by Mrs. Russell Perry, Editor, and by Elizabeth Valovic, Administrative Assistant. Ill COPYRIGHT NATIONAL SAFETY COUNCIL, INC. 1951 ALL RIGHTS RESERVED This book may not be repro duced in part or in whole with out written permission of the N ation al Safety Council, 425 N orth M ichigan Avenue, Chi cago 11, Illinois. PRINTED IN THE UNITED STATES OF AMERICA 18M851 IV r ACCIDENT w. PREVENTION Ma n u a I SECOND EDITION ------ F O R INDUSTRIAL O P E R AT I O N S g - 1 3 ' /p o I-------------- : ACCIDENT : 1 PREVENTION M A N U A L , Second Edition, is another step in the National Safety Council's program for the development of technical material, a program which is continuous. Council staff and members have need, there fore, to keep abreast of new materials, new equipment, and new processes, and of haz ards which may be involved in them. In order that the eventual third edition may, at the time of its publication, represent the best in the field of safety engineering knowledge, comments and suggestions are requested of readers. II Substance antimony (salts) arsenic arsine asbestos barium (compounds) benzene (benzol) beryllium bromine TABLE OF CHEMICAL HAZARDS-- Continued Flash point F. Explosive limits % by volume Auto ignition temperature F. Probable safe concentration for 8-hr. exposure Usual mode of entrance to body Signs and symptoms of poisoning Lower Upper metal and sulfides flammable ... ... ... ... nonflammable peroxide, chlorate, and nitrate produce violent combustion in flammable materials 12 1.5 8 1000 .................. 0.1 mg/cu.m." inhalation of dust, ingestion Acute: vomiting, colic, diarrhea, irritation of mouth and throat. Chronic: indigestion, loss of weight and appetite, so m e tim e s severe dermatitis. 0.15 mg/cu.m.4 inhalation of Irritation of skin, loss of hair and dust, ingestion nails, perforation of nasal septum, and direct action hoarse voice, cough, n e u r a l g ic on skin and pains, diarrhea. mucous membrane 1 p.p.m.3 0.05 p.p.m." inhalation Headache, nausea, vomiting, chills and shivering, jaundice, dark or bloody urine. 5 million particles per cubic foot7 inhalation Chronic: shortness of breath, as bestos corns. 0.5 mg/cu.m." inhalation or ingestion of soluble salts, direct action on skin Severe dermatitis from the caustic salts, vomiting, dyspnea, abdominal pain, cyanosis, paralysis. 100 p.p.m.8 50 p.p.m." inhalation Chronic: weakness, fatigue, bleed ing from the gums and nose, head ache, dizziness. Acute: inebriation, convulsions, and loss of consciousness. 2 micrograms/cu.m.38 inhalation 1 p.p.m.8 inhalation direct attack on skin and mu cous membranes Irritation of eyes and respiratory tract, irritation and corrosion of skin, probable lung irritation in acute cases. 23-29 TABLE OF C H E M IC A L H A Z A R D S 21-16 INDUSTRIAL HEALTH ENGINEERING TABLE 2 1-F CONVEYING VELOCITIES FOR INDUSTRIAL DUSTS DUST VELOCITIES--T E ST RECOMMENDED TRANSPORT VELOCITIES Description Method of Production Median Dens- Size ity in. Bounce Roll Clean Bull.2 Alden1 217 Brandt' Table Table K 11 Withe- Auth. ridge4 Results Aluminum chips Asbestos Casein Catalin Foundry, nonferrous Foundry, ferrous Grain Lead oxide Lea ther--shavings Leather-- sanding Limestone, coarse Limestone, fine Litho powder Litho bronze Metal (alum. & bronze) Rosin Rubber Starch Steel shot blasting Steel shot blasting Vinyl Wood flour Wood hog dust Wood sawdust, heavy Wood sawdust, light Wood shavings, hard wood Wood shavings, soft wood Wood composition, chips Grinding Saw Lathe & sanding Lathe & sanding Wheelabrator Tumblers Blast cabinet Mixer Edge trimmer Sanding Drilling Drilling Grinding Hog Grinding Blast cabinet Blast cabinet Grinding Sanding Hog Tumbling barrel Table saw Planer Matcher Hog 2.72 .0132 2.20 .0138 1.27 .0070 3.02 .0046 2.52 .0092 1.41 8.26 .00058 1.34 .054 1.32 .021 2.83 .0057 2.78 .0028 1.94 .0048 4.44 .0082 6.34 .0039 .020 1.14 .060 1.27 .0025 6.85 .0038 4.61 .0172 1.82 .0064 .012 .023 .055 1.18 0.54 3800 1800 1370 1820 2800 1570 2500 1880 1330 2410 1420 610 1570 2730 3900 2000 1300 2500 1500 2020 1560 3750 2950 2400 2150 1590 3900 3000 1560 1210 1250 2340 1430 2400 1640 1270 1750 1420 1350 2600 3900 1390 2420 1320 1880 1390 3300 2220 1730 2000 1450 3050 2200 1500 1270 1610 1650 1300 1950 3050 2380 1120 1530 1720 1270 16 20 1560 1890 1800 2300 1900 2180 1390 1390 1900 1620 2000 1770 1550 1560 4000 3000 3000 3500 3500 2000 3000 3000 4000 2000 3000 2000 3500 3500 3000 1500 3500 3000 2000 3000 3000 3500 2200 2000 2000 2000 3000 3000 (3500 5000 4000 4000 5000 5000 3000 4000 4000 )35 4500 4500 3500 3500 3500 3500 3500 4000 3000 4000 4000 4000 3000 4000 4000 4500 3000 3500 (3500 (4000 2000 3000 3000 3500 3500 3000 2000 2000 3500 3000 2000 3500 3500 4000 2000 16OO 2000 3100 1800 2800 3400 2700 1500 2700 1600 1400 1800 3100 4000 2200 2600 2800 2400 2300 1800 4000 3300 2700 2400 1800 4000 R e sig n of Industrial Exhaust Systems, John L. Alden, Industrial Press, 1939-The Determination and Control of Industrial Dust; Public Health Bull. 217, J. J. Bloomfield & J. M. D allaValle, 1938. Industrial Health Engineering, Allen D. Brandt, John Wiley & Sons, Inc., 1947. lAir Sanitation and Industrial Ventilation, W. N. Witheridge, 1945. ( re oo ta o-* pi Bre n Si 51 PS O3 3O 5' i O' S' S* o 43 3 3p ? a - _ P p. a15*^3 S. ?H >*5d *O' pK <P OHr% 9 5 3 D B"2 f8t .8 -S ' n . f? n o fnt Sp-* hO* cOa *. *ft 2 a 3--<Be. ron>r!e C 1 ftr -- 5a-oQ-.cg. Jo h * cr re g ^ re ^ g SP * S ^ sre-ss.