Safe Manual Handling of Chemicals 1671799519

SAFE MANUAL HANDLING
OF CHEMICALS IN THE
AUTOMOTIVE INDUSTRY
1ST EDITION
OCTOBER 2006
MANUFACTURING
On 18 June 2017, the Occupational Health and Safety Regulations 2017 (OHS Regulations
2017) replaced the Occupational Health and Safety Regulations 2007 (OHS Regulations
2007), which expired on this date. This publication has not yet been updated to reflect
the changes introduced by the OHS Regulations 2017 and should not be relied upon
as a substitute for legal advice.
Information on the key changes introduced by the OHS 2017 Regulations can be found in
the guidance titled Occupational Health and Safety Regulations 2017: Summary of changes
- available at https://www.worksafe.vic.gov.au/__data/assets/pdf_file/0011/207659/ISBN-
OHS-regulations-summary-of-changes-2017-04.pdf. However, this guidance document
contains material of a general nature only and is not to be used as a substitute for obtaining
legal advice.
NEW Dangerous Goods (Storage and Handling) Regulations 2012
On 1 December 2012, the Dangerous Goods (Storage and Handling) Regulations 2012
(DG (S&H) Regulations 2012) replaced the Dangerous Goods (Storage and Handling)
Interim Regulations 2011 (Interim Regulations) which expired on this date. The DG (S&H)
Regulations 2012 have retained most of the legal requirements contained in the Interim
Regulations. There are only a small number of changes. This document has not yet been
updated to reflect the changes introduced by the DG (S&H) Regulations 2012. More
information on the key changes introduced by these new regulations can be found in the
guidance titled Information about: Key changes to dangerous goods storage and handling
requirements available at worksafe.vic.gov.au/dgkeychanges and More information about:
Incident reporting available at
worksafe.vic.gov.au/incidentreporting
CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Packages and containers . . . . . . . . . . . . . . . . . . . . . . 29

Why has this guide been produced? . . . . . . . . . . . . . . . . 1 Examples of problems with packages
Injuries and health effects – exposure to hazardous and containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
manual handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Identifying and fixing problems with packages and
Injuries and health effects – exposure to chemicals . . . 2 containers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Manual handling of chemicals . . . . . . . . . . . . . . . . . . . . . 3 Container and package health & safety checklist . . . . . 32
Consulting employees and health and safety Fixing container and packaging problems . . . . . . . . . . . 34
representatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Adding handles to bags and sacks . . . . . . . . . . . . . . . . . 34
Information and training. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Effective closures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
The legal status of this guide . . . . . . . . . . . . . . . . . . . . . . 4
Protective clothing and equipment . . . . . . . . . . . . . 36
How to use this guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Risks of using protective clothing and equipment. . . . . 36
Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Steps to follow before using protective clothing and
1. Manual handling chemicals during delivery, equipment as a risk control. . . . . . . . . . . . . . . . . . . . . . . 38
unloading and storage . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Further information and guidance. . . . . . . . . . . . . . 42
Unloading containers and bags from pallets and
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
putting them into storage . . . . . . . . . . . . . . . . . . . . . . 8
Legislation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Unloading shipping containers and enclosed
trailers – manual handling . . . . . . . . . . . . . . . . . . . . . 13 Publications and further information available
from WorkSafe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Manual handling of gas bottles . . . . . . . . . . . . . . . . 14
2. Manual handling chemicals in the workplace . . . . . . 15 Acknowledgements. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Moving chemicals and storing in work areas . . . . . 15
Emptying, decanting, measuring and
mixing chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3. Cleaning components and parts. . . . . . . . . . . . . . . . . 25
4. Dipping components . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5. Disposing of waste chemicals . . . . . . . . . . . . . . . . . . 27
The information presented in Safe Manual Handling of Chemicals in the Automotive The information contained in Safe Manual Handling of Chemicals in the Automotive
Industry is intended for general use only. It should not be viewed as a definitive guide Industry is protected by copyright. The Victorian WorkCover Authority hereby grants
to the law, and should be read in conjunction with the Occupational Health and Safety a non-exclusive licence in this publication to the recipient of this publication on the
Act 2004. Whilst every effort has been made to ensure the accuracy and completeness condition that it is not disseminated for profit. The Victorian WorkCover Authority
of this guide, the advice contained herein may not apply in every circumstance. encourages the free transfer, copying and printing of the information in this publication
Accordingly, the Victorian WorkCover Authority cannot be held responsible, and if such activities support the purposes and intent for which the publication was
extends no warranties as to: developed.
• the suitability of the information for any particular purpose;
• actions taken by third parties as a result of information contained in this publication. WorkSafe Victoria is a division of the Victorian WorkCover Authority.
INTRODUCTION
WHY HAS THIS GUIDE BEEN PRODUCED?

Many tasks undertaken in the automotive industry involve the manual handling of
chemicals, placing employees at risk of injuries and adverse health effects due to
manual handling and/or exposure to chemicals.
This guide will help workplaces control risks and reduce injuries and adverse
health effects by:
• identifying tasks that require the manual handling of chemicals which may lead
to injury or illness;
• identifying the work areas and work processes involving these tasks;
• providing practical tools to assist in identifying risks and developing risk controls;
and
• providing practical risk control solutions that will eliminate or reduce risks.
Consultation with the Victorian automotive industry helped the development of
this guide. The work areas, jobs and tasks covered have been identified by the
industry as the primary areas that need to be addressed. Risk control solutions
have also been developed in consultation and with the support of the industry.
This guide may also be of use in other industries and workplaces where chemicals
are handled.
This guide is provided in accordance with section 7(1)(f) of the Occupational
Health and Safety Act 2004 to assist employers, employees, their health
and safety representatives (HSRs) and others to comply with their duties
and obligations.
It provides guidance on controlling risks that may arise from the manual
handling of chemicals, while also referring to controlling employee exposure
to chemicals and associated areas.
However, it is not intended to and should not be read as providing guidance
on the management of hazardous substances and dangerous goods and the
risks associated with them, as these are covered by a range of Acts,
Regulations, Codes of Practice and WorkSafe publications and guidelines.
This guide does not address every single situation where chemicals are
manually handled in the workplace.
For further information see page 42.
WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 1

INTRODUCTION
Musculoskeletal disorders from INJURIES AND HEALTH EFFECTS – EXPOSURE TO HAZARDOUS
manual handling MANUAL HANDLING
Muscle Tasks such as unloading containers from pallets, transporting them to storage
sprains areas, moving 205 litre (44 gallon) drums, carrying containers to work areas,
and strains
cleaning components, cleaning leaks and spills, emptying bags and sacks and
Injuries to decanting or mixing substances typically occur in the automotive industry.
muscles,
ligaments, These tasks may cause injuries, such as musculoskeletal disorders (MSDs).
spinal discs
and other
However, it is important to note that not all manual handling is hazardous.
structures Hazardous manual handling refers to manual handling with any of the following
in the back
characteristics:
Abdominal
hernias • repetitive or sustained application of force, awkward postures or sustained
Injuries to movements;
soft tissues
such as • application of high force;
nerves,
ligaments
• exposure to sustained vibration; or
and tendons • unstable or unbalanced loads or loads that are difficult to grasp or hold.
in the wrists,
arms, MSDs are often caused by incorrect manual handling and often includes:
shoulders,
neck or legs • muscle sprains and strains;
• injuries to muscles, ligaments, spinal discs and other parts of the back;
• injuries to soft tissues, e.g. nerves, ligaments and tendons in the wrists,
arms, shoulders, neck or legs; and
Exposure to substances
• abdominal hernias.
Chemical
burns and
irritation of INJURIES AND HEALTH EFFECTS – EXPOSURE TO CHEMICALS
the skin,
Poisoning
eyes, etc. Manual handling chemicals in the automotive industry can also expose employees
Diseases to chemicals that may affect employees’ health immediately or take months, or
of certain even years, to appear. These effects include:
organs such
as the skin, • poisoning;
lungs, liver, • irritation;
kidneys and
nervous • chemical burns;
system
• sensitisation;
• cancer;
Cancer,
birth defects • birth defects; and
• diseases of certain organs such as the skin, lungs, liver, kidneys and
nervous system.
The severity of the health effects depends on the substance, nature and extent
of the exposure.
Chemicals that have the potential to harm health are known as hazardous
Routes of exposure substances. They may be solids, powders, liquids or gases, pure chemicals or
mixtures. When used in the workplace, these chemicals often generate vapours,
fumes, dusts and mists. A wide range of chemicals are classified as hazardous.
Inhalation These may enter the body in a number of ways, depending on the chemical and
how it is used (the nature of the work).
Ingestion
The major routes of exposure to hazardous chemicals in the workplace are:
• breathing in (inhaling) vapours, fumes, dusts and mists;
• absorption into the body from direct contact with the skin, eyes, etc.; or
• swallowing (ingesting) or injecting into the body (for example, unclean hands,
smoking or contaminated food).
Skin
absorption
2 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

