APPENDIX A – SAMPLE RISK ASSESSMENT SHEET Date: 1 February 2012 Assessor: Ann Person Location: Main spray painting and baking line Tasks: Paint mixing, colour matching, spraying, baking and cleaning up Workers involved: P. Stone and J. Saunders Duration of work: Approximately 1.5 hours of preparation and mixing, 5 hours spraying and 1.5 hours cleaning up HAZARDS IDENTIFIED Hazardous chemicals: 2-pack paint containing isocyanates (toxic, possible skin/respiratory sensitisation), thinners containing xylene (harmful by inhalation or through skin, skin irritant). Static electricity: potential contact of flammable solvents with static electricity may result in fire and explosion. Other issues: manual tasks, heat stress, visibility, noise from plant and injection injury. REVIEW OF CONTROL MEASURES review control measures including work processes and systems of work review the safety data sheets and label of the products review induction training (as required) review inspection and maintenance logs of plant review notifiable incidents POSSIBLE EXPOSURE FOR EACH TASK Paint mixing - conducted on open bench no ventilation possible static electricity exposure of skin to paint inhalation of vapour possible Colour matching - conducted indoors no ventilation intermittent inhalation exposure to spray paint aerosols hands protected but body unprotected Spraying -conducted in spray booth possible inhalation exposure route skin exposure possible to whole of body possibility of skin injection injuries heat stress in hot weather with unbroken work Baking vapours from curing paint and solvents drying line obstructs access up – conducted indoors skin exposure to solvents such as gun washing product inhalation of cleaning solvent and residual paint vapours area contaminated by solvent cleaning rags
noise from extraction system and spray gun risk of fire from solvent soaked rags EXISTING CONTROLS none gloves half face (class 2 respirator) latex gloves, spray booth none latex gloves POTENTIAL FOR EXPOSURE skin- high inhalation – possible vapour skin – high inhalation – high skin – high inhalation – extremely high noise - moderate skin – high paint inhalation - moderate skin – high paint inhalation - moderate CONTROL conduct paint mixing in the spray booth with air supplied respirator or conduct paint mixing in a specially constructed extracted booth skin protection by chemically resistant gloves required conduct air monitoring to determine isocyanates and solvents to determine level of respiratory protection required use of static spark arrester conduct colour matching in the spray booth with air supplied respirator or conduct colour matching in a specially constructed extracted booth skin protection by chemically resistant gloves required use of air supplied respirator is required full body protection gloves and eye protection mandatory and boot covers continued use of spray booth extra work breaks into schedule in hot weather install low fan to reduce extraction noise and use quieter nozzle for spray gun hearing protectors against any remaining noise risks if entry is required, wearing of air supplied respirator is preferred air monitoring may establish the need for 3 organic and gas vapour filtering respirator skin - hand and arm dermal protection required Chemically resistant gloves inhalation protection from solvent vapours using an air supplied respirator, unless air monitoring indicates that a half-face air purifying respirator with a solvent vapour cartridge is adequate alternatively, conduct all equipment cleaning in an automatic solvent washing system store solvent soaked rags submerged in water in a lidded metal container AIR AND HEALTH MONITORING Air monitoring is required during the paint mixing process and also on clean up to determine the need for respiratory protection. Health monitoring by doctor to be provided for all workers who previously worked with insufficient controls (half-face respirator and latex gloves) and to painters on an ongoing basis due to the high hazard of the isocyanates in paint.
LIST OF AMENDMENTS Date Page Number Amendments 13 September 2013 Front page Publication date changed from first published date of October 2012 to republished date of September 2013. 13 September 2013 12 Removed ‘In addition’ at the start of the 2nd paragraph in section 2.2. 13 September 2013 33 Two paragraphs at the end of section 5.1 to the word version consistent with the PDF version. 13 September 2013 35 Regulation 66 revised to match the PDF version. 13 September 2013 Whole document Formatting has been reviewed. 24 September 2013 9 Regulation 382 amended consistent with the technical amendment made to the model WHS Regulations. The following dot point was removed from the grey box. free silica (crystalline silicon dioxide) 11 2015 Front cover Publication date changed from republished date of September 2013 to second republished date of March 2015. 11 March 2015 19 Section 3.1 - Text amended by replacing ‘and’ with ‘or’ at the end of the first dot point.