-eo. g-s o-* aft cftr 9 P P- >-- ~3 . Sf aft. &e (A ' /~~*tiline re4 per . insoluonged off ' acid di burns. ever, one move the he off the y shower. ically rethe gross in be rehol when of aniline in contact d to fresh ulant such and kept put under r observaptoms ocs stopped, plied, it the acto be so e without --- . of the and the :xcept for gn is usu- liline is to i, and the much as /orkrooms Personal mention of sort. othing on :ly change with anipart of. a .use severe ilts, severe in contact an aniline s are irrinembranes ion on the : and lead, causing a ting, colic, trhea is BENZENE 22-7 much more common. Effects of antimony resemble those of arsenic primarily in the dermatitis, which may start as an inflamma tion of the hair f o l l i c l e s and progress through pus formation and sloughing to leave a contracted scar. Arsenic, in the form of arsenic trioxide, is traditionally the most important of the poi sonous materials used for criminal purposes. It is a profoundly irritating material which produces inflammation of the stomach and intestines, destroys the hemoglobin, and causes nervous collapse. However, cases of severe industrial poisoning are rare. Men. who handle the solid compounds of arsenic may suffer from a husky voice and cough, perforation of the nasal septum, ulceration of the skin, loss of hair and nails, warts and sometimes skin cancers which tend to follow a slow and not very malig nant course. These troubles are all severe nuisances, but they are practically never fatal and seldom disabling. Arsine. Severe and acute industrial poi sonings with arsenic are likely to be the result of inhalation of arsine, produced acci dentally when hydrogen has been generated in the presence of a material which contains arsenic. This gas has been reported in the acid cleaning of filter plates, 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 clean ing of pipes with an acid contaminated with arsenic, in the precipitation of cadmium with metallic zinc, and in other circum stances as well. 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. The possibility of arsine formation should always be considered when there is hydro gen formation around the active metals or around ores of the heavy metals, since ar senic is widely distributed in small amounts and only a trace of it is required to pro duce enough arsine to be troublesome. Asbestos is a hydrated magnesium silicate found in the 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 heat 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 slowly and advances slowly and is equally resistant to treatment. Prevention is essentially dust control. A maximum dust concentration of 5 million particles per cubic foot has been suggested, precisely as for pure free silica. Barium. The soluble salts of barium are toxic when ingested, as well as highly caus tic on the skin. There seems to be little toxic hazard in the inhalation of the dust of the less soluble salts. 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 ap parently not disabled or inconvenienced in any way. Benzene is a colorless, flammable, volatile liquid with a rather pleasant aromatic odor. Its fire hazard is between that of ethyl alco hol and that of ether. The greatest hazard is that of chronic poisoning by inhalation of comparatively small amounts over a long pe riod of time. It is one of the two or three most dangerous organic solvents in com mercial use. The action is primarily on the bloodforming organs, producing severe anemia, bleeding under the skin, and great reduc tion in the ability of the blood to clot. The extent of chronic exposure to benzene may be determined qualitatively by measure ment of the ratio of organic to inorganic sulfates in the blood. The most convenient measurement of damage is given by a blood count. People who may be exposed to benzene vapor should have blood counts at regular intervals. Consistent change in the blood count should be closely investigated. Par ticularly significant changes are diminution in the total numbers of red cells, platelets or white cells.