INTRODUCTION
Hazardous chemicals include:
• acute toxins such as cyanide;
• substances harmful after repeated or prolonged exposure such as mercury and
silica;
• corrosives such as sulphuric acid and caustic soda;
• irritants such as ammonia;
• sensitising agents such as isocyanates; and
• carcinogens such as benzene and vinyl chloride.
Other chemicals employees may be exposed to and harmed by are known as
dangerous goods, classified on the basis of immediate physical or chemical effects
such as fire, explosion, corrosion and poisoning, affecting property, the
environment or people.
Hazardous substances and dangerous goods are covered by separate legislation,
which focus on controlling the risks described above.
As many hazardous substances are also classified as dangerous goods, the
requirements of both pieces of legislation apply in these cases. As there may be
overlaps, each legislation complements the other, ensuring the effective control
of all risks.
Requirements for managing hazardous substances and dangerous good risks are
specified in the Dangerous Goods Act, Regulations and Codes of Practice and
the Hazardous Substances Regulations.
WorkSafe publications that provide information and guidance about hazardous
substances and dangerous goods are listed on page 42.
MANUAL HANDLING OF CHEMICALS

Manual handling of chemicals can create extra risks compared to other
manual handling jobs and tasks.
Employees manually handling containers of chemicals may adopt awkward
postures and movements in order to:
• avoid contact with residues and contaminants on the outside of containers or
being exposed to vapours or fumes from open containers; or
• avoid spillages while carrying, emptying, decanting, measuring and mixing
chemicals.
The use of protective clothing and equipment can increase manual handling risks
by restricting movement, limiting grip, increasing the physical effort required to do
the job and increasing heat stress.
Sometimes when completing manual handling tasks, protective clothing and
equipment may be used incorrectly, increasing exposure to chemicals. Measures
to reduce or eliminate the need to use protective clothing and equipment can
reduce manual handling risks.
Reducing manual handling risks associated with protective clothing and equipment
can also mean such equipment is used properly because it is more comfortable
(e.g. less sweating) and interferes less with doing the job at hand.
Implementing manual handling risk controls can reduce exposure
to chemicals
Manual handling risk controls can reduce exposure to chemicals by preventing
damage to chemical packages and reducing spills, leaks and clean ups when:
• delivering, unloading and storing chemicals; and
• moving chemicals within the workplace and storing them in work areas.
Changing the packaging – e.g. size, shape and weight – can reduce manual
handling risks and exposure to chemicals.

INTRODUCTION
Implementing risk controls to reduce exposure to chemicals can also reduce
manual handling risks
For example, using a vacuum cleaner fitted with HEPA (High Efficiency Particulate
Air) filters to clean spilt powders and dusts improves manual handling as there is
less bending, less repetitive forceful movements and less physical effort required
compared to sweeping.
Caution needs to be taken to ensure a vacuum cleaner is not used on
chemical spills unless specifically designed to do so.
CONSULTING EMPLOYEES AND HEALTH AND SAFETY

REPRESENTATIVES
When identifying, assessing and controlling health and safety risks posed by the
manual handling of chemicals, consultation with affected employees and their HSR
is essential.
Everyone has a role to play in workplace health and safety.
Healthier and safer work environments and improved productivity can be more
Before: Dry sweeping can create
easily achieved when employers and employees discuss risks and problems and
airborne dust in the breathing zone.
work together to find solutions.
Consultation is required under sections 35 and 36 of the Occupational Health and
Safety Act 2004. It must involve the sharing of information, giving employees the
opportunity to express their views, valuing their views and taking them into
account when making decisions.
Labour hire employees, employees of contractors and their supervisors and
managers must be included in any workplace consultation.
INFORMATION AND TRAINING

Where necessary, training and support must be provided to employees,
supervisors and managers to ensure they can effectively identify, assess and
control risk and meet all legal duties and responsibilities.
After: Use a mobile vacuum cleaner fitted

with a HEPA filter.

INTRODUCTION
HOW TO USE THIS GUIDE
The red, amber and green or ‘traffic light’ format will help identify high-risk activities and assist workplaces in implementing
safer work practices.
The rationale is simple: to reduce injury rates and compensation claims, high-risk situations must be controlled.
Companies with red (high-risk) work practices who fail to implement risk control measures for these practices may be in
breach of legislation, and may be placing the health and safety of their employees at risk.
The red column is split into two sections: one is for the actions (postures, movements or forces) that may cause the risk of
MSD and the other is for potential sources of that risk.
A better understanding of what causes the risk of MSD (or the source of the risk) results in more effective risk control.
Potential sources of the risk are listed, although each workplace may identify other reasons why those actions are being
undertaken and should control these accordingly.
If high-risk practices are followed in your workplace, you should determine if the solutions listed in the green column may
be effective. If this is not reasonably practicable, consider putting in place the comparable practice in the amber column as
an interim solution.
Generally, the manual handling solutions in the amber and green sections provide different options as the tasks, and the
risks, will vary according to the specifics at each workplace. It is important any controls implemented address the risk
factors in the task.
RED (HIGH RISK) AMBER SOLUTION GREEN SOLUTION

The practices in the red column should The solutions in the amber column are The solutions in the green column are
not be used in workplaces; an less effective in reducing risk than the most effective at reducing risk and
employer who allows these practices those in the green column, and should should be regarded as the target for all
to be used is likely to be in breach of be regularly reviewed with the aim to workplaces.
OHS legislation. move towards higher order solutions
(green).
Red, high risk, column
Solutions should Are any solutions YES Implement a solution

continue to be from the green column from the green,
reviewed as higher reasonably practicable low risk solution,
order controls for the workplace? column
become more (Undertake
practicable practicability test)
NO
Implement solutions
from the amber,
reduced-risk, column
These guidelines apply no matter what the time of day, or day of the week
Note: In most cases, solutions in the green column reflect the most effective control, while the amber column provides
interim solutions.
However, if you are able to demonstrate an appropriate risk assessment process has been undertaken and are able to
verify that the ‘reasonably practicable’ test has been applied to the controls you implement, then amber (interim) control
measures may be reasonably practicable. The interim solutions should be reviewed as green (higher order) solutions
become more reasonably practicable.
For more information identifying and controlling potential risks visit www.worksafe.vic.gov.au or contact the WorkSafe
Advisory Service on 1800 136 089.

TASKS
1. Manual handling chemicals during delivery,

unloading and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Unloading containers and bags from pallets and putting
them into storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unloading shipping containers and enclosed trailers –
manual handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Manual handling of gas bottles . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2. Manual handling chemicals in the workplace . . . . . . . . . . . . . . . . . 15
Moving chemicals and storing in work areas . . . . . . . . . . . . . . . 15
Emptying, decanting, measuring and mixing chemicals . . . . . . . 18
3. Cleaning components and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4. Dipping components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5. Disposing of waste chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1. MANUAL HANDLING CHEMICALS DURING
DELIVERY, UNLOADING AND STORAGE
The delivery, unloading and storage of chemicals can potentially expose
employees to chemicals and a range of manual handling risks.
Low risk control solution: bulk delivery, unloading and storage

of chemicals
When large amounts of chemicals are used, the low risk control solution is
bulk supply, storage and handling of chemicals whenever reasonably
practicable.
This eliminates or reduces manual handling and employees being exposed
to hazardous substances during handling. Bulk refers to supply in large
quantities and in containers such as pallet bags or palcons that must be
handled mechanically. It does not mean bulk as defined in the Dangerous
Goods (Storage and Handling) Regulations 2000.
Bulk bags or boxes holding up to 1000kg Any proposed changeover to bulk supply and handling of chemicals must be
or more of material. assessed in consideration of the Dangerous Goods Act, Regulations and
Code of Practice and the Hazardous Substances Regulations.
Examples of bulk delivery, unloading and storage at an automotive

manufacturing site
Most major ingredients are supplied in pallet bulk bags that are unloaded into the
storage area and then moved to the inside of the plant by forklift. Other
ingredients may be delivered by truck and pumped directly into silos before being
pumped into the plant.
In both of these cases, hazardous manual handling has been eliminated, while
productivity and financial gains have also been achieved. Suppliers will often meet
some of the costs associated with implementing the new infrastructure required
for bulk handling.
Liquid chemicals can be supplied in bulk

stackable containers.
Bulk silo storage.

UNLOADING CONTAINERS AND BAGS FROM PALLETS AND PUTTING THEM INTO STORAGE
HIGH RISK REDUCED-RISK SOLUTION LOW RISK
ACTION POTENTIAL SOURCE – Ensure there is enough space – Bulk supply and storage.
OF RISK in unloading and storage areas,
which allows pallets to be
Exerting force while in Unloading heavy unloaded as near as possible to
an awkward posture. containers and storage areas and reduces the
packages from pallets distances containers must be
Lifting, lowering and
by hand, then carrying carried. It also allows the use
exerting force while in
and putting them into of mechanical handling aids.
an awkward posture.
storage areas.
Bending the back
more than 20 degrees
or twisting. Carrying a
load:
• more than twice
a minute;
• more than 30
seconds at a time;
or
• with long duration Repetitive bending below
(more than 30 the knees and use of high
minutes at a time force to de-palletise bags
of material.
or more than
2 hours over a shift).
Crowded and – Increase space in unloading and – Increase available unloading and
High force congested unloading storage areas to allow forklift storage space by reducing the
Lifting, carrying and and storage areas. access. range of chemicals used and
lowering heavy loads. having a just-in-time system for
– Provide sufficient pallet racking ordering and stocking to avoid
that follows the 2005 WorkSafe overstocking. Refer to WorkSafe
Pallet Racking Guidance Note. Victoria’s Guidance Note
Unload pallets with a forklift and Production Flow Fluctuations –
store on pallet racking. Managing Risks to Health and
Safety.
– Storage areas should be well
maintained and regularly
Crowded storage area. inspected, providing enough
Lifting and lowering above room as well as easy forklift and
shoulder height. pallet jack access.
Sufficient, easy access pallet racking

used to store materials.

ACTION POTENTIAL SOURCE – Use height adjustable pallet – Use vacuum lifters to move
OF RISK lifters to lower, raise and rotate containers off pallets and onto
pallets. storage racks and shelves.
Exerting force while in Pallet is located on
an awkward posture. the ground.
an awkward posture.
Bending the back
or twisting. Carrying a
load:
• more than twice
a minute;
• more than 30
seconds at a time;
or – Provide a pallet stand.
• with long duration
(more than 30
minutes at a time
or more than
2 hours over a shift).
High force
Lifting, carrying and
lowering heavy loads.
Vacuum lifters can be used for all types

– Use mechanical aids such as of packages.
height adjustable trolleys to
move containers from unloading
to storage areas.

ACTION POTENTIAL SOURCE – Order chemicals in smaller – Increase size of container (e.g.
OF RISK containers and bags. Caution palcons) so materials must be
should be taken to ensure handled mechanically.
High force Weight of containers repetitive manual handling of
Lifting, carrying and or bags. smaller containers or bags is
lowering heavy loads. assessed.
Bulk supply eliminates the need to

physically handle chemicals.
Exerting force while in Unloading 20 litre tins – Provide a height adjustable – Supply in bulk containers so
an awkward posture. from pallets on the trolley that can be set at the paint must be handled
ground, carrying them same height as the bottom of mechanically.
to storage areas and the tins.
stacking them on
an awkward posture. Tins are loaded onto the trolley
shelves.
and moved to storage racks.
Bending the back
more than 20 degrees Storage racks are fitted with
or twisting. Carrying a rollers and tins are slid from
load: the trolley onto the racks then
• more than twice pushed to back of racks and
a minute; retrieved with push sticks/pick
sticks.
• more than
30 seconds at a
time; or
(more than 30
minutes at a time
or more than 2
hours over a shift).
High force
Lifting, carrying and
lowering heavy loads.
Paint tins are mechanically loaded into

custom made racks fitted with rollers.

ACTION POTENTIAL SOURCE – Use stretch-wrap and banding – Bulk supply and storage.
OF RISK to stabilise the loads on pallets
during transport.
High force Containers ‘stuck’
• Exerting force from together during
an awkward transport to stabilise
posture. the pallet load.
• Applying sudden Containers are difficult
forces. to separate from each
• Applying uneven, other.
fast or jerky forces
during pushing and
pulling.
• Pushing or pulling
hard to move
objects.
Lifting, lowering and Crowded and – Provide a stable platform/steps – Bulk supply and storage.
exerting force while congested unloading to raise employee and eliminate
in an awkward and storage areas may reaching above shoulder height.
posture. cause pallets to be
– Provide a stable raised surface
stacked on top of each
Bending the back (e.g. scissor lift) at the same
other.
more than 20 degrees height as containers on the top
or twisting. layer and move containers onto
this surface.
Working with one or
both hands above – Ensure there is enough room in
shoulder height: unloading areas so pallets are
• more than twice a not stacked unnecessarily.
minute; – Implement work systems so
• more than 30 that pallets are not stacked
seconds at a time; during the unpacking process.
or
(more than 30
minutes at a time Operator forced to
or more than 2 manually unload pallets
above shoulder height
using high force.
High force
Lifting heavy loads in
an awkward posture.
Exerting force while
in an awkward
posture.

ACTION POTENTIAL SOURCE – Arrange with supplier to reduce – Bulk supply and storage.
OF RISK height of pallets.
Lifting, lowering and Pallet is stacked above – Provide a stable platform/steps
exerting force while in shoulder height. to raise employee and eliminate
an awkward posture. reaching above shoulder height.
Bending the back – Provide a stable raised surface
more than 20 degrees (e.g. scissor lift) at the same
or twisting. height as containers on the top
layer and move containers onto
Working with one or this surface.
both hands above
shoulder height:
• more than twice
a minute;
• more than 30
seconds at a time;
or
This pallet is over stacked
(more than 30
and well above shoulder
minutes at a time height.
or more than 2
High force
an awkward posture.
Exerting force while in
an awkward posture.
Unloading containers and bags from pallets and putting them into storage – exposure to chemicals
Reducing the range of chemicals used and having a just-in-time stock control system reduces the amount of chemicals
stored on-site, simplifies safe handling and use and makes identification of individual chemicals easier in the workplace.
Improving manual handling as described above cuts the risk of damaging containers and causing spills and leaks. This also
reduces employees’ exposure to hazardous chemicals, reducing clean ups and waste disposal.

UNLOADING SHIPPING CONTAINERS AND ENCLOSED TRAILERS –
MANUAL HANDLING
Packing and unpacking shipping containers and pantechnicons (enclosed
semi-trailers) is a manual handling task associated with severe injuries and
musculoskeletal disorders. For further guidance and information see:
• WorkSafe Guide to Preventing Injury from Packing and Unpacking Shipping
Containers and Enclosed Trailers, 2003.
• WorkSafe Guidance Note: Slip-sheets or Pallets Ease Packing and Unpacking
of Shipping Containers, 2005.
Unloading shipping containers and enclosed trailers – exposure to
chemicals
Employees may be exposed to hazardous chemicals when imported shipping
containers have been fumigated and their contents have been damaged in transit,
causing spills and leaks in the container.
For further information and guidance refer to WorkSafe Guidance Note: Fumigated
Shipping Containers: Safe Transport and Unloading, 2005.
Safely loading and unloading shipping

containers can be challenging.

MANUAL HANDLING OF GAS BOTTLES
Gas cylinders are not designed for manual handling. They are cumbersome, heavy,
awkwardly shaped, and some do not have handles.
In almost all situations they must be transported and stored vertically, creating a
risk of MSD occurring.
For information and guidance on safe manual handling of gas bottles see the
WorkSafe publication Delivering Large Gas Cylinders 2002.
Dangerous goods and hazardous substances
Gas cylinders contain dangerous goods and hazardous substances and are subject
to regulatory control.
Cylinders should be stored in an area that allows air movement to prevent any
build up of harmful gases in the event of a leak. Refer to Australian Standards
AS 4332–2004: The Storage and Handling of Gases in Cylinders.
Gas cylinders are not designed to be
manually handled safely.

2. MANUAL HANDLING CHEMICALS IN THE WORKPLACE
MOVING CHEMICALS AND STORING IN WORK AREAS
ACTION POTENTIAL SOURCE – Use a mechanical aid such as a – Bulk distribution system.
OF RISK drum mover or overhead crane.
Example: In an engine casting
High force Requirement to plant two-part resins are delivered
manually move 205 in bulk (pallet containers),
• Pushing and pulling unloaded by forklift and directly
objects that are litre (44 gallon) drums.
connected by hose to the casting
hard to move or process.
stop.
• Lifting or lowering
heavy loads.
• Exerting high force
while in an
awkward posture.
Manually moving 205 litre

containers from pallets is
hazardous.
– Materials are supplied in pallet
bulk bags and the contents are
fed directly into the process
automatically.
– Use a forklift with a drum

moving attachment.
Forklift drum attachments eliminate

the need to physically handle 205 litre
containers of substances on and
off pallets.

ACTION POTENTIAL SOURCE – Use mechanical aids such as – Change to a bulk distribution
OF RISK trolleys to move containers. system.
Carrying a load. Manually carrying – Use vacuum lifters to move
chemical containers to containers.
Bending the back
work areas. – Use motorised stock chasers to
or twisting. Size, shape and move containers.
weight of container.
Lifting or lowering and
repetitive grasping:
• more than twice a
minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
High force
carrying heavy loads.
an awkward posture.
Exerting high force
while in an awkward
posture.
– Change container, e.g. transfer

chemicals from bulk storage
containers (hoppers, pallet
containers) to wheelie bins
which are then wheeled to work
areas.
Wheelie bins provide a means to

manually move materials from one
process to another. Care must be taken
to ensure bin weights are kept low.
– Reduce weight of container.

– Change design to allow easier
handling.

ACTION POTENTIAL SOURCE – Alter the layout of the work area – Change to a bulk distribution
OF RISK to allow easy access to storage. system.
Carrying a load. Crowded and – Store heavier items between
congested work areas knee and shoulder height.
Bending the back Provide sufficient shelving,
and poor local storage
more than 20 degrees racking and cradles that fit
facilities increase the
or twisting. containers in use. See
amount (e.g. double
Lifting or lowering and handling) and difficulty WorkSafe’s A Guide to Manual
repetitive grasping: of manual handling, Order Picking 2004 for further
and prevent trolley information.
minute; access and other
handling aids.
• more than 30
seconds at a time; Containers stored on
or the ground, stacked
behind other
containers or on top
(more than 30
of each other.
minutes at a time
or more than 2
High force
an awkward posture. Manual handling gas
Exerting high force bottles in congested work
while in an awkward areas is hazardous.
posture
Messy and congested

storage areas are
hazardous.
Manually lifting heavy

loads, especially above
shoulder height, is
extremely hazardous.
Moving chemicals and storing in work areas – exposure to chemicals

Poor practices in moving chemicals to work areas and storing them locally may damage containers and cause spills.
Poor local storage may mean chemicals are not properly separated and cross contamination may occur.

EMPTYING, DECANTING, MEASURING AND MIXING CHEMICALS
ACTION POTENTIAL SOURCE – Build chutes with benches at – Change to a bulk distribution
OF RISK waist height that feed into a system.
hopper.
Bending the back Emptying heavy bags – Supply contents in bulk and
forward more than 20 and sacks. – Change the bag or container and transfer directly into process.
degrees or twisting. work process.
Chemical bags are
Lifting, lowering and hand-lifted from a – Supply chemicals in bulk
carrying a heavy load pallet on the ground hoppers or palcons and transfer
with repetitive and the bag is held to wheelie bins that are then
grasping. well above or below wheeled to the take up area and
waist height, slit open connected to suction hoses to
Excessive bending of suck up contents and feed them
and emptied into a
the wrist: into the process.
hopper, chute or
• more than twice similar.
a minute;
No shelf or bench at
• more than 30 waste height on which
seconds at a time; to rest bag while
or being opened and
• with long duration emptied.
(more than 30
minutes at a time Weight, size and
or more than 2 shape of bag.
High force – A purpose designed sack tipping
– Make the bags smaller. station with a vacuum lifter
Lifting, lowering and minimises handling and
carrying heavy loads. – Change the design of the
exposure to dust by sucking
container to allow easier
Lifting heavy loads in powder away.
handling.
an awkward posture.
an awkward posture.

ACTION POTENTIAL SOURCE – Use handling aids such as an – Use a bulk decanting facility
OF RISK overhead crane, forklift with with closed systems and
drum attachment or drum integrated automatic feed and
Bending the back Lifting containers from handler. pumping systems for supply
forward more than 20 below knee height. and mixing.
degrees or twisting.
carrying a heavy load
with repetitive
grasping.
Excessive bending of
the wrist:
• more than twice
a minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
High force
an awkward posture.
an awkward posture.

ACTION POTENTIAL SOURCE – Provide racks, shelves, holders – Supply pre-mixed or pre-diluted
OF RISK or cradles that hold containers. chemicals in pre-measured
amounts to eliminate mixing and
Gripping and working Holding and tipping decanting. It may be necessary
with the fingers close containers to decant, to change the batch size to
together and/or wide dispense or mix enable this.
apart. liquids.
Twisting or turning
actions with the hands
or arms.
Exerting force with
one hand or one side
of the body.
Awkward wrist
postures when
holding or supporting.
– Purpose built stand for
Twisting, turning, decanting with supporting stand
grabbing, picking or for the container. Ensure the
wringing actions with container receiving the liquid is
the fingers, hands or close enough to prevent
arms: splashing.
minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
The photos above

demonstrate examples
of hazardous manual
– Fit pumps, taps, bungs, siphons
decanting of chemicals. or spigots onto main container.

ACTION POTENTIAL SOURCE – Install a fixed dosing pump that – Use ‘process rooms’ or ’mix
OF RISK moves the liquid from the rooms’ and then pump the
container to the process – substance to the process area.
Gripping and working Decanting or mixing in eliminating lifting, holding and
with the fingers close cramped and tipping.
together and/or wide congested work areas
apart. makes the task more
difficult.
Twisting or turning
or arms.
Exerting force with
of the body.
Awkward wrist
postures when
holding or supporting.
– Wheels on cradles enable them
Twisting, turning, to be moved around and help
grabbing, picking or ease crowding and congestion
wringing actions with of the work area.
the fingers, hands or
arms:
minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
– Drums fitted with pumps make

dispensing easier and dollies
help ease crowding and
congestion of the work area.
– Change the layout of the work

area to make more space
available and improve access
to dispensers, etc.
– Reduce local storage space
needed for chemicals by using
a just-in-time delivery program.

ACTION POTENTIAL SOURCE – Use smaller containers. – Increase the size of the
OF RISK container so it must be handled
– Reduce the container’s weight.
with a mechanical aid.
Gripping and working Size, shape and – Change container design to
with the fingers close weight of containers. improve grip.
together and/or wide
apart.
Twisting or turning
actions with the
hands or arms.
Exerting force with
of the body.
Awkward wrist Large container size
postures when requires higher force
holding or supporting. during decanting.
Twisting, turning,
grabbing, picking or
wringing actions with
arms:
minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2

ACTION POTENTIAL SOURCE – Use a purpose designed – Increase the size of the
OF RISK opening tool. container so it must be handled
with a mechanical aid. The
High force Buckets and drums container is then connected to
that are difficult to the process once, to avoid the
Applying high force
open. need to continually open and
with the hands and
close the containers.
arms, hitting, exerting Hands, screwdrivers,
force with the claw hammers, etc.
non-preferred hand, used to open buckets.
applying uneven,
fast or jerky forces.
Emptying, decanting, measuring and mixing chemicals – exposure to chemicals

Employees may be exposed to hazardous chemicals when emptying, decanting, measuring and mixing. Some of the
solutions identified above may also reduce exposure to chemicals.
Risk controls to reduce exposure to chemicals may also improve manual handling.

DECANTING EXAMPLE – AUTOMOTIVE PAINT KITCHEN

Potential source of risk: Lifting containers off the floor and then holding and tipping them to decant, dispense
or mix liquids.
Example of low risk solution: Increase the size of the container so it must be handled with a mechanical aid.
A parts manufacturer has an automated line to paint and coat automotive panel components. These are piped to the
line from vats in a ‘paint kitchen’.
Containers were manually filled from 20 litre drums, lifted from a trolley and then poured into vats. After emptying,
the drums were carried from the paint kitchen, stacked on the ground, and lifted into a waste bin.
Risk Control
Some coatings and paints, such as clear finishes, were used in higher volumes than others and, as such, were
supplied in 205 litre drums.
The drums are delivered to the paint kitchen by forklift and moved inside and put in place using an overhead crane.
The 205 litre drum is directly connected to the paint supply system.
Once empty, the drum is placed outside the kitchen by the crane and then removed by a forklift.
Benefits
Hazardous manual handling of 20 litre drums of high use coatings has been completely eliminated. There have also
been productivity and financial gains due to changes in buying in bulk, delivery, storage, transport within the plant and
disposal.
205 litre drums are moved inside the paint kitchen using the overhead tracked crane.

3. CLEANING COMPONENTS AND PARTS
Components and parts are often cleaned by hand, requiring repetitive manual handling tasks, awkward postures and high
force, especially to the hands and arms.

ACTION POTENTIAL SOURCE – Change the set up of work area – Change upstream process to
OF RISK to bring components closer to minimise cleaning.
the body and raise them to
Gripping and working Cleaning components – Some cleaning, e.g. degreasing,
waist height.
with the fingers close by hand. may be unnecessary and the
together and/or wide task can be eliminated.
apart. – Change the cleaning process by
Twisting or turning using an ultrasonic bath to clean
actions with the hands components in batches. This
or arms. bath uses water and vibration
to clean. Use mechanical
Exerting force with handling aids to handle crated
one hand. batches of components in and
Awkward wrist out of the bath.
postures.
Holding or supporting
components and
parts.
Twisting, turning,
grabbing, picking or
wringing actions with
arms.
Bending the back
more than 20 degrees Ultrasonic cleaning baths eliminate
or twisting. hazardous manual handling and
chemical exposure associated with
Reaching more than Manual workstations for part degreasing or cleaning.
30cm from the body: degreasing or cleaning
• more than twice a parts can be hazardous.
minute;
• more than 30
seconds at a time;
or
(more than 30
minutes at a time
or more than 2
High force
Applying high force
with the hands and
arms, exerting force
with the non-preferred
hand, applying
uneven, fast or jerky
forces.
Cleaning components and parts – exposure to chemicals

Manual cleaning of components and parts can expose employees to chemicals. The low risk solution listed above may help
reduce or eliminate this exposure.

4. DIPPING COMPONENTS
Components and parts are often dipped by hand involving lengthy and repetitive manual handling tasks and awkward
postures and the application of high force, especially by the hands and arms.

ACTION POTENTIAL SOURCE – Change set up of workstation to – Automate the task using robots
OF RISK bring components closer to the or similar.
body and raise them to waist
Gripping and working Manually dipping height.
with the fingers close components.
together and/or wide – Use a chain conveyor or similar.
The shape, size
apart.
and weight of
Twisting or turning components.
or arms.
Awkward wrist
postures.
Holding or supporting
dipping components.
Twisting, turning,
grabbing or picking
actions with the
fingers and hands.
Bending the back
or twisting.
Reaching more than
30cm from the body:
minute; or,
• more than 30
seconds at a time;
or,
(more than 30
minutes at a time
or more than 2
High force
Applying high force
with the hands and
arms, exerting force
with the non-preferred
hand, applying
uneven, fast or jerky
forces.
Dipping components – exposure to chemicals

Manual dipping of components and parts can expose employees to chemicals. The low risk solution listed above may help
reduce or eliminate this exposure.

5. DISPOSING OF WASTE CHEMICALS

ACTION POTENTIAL SOURCE – Reduce the weight of the drum – Use a closed system, with
OF RISK by replacing it before it fills up integrated automatic feed and
with waste. pumping that automatically
High force Manually moving collects liquid waste and
• Pushing and pulling 205 litre (44 gallon) transfers it to collection or
objects that are drums of waste recycling stations.
hard to move or liquids.
stop. Weight, size and
• Lifting or lowering position of drum.
heavy loads.
Manual handling 205 litre

drums on and off pallets
is hazardous.
WASTE DISPOSAL EXAMPLE

Waste solvent from a spray painting line is automatically pumped along a line to a sealed and labelled drum on a
pallet in a cabinet.
At regular intervals the drum is disconnected, sealed and removed from the cabinet, and a forklift is used to replace
the empty drum.
The drum on the pallet is then picked up by a forklift and moved to a waste disposal contractor’s depot on-site.
Forklift tines enable direct access to the cabinet.

5. DISPOSING OF WASTE CHEMICALS
WASTE RECYCLING EXAMPLE

Waste oil is piped automatically from an injection moulding production area and stored in a closed sump.
An external contractor regularly brings a processing and recycling truck on-site and the waste oil is processed and
reused. This reduces manual handling and exposure to contaminated oils is eliminated.
Connections and hoses during recycling are well maintained and there are splash guards in place in the unlikely event
of a hose break.
Emergency stops should also be appropriately located and fitted.
A mobile waste hydraulic oil refiner helps to reduce manual handling and exposure to oils.

ACTION POTENTIAL SOURCE – Extend the chute into a closed – Extend the chute into a closed
OF RISK wheelie bin and change the bin drum and move the drum using
before it fills. Wheel the bin to mechanical aids.
High force Untying heavy bags of disposal point.
waste dust, powder,
Pulling hard to move
granules, etc.
objects.
collected from a chute
Exerting force while in and dragging them to
an awkward posture. a disposal point. After
The weight, size and Flexible
connector
shape of the bag. to bin
Before
Nylon bag
Disposing of waste chemicals – exposure to chemicals

Manual handling during disposal can expose employees to chemicals. The low risk solutions above may help to reduce or
eliminate this exposure.

PACKAGES AND
CONTAINERS
Bottles, bags, sacks, tubs, cylinders, boxes, cans, drums, trays and buckets are all
considered packages and containers.
This section applies to those packages and containers supplied to and used in the
workplace.
Problems with packages and containers may contribute to manual handling risks
and increase the exposure of employees to chemicals.
The size, shape, weight and other features of packages and containers may be a
source of manual handling risk.
Identifying a feature as a source of risk will depend on the particular circumstances
in which the package or container is handled and needs to be determined using
the hazard identification and risk assessment processes described in the WorkSafe
Manual Handling Code of Practice, No. 25, 2000.
Other features of packages and containers can expose employees to chemicals
during handling, depending on the way it is handled and used. Refer to the
Dangerous Goods Act, Regulations and Code of Practice and the Hazardous
Substances Regulations.
EXAMPLES OF PROBLEMS WITH PACKAGES AND CONTAINERS
These tins have poor handholds making Pallets stretch-wrapped too tightly can These bags of sand used for spill clean ups
them difficult to handle and cause poor damage containers resulting in spills and are difficult to handle because of their
posture. leaks. weight and lack of handholds.

PACKAGES AND CONTAINERS
EXAMPLES OF PROBLEMS WITH PACKAGES AND CONTAINERS
Containers that can’t be resealed properly The size, shape and weight of the container The contents of bags and sacks can move,
are more likely to cause leaks and spills. and the handholds can cause hazardous unbalancing them and making them difficult
manual handling. to hold.
These containers have poor handholds requiring a grip that is too Using the wrong containers to collect liquid wastes can expose
narrow or too wide. employees to fumes and cause spills.
Damaged containers are more likely to Containers of decanted chemicals must be properly and legibly labelled or marked.
cause leaks and spills and can be difficult Containers must be right for the chemical – empty food containers should never be used.
or impossible to handle with mechanical
aids.

IDENTIFYING AND FIXING PROBLEMS WITH PACKAGES AND CONTAINERS
The following flowchart outlines the process for identifying and fixing packaging and container problems. A useful tool in
this process is the Container and Package Health & Safety Checklist over the page.
Step 1 Identify problems Step 2 Fix problems
Information from injury, Change packages

damage, accident and and containers
incident records
Discuss and
Information from Job
consult with
Safety Analysis (JSA),
manufacturers,
routine safety
suppliers and
inspections, etc.
transporters
High levels of use due Change tenders and

to spills and leaks due supply specifications
to container and
package problems
Use the Container The Container and Chemical

and Package Health & Package Health & manufacturers
Safety Checklist, which Safety Checklist can be and suppliers
can be completed in used to specify what meet their
consultation with changes are required legislative duties
employees, etc. to control hazards
At all stages consult with employees (including labour hire employees) who
handle and work with containers and packages and their HSRs.
Everyone involved in working with containers and packages needs to be

properly informed of the risks to health and safety and what controls are
in place to reduce these risks. Where determined, effective training should
be provided to ensure risk control solutions are properly implemented,
e.g. understanding labels on containers, understanding how to undertake
new processes, and following standard operating procedures.

CONTAINER AND PACKAGE HEALTH & SAFETY CHECKLIST
This checklist can be used to assess containers and packages currently used or planned on being used. It is not for bulk
containers. For each feature a tick in a red box may indicate a problem.
FEATURE YES NO N/A
Size, shape and contents

Weight: ________ kg
Is it heavier than it looks?
Does it come in a pre-measured size or quantity that makes measuring, partial decanting
or emptying unnecessary?
Does the packaging allow for a pre-measured size or quantity to be directly added
to the process without unwrapping?
Does the size and shape allow for it to be easily handled by hand?
Does the size and shape make it easy to handle with a mechanical aid?
Is it less than 500mm wide – measured across the body?
Is it less than 300mm deep – measured away from the body?
Is it stable? Is it hard to knock or tip over?
Does it block the worker’s view when being handled?
Are the contents stable during handling?
Is the centre of gravity in the middle?
Can it be moved with a mechanical handling aid?
Handles and grips
Are there good grips or handles?
Are grips and handles located in good positions for manual handling?
Do gloves need to be used during handling?
Does it have any sharp edges or protrusions?
Are there good grips or handles when wearing gloves?
Other
Is it slippery to hold?
Does it have chemicals on the outside?
Is it open during handling?
Is it in good condition, not crushed, torn or leaking?
Is it tough enough for all different workplace conditions?

FEATURE YES NO N/A
Opening, decanting, pouring, emptying
Is it easy to open?
For liquid containers that can have a high internal pressure, does the design of the lid,
cap, bung, closure, etc. prevent liquid or fumes spraying the employee during opening?
Is it easy to empty/pour?
For decanting liquids, is a bung/tap fitted at the bottom, can a pump be inserted,
or can a nozzle be used for decanting?
Is it easy to use a scoop with?

Does it minimise spills and leaks when emptying, is it fitted with anti-glug pouring?
Can the lid, top or closure be removed easily?
Can the lid, top or closure be put back on the container?
Labelling
Can the label be read after the package is removed from a pallet, stacked or shelved,
or when it is being used or disposed of?
Does the label clearly display the weight of the package?
Does the label clearly show information about the contents, such as physical form and
ingredients?
Does the label clearly detail if the contents may have moved during handling?
Does the label clearly show if there are any special manual handling requirements?
Does the label clearly show if gloves or protective clothing or equipment should be used
during handling?
Does the label clearly show how to safely use the contents?
Does the label identify any special storage or stacking requirements?
Does the label detail what to do if there are spills or leaks?
Does the label meet the requirements of the Dangerous Goods Act, Regulations and the
Hazardous Substances Regulations?
Can the label be understood by someone who can’t read English?
Is the label securely fixed to, or printed on, the container or package? Is the label
long-lasting?
Disposal
Can it be easily rinsed/cleaned out before disposal/recycling?
Can it be easily stacked or binned when empty?
Other
Does it fit in with how things are unloaded, stored, moved and used in the workplace?
Does it fit in with the workplace’s systems of work?

FIXING CONTAINER AND PACKAGING PROBLEMS
Example: Working with employees, HSRs and suppliers to change

packaging to reduce hazardous manual handling and exposure to
chemicals in an engine foundry
Problem
A hazardous substance was introduced to an engine foundry’s melt area.
Having been removed from its container with a scoop, it was measured
and then added to the process. Employees are exposed to a hazardous dust
and wear protective clothing and equipment. The task is done in a hot and
hazardous area.
Solution
Chemicals supplied in convenient
In consultation with the HSR and the supplier, the substance was re-supplied
pre-measured sealed bags.
in pre-measured sealed bags that are added directly to the process
unopened. The tasks of opening the bag, scooping and measuring were
eliminated along with exposure to the powder.
ADDING HANDLES TO BAGS AND SACKS

Adding handles to bags improves grip and ease of handling, decreasing the risk
of injury.

EFFECTIVE CLOSURES
The closures on these containers are reusable, easy to use and provide an effective seal.

PROTECTIVE CLOTHING
AND EQUIPMENT
The use of protective clothing and equipment is a common risk control for
employees exposed to chemicals. However, it is not a good idea to rely on
protective clothing and equipment to control risk as it may not properly protect all
employees from risks and can create new risks.
Controls other than the use of protective clothing and equipment should be used
to manage risks arising from the use of chemicals, so far as reasonably practicable.
Personal protective clothing and equipment should be used when recommended
in a Material Safety Data Sheet (MSDS) and when other controls do not
adequately control exposure.
RISKS OF USING PROTECTIVE CLOTHING AND EQUIPMENT

Personal protective clothing and equipment is not a good risk control because it:
• does not eliminate or reduce the risks and dangers;
• may not be cost effective – often the long-term monetary and employee time
costs of using protective clothing and equipment are not taken into account.
This includes the costs of:
– selection;
– storage;
– cleaning;
– fitting;
– medical examinations required before use;
– purchase;
– replacement;
– maintenance;
– training employees in use and maintenance; and
– monitoring use and extra supervision;
• only provides limited protection;
• will not protect employees if it is not properly selected, fitted, used, maintained
and stored;
• is often less effective if more than one type of personal protective clothing and
equipment is used at the same time;
• is not always used when it should be because it:
– interferes with doing the job;
– causes discomfort and/or pain;
– affects vision, e.g. safety goggles, full face respirators;
– interferes with hearing and talking, e.g. hearing protection, respirators;
– is not used by some employees for health, physical and psychological
reasons;
– is difficult to use correctly if not properly supervised; or
– interferes with employee concentration; and
• could be contaminated if not stored properly.

PROTECTIVE CLOTHING AND EQUIPMENT
Protective clothing and equipment can increase manual handling risks by:
• increasing heat stress in hot work areas, as this makes the work harder and
increases tiredness and the risk of heat illness;
• restricting postures and movements, as this can make the job harder to do and
increases the chances that protective clothing and equipment won’t be properly
used, e.g. gloves can prevent getting a good grip on tools, components and
materials – this puts more physical stress on the hands, arms and shoulders;
• using non-powered respirators that can make breathing harder, worsened if the
filters need changing, making the job harder to do; and
• restricting movement and mobility if air-lines and air-hoses are used with air
supplied respirators, as this can make the job harder to do and creates tripping
risks.
Wearing personal protective clothing and

equipment can increase heat stress, make
the job harder to do, affect grip and restrict
postures and movements.

STEPS TO FOLLOW BEFORE USING PROTECTIVE CLOTHING AND
EQUIPMENT AS A RISK CONTROL
Step 1
A risk assessment, as required by the Hazardous Substances Regulations, should
be completed prior to using protective clothing and equipment. Consultation with
employees exposed to the chemicals and their HSRs is required.
Step 2
If the risk assessment shows risk controls are needed, the following must be
considered when consulting employees exposed to the chemicals:
• eliminating the hazardous chemicals;
• using less hazardous substances, or substances in less hazardous forms;
• isolating employees from the chemicals;
• engineering controls that reduce employee exposure to chemicals; and
• changing the systems of work to reduce or eliminate employee exposure.
If these risk controls are not reasonably practicable in the short term then
protective clothing and equipment may be suitable as a temporary risk control.
Can you eliminate the hazard/risk? YES
NO
Can the hazard/risk be replaced with something less hazardous?
NO YES Does this control the hazard? YES
NO
Can you isolate the hazard/risk from people?
Protective
clothing and
equipment
not required
NO
Can engineering controls be used to control the hazard/risk?
NO
Can administrative changes control the hazard/risk?
GO TO STEP 3 NO

Step 3
This checklist will help determine if protective clothing and equipment is a suitable risk control.
It identifies factors that may need to be addressed when using protective clothing and equipment as a risk control.
Answers in a red box indicate that protective clothing and equipment may not be a suitable primary risk control.
YES NO
Are employees potentially exposed to chemicals and have they and their HSRs been consulted about
the use of protective clothing and equipment?
Is there protective clothing and equipment that will effectively protect employees from the
chemicals?
Is this protective clothing and equipment readily available?
Will the protective clothing and equipment interfere with vision and communication?
Will any exposed employees be unable to use the protective clothing and equipment due to physical,
psychological or medical factors?
Will the protective clothing and equipment interfere with the job or task?
Will using protective clothing and equipment create other risks, e.g. manual handling risks or heat
stress?
Step 4
Take action to address any problems identified in Step 3, indicated by ticks in any of the red boxes.

Step 5
Implement an effective personal protective clothing and equipment program.
When protective clothing and equipment are used as a temporary risk control, a protective clothing and equipment
program should be in place and reviewed regularly.
This checklist contains the essential requirements of an effective program and can be used to evaluate an existing
program. Answers in a green box indicate the requirement has been satisfied.
REQUIREMENT YES NO N/A

Did the employer establish the program?
Did the employer consult employees and HSRs when establishing the program?
Are employees and HSRs active participants in the program, involved in its planning,
implementation, monitoring and evaluation?
Is someone designated to be responsible for the program?
Does that person have the full support of employees and the employer?
Is there an effective procedure for dealing with situations where clothing and equipment
are not being used as required?
Does the procedure for selecting protective clothing and equipment include consultation?
Are the following considerations met when selecting protective clothing and equipment:
• Is it comfortable, a good fit?
• Does it not interfere with the job?
• Does it provide employees with choice?
• Does it cater for differences between employees?
• Does it provide adequate levels of protection?
• Can it be used together with other clothing and equipment?
Is there medical screening of each employee assigned to wear respirators?
Are employees and supervisors (including labour hire and contractors) appropriately
trained in:
• the program;
• why the program is the only reasonably practicable risk control solution at present;
• future risk controls which may replace the use of protective clothing and equipment;
• proper use and fitting;
• how to test the equipment (e.g. respirators);
• cleaning, storage, maintenance and replacement;
• the limitations of the equipment and clothing;
• the risks, dangers, and need for protection;
• when, where and how the clothing and equipment is to be used; and
• how any problems/issues with the equipment and its use are to be reported and fixed.
Is clothing and equipment supplied to each employee for their use?

Do employees get a copy of the operator’s manual for the clothing and equipment
provided?
Is there proper fitting and testing of clothing and equipment?
Is there regular cleaning/disinfecting of clothing and equipment?
Is proper storage for the clothing and equipment available?
Is there periodic inspection and maintenance of the equipment and/or replacement as
required and as per manufacturer’s/supplier’s instructions?
Is there adequate employee time allocated for training, fitting, cleaning and rest breaks
(if necessary) when using some equipment?
Are there procedures for non-routine situations such as spills and leaks?
Is there regular assessment of the program to ensure procedures are being followed and
employees are being properly protected?

Step 6
Protective clothing and equipment is a temporary measure, a last resort, to
be used when other risk controls do not control exposure or are not reasonably
practicable and steps 1-5 have been completed.
If protective clothing and equipment is being used for extended periods in a
workplace, then alternative risk controls may not have been properly considered.
It is the employer’s responsibility to provide protective clothing and equipment for
employees, including labour hire employees.
Step 7
A continuous improvement approach is essential. This includes yearly reviews of:
• changes in knowledge about the effects of the substance on health;
• existing, and any new, risks due to changes in chemicals used and work
processes;
• changes in technology and state of knowledge about risk control measures
including elimination, substitution, engineering and changing systems of work
or work practices;
• changes in technology and state of knowledge about protective clothing and
equipment; and
• the workplace’s protective clothing and equipment program.
The basis for these reviews can be steps 1, 2 and 3 and the checklist on page 40.

FURTHER INFORMATION
AND GUIDANCE
GENERAL
• Employees can contact their union.
• Employers can contact their industry association.
• WorkSafe publications can be obtained by phoning WorkSafe on toll free
1800 136 089 or emailing info@workcover.vic.gov.au
• Visit www.worksafe.vic.gov.au
LEGISLATION
• Occupational Health and Safety Act 2004
• Road Transport (Dangerous Goods) Act 1995
• Road Transport Reform (Dangerous Goods) Act 1995 (Commonwealth)
• Dangerous Goods Act 1985
• Manual Handling Regulations 1999
• Dangerous Goods (HCDG) Regulations 2005
• Dangerous Goods (Storage and Handling) Regulations 2000
• Occupational Health and Safety (Hazardous Substances) Regulations 1999
• Occupational Health and Safety (Confined Spaces) Regulations 1996
For copies of the above Acts and Regulations go to www.dms.dpc.vic.gov.au or
phone Information Victoria on 1300 366 356.

FURTHER INFORMATION AND GUIDANCE
PUBLICATIONS AND FURTHER INFORMATION AVAILABLE FROM
WORKSAFE
Consultation
• There are many publications available including Talking Safety Together and
Consultation – A User’s Guide.
Manual Handling
• Manual Handling Code of Practice, No. 25, 2000
• Manual Handling in the Automotive Industry, March 2005
• Manual Handling Risk – Assessing and Controlling, 2005
• Production Flow Fluctuations – Managing Risks to Health and Safety,
October 2005
• Delivering Large Gas Cylinders – A Guide to Manual Handling
• A Guide to Handling Large, Bulky or Awkward Items, August 2005
• A Guide to Manual Order Picking, March 2004
• A Guide to Manual Handling in the Food Industry, April 2006
• Guidance Note: Slip-sheets or Pallets Ease Packing and Unpacking of Shipping
Containers, 2005
• Guide to Preventing Injury from Packing and Unpacking Shipping Containers and
Enclosed Trailers, 2003
Forklift safety
• Forklift Safety Reducing the Risk, February 2006
Pallet racking
• Guidance Note: WorkSafe Pallet Racking, 2005
Chemicals – Hazardous substances, dangerous goods, confined spaces
• Chemical Safety Self Assessment Tool, March 2006
• A Step by Step Guide for Manufacturers, Importers and Suppliers of Hazardous
Substances and Dangerous Goods, 2001
• Safe Handling of Industrial Waste, 2003
• Guidance Note: Fumigated Shipping Containers: Safe Transport and Unloading,
2005
• Hazardous Substances Code of Practice, No. 24, 2000
• Confined Spaces Code of Practice, No. 20, 1996
• Storage and Handling of Dangerous Goods Code of Practice .
Incident Reporting – Notifying WorkSafe Victoria
• Guide to incident notification – August 2005

ACKNOWLEDGEMENTS
This publication is part of the Safe Handling of Chemicals in the Automotive

Industry Project (SHOCAi). It has been funded by WorkSafe Victoria’s Safety
Development Fund.
The project’s steering group is the Motor Vehicle and Parts Manufacturing Health
and Safety Forum.
The following organisations are represented on the forum and WorkSafe would
like to thank them for their generous contributions to the guide’s development:
• Australian Industry Group
• Australian Manufacturing Workers Union – Vehicle Division
• Australian Manufacturing Workers Union – Metals Division
• Department of Industry Innovation and Regional Development
• Electrical Trades Union
• Liquor, Hospitality and Miscellaneous Union
• National Union of Workers
• Plastics and Chemical Industry Association
• Victorian Employers Chamber of Commerce and Industry
Thanks to all workplaces and individuals who participated in the Automotive and
Parts Industry Solutions Workshop in October 2005, those who provided images
for this publication, and Ross Armstrong of Global Ergonomics Pty Ltd.

WORKSAFE VICTORIA
Advisory Service
222 Exhibition Street
Melbourne VIC 3000
Phone . . . . . . . . . . . . . . 03 9641 1444
Toll-free . . . . . . . . . . . . . 1800 136 089
Email . . . . . info@workcover.vic.gov.au
Head Office
222 Exhibition Street
Melbourne VIC 3000
Phone . . . . . . . . . . . . . . 03 9641 1555
Toll-free . . . . . . . . . . . . . 1800 136 089
Website . . . www.worksafe.vic.gov.au
Local Offices
Ballarat . . . . . . . . . . . . . 03 5338 4444
Bendigo. . . . . . . . . . . . . 03 5443 8866
Dandenong . . . . . . . . . . 03 8792 9000
Geelong. . . . . . . . . . . . . 03 5226 1200
Melbourne
(628 Bourke Street). . . . 03 9941 0558
Mildura . . . . . . . . . . . . . 03 5021 4001
Mulgrave . . . . . . . . . . . . 03 9565 9444
Preston . . . . . . . . . . . . . 03 9485 4555
Shepparton . . . . . . . . . . 03 5831 8260
Traralgon . . . . . . . . . . . . 03 5174 8900
Wangaratta . . . . . . . . . . 03 5721 8588
Warrnambool . . . . . . . . 03 5564 3200
VWA1063/02/05.13

Safe Manual Handling of Chemicals 1671799519

Uploaded by

Copyright:

Available Formats

You might also like

Safe Manual Handling of Chemicals 1671799519

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Safe Manual Handling of Chemicals 1671799519

Uploaded by

Copyright:

Available Formats

SAFE MANUAL HANDLING

NEW Dangerous Goods (Storage and Handling) Regulations 2012

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Packages and containers . . . . . . . . . . . . . . . . . . . . . . 29

WHY HAS THIS GUIDE BEEN PRODUCED?

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 1

2 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

MANUAL HANDLING OF CHEMICALS

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 3

CONSULTING EMPLOYEES AND HEALTH AND SAFETY

INFORMATION AND TRAINING

After: Use a mobile vacuum cleaner fitted

4 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

RED (HIGH RISK) AMBER SOLUTION GREEN SOLUTION

Red, high risk, column

Solutions should Are any solutions YES Implement a solution

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 5

1. Manual handling chemicals during delivery,

6 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

Low risk control solution: bulk delivery, unloading and storage

Examples of bulk delivery, unloading and storage at an automotive

Liquid chemicals can be supplied in bulk

Bulk silo storage.

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 7

Sufficient, easy access pallet racking

8 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

Vacuum lifters can be used for all types

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 9

Bulk supply eliminates the need to

Paint tins are mechanically loaded into

10 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 11

12 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

Safely loading and unloading shipping

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 13

14 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

Manually moving 205 litre

– Use a forklift with a drum

Forklift drum attachments eliminate

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 15

– Change container, e.g. transfer

Wheelie bins provide a means to

– Reduce weight of container.

16 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

Messy and congested

Manually lifting heavy

Moving chemicals and storing in work areas – exposure to chemicals

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 17

18 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 19

The photos above

20 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

– Drums fitted with pumps make

– Change the layout of the work

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 21

22 WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY

Emptying, decanting, measuring and mixing chemicals – exposure to chemicals

WORKSAFE VICTORIA / SAFE MANUAL HANDLING OF CHEMICALS IN THE AUTOMOTIVE INDUSTRY 23

DECANTING EXAMPLE – AUTOMOTIVE PAINT KITCHEN