Department 4 Planning and Development Chemical Management Guide for Small and Medium Sized Enterprises Improve Chemical Management to Gain Cost Savings, Reduce Hazards and Improve Safety August 2008 Commissioned by: Federal Ministry for Economic Cooperation and Development The method of linking Risk Phrases (R-Phrases) with classification into hazard bands and the identi- fication of needed control approaches described in Tools 4a and 4b of this Guide is based wholly on the approach of the ILO Safework Chemical Control Toolkit © 2001 produced by the Geneva-based International Labour Organisation working in collaboration with the International Occupational Hygiene Association (IOHA) and Health and Safety Executive (HSE) in the UK. The permission to integrate this approach into the guide is gratefully acknowledged. Tool 7 is based on following references: Safe Storage of Hazardous Chemicals; University of California, Berkeley; Office of Environment, Health & Safety; April 2001;Occupational Safety and Health Aspects of Leather Manufacture – Guidelines and Recommendations for Managers and Effluent Treatment Plants. Buljan, J., Sahasranaman, A. & Hannak, J.; Regional Programme Office United Nations Industrial Development Organization and Council for Leather Exports, Chennai, India; 1999 Deutsche Gesellschaft für Technische Zusammenarbeit (GTZ) GmbH Dag-Hammarskjöld-Weg 1-5 65760 Eschborn Germany Internt: http://www.gtz.de Department 4 – Planning and Development Responsible Person for the Guide: Dr. Alberto Camacho Convention Project Chemical Safety Tulpenfeld 2 53113 Bonn Germany Tel.: +49 (228) 98 57 015 Fax: +49 (228) 98 57 018 E-Mail: [email protected] Internet: http://www.gtz.de/chemical-safety Authors: Dr. Kerstin Bark, Dr. Alberto Camacho, Vera Weick, Joyce Miller, Dr. Martin Tischer, Christof Vosseler, Dr. Susanne Scholaen, Dr. Edith Kürzinger, Dr. Ralf Steinberg and MSc Miriam Wendland Ilustrations: Wedha and Stöber Photos: Cover photo from stone images, photos on pages 27 and 41 from Wolfgang Schimpf; Photos in Figures 16 a, b and c and page 90 are courtesy of Dräger, Germany Layout: Kerria Geller and www.design-werk.com The Convention Project Chemical Safety is implemented by GTZ on behalf and with the funding of the German Ministry for Economic Cooperation and Development (BMZ). Revised edition © GTZ, August 2008 No reproduction without authorization of GTZ Disclaimer: Though all care has been taken while researching and compiling the contents provided in this guide, GTZ accepts no liability for its correctness. The reader is advised to confirm specifications of any recommended equipment prior to purchase or use. Information provided here does not constitute an endorsement for recommendation of a product by GTZ. Department 4 Planning and Development Chemical Management Guide for Small and Medium Sized Enterprises Improve Chemical Management to Gain Cost Savings, Reduce Hazards and Improve Safety August 2008 Table of Contents Preface ................................................................................................ 6 Part I – How can you benefit by improving chemical management? ....... 8 1. Why should companies manage chemicals? ..................................................... 9 1.1 Benefit from reducing costs and environmental impact ........................ 9 1.2 Benefit from becoming more competitive ............................................. 9 1.3 Benefit from improving workers‘ health & safety .................................. 9 2. What does chemical management involve? ..................................................... 10 3. What hinders companies from doing chemical management? ......................... 10 4. Taking a step-by-step approach to chemical management .............................. 11 Part II – Going into action ................................................................... 12 First Module – Identifying ‘hot spots’ ...................................................................... 13 Step 1: Fact finding/identification of potential ‘hot spots’ .............................. 15 Step 2: Analysis of effects related to costs, hazards and environmental impacts ....................................................................... 17 Step 3: Analysis of causes – Why are chemicals being wasted, why do risks exist?......................................................................................... 20 Step 4: Development of measures ................................................................. 20 Step 5: Action/implementation of measures (chemical management action plan) ........................................................................................ 23 Step 6: Evaluation and integration into the company structure ....................... 26 Second Module – Making a comprehensive inventory ............................................. 28 Step 1: Fact finding/inventory of chemicals ................................................... 31 Step 2: Risk and cost assessment .................................................................. 35 Step 3: Analysis of causes ............................................................................. 36 Step 4: Development of measures ................................................................. 37 Step 5: Action/implementation of measures ................................................... 38 Step 6: Evaluation and integration into the company structure ....................... 38 Part III – Chemical Safety Tools .......................................................... 43 Tool 1 Symbols used for classification and for labelling hazardous substances in the EU ........................................................................ 44 Tool 2 EU Risk and Safety Phrases for hazardous substances ...................... 48 Tool 3 Using Material Safety Data Sheets (MSDS) ......................................... 63 Tool 4a Identifying inhalation hazard groups .................................................. 71 Tool 4b Description of control approaches for chemicals causing harm when inhaled ..................................................................................... 79 Tool 4c Respiratory Protection Program..................................................... 86 Tool 4d Selection of respirators 90 Tool 4e Filter Selection for Respirators.......................................................... 93 Tool 5a Identifying skin hazard groups ........................................................... 96 Tool 5b Description of control measures for chemicals causing harm via skin and eye contact .......................................................................... 98 Tool 5c Use of Gloves, Aprons, Goggles and Boots .......................................101 Tool 5d Gloves selection criteria................................................................. 105 Tool 6 Written and oral work instructions ....................................................108 Tool 7 Safe storage of hazardous chemicals ...............................................112 Tool 8 Fire safety and extinguishers........................................................... 122 Tool 9 Hazardous substances that can cause harm to the environment and basic recommendations for disposal 130 Abbreviations – Chemical Management Guide .................................. 134 Abbreviations used in MSDS ............................................................. 135 Preface 6 Preface This Guide aims to assist companies who want to alternative substances), determine measures for gain cost savings and reduce risks in the workplace improvement and adequate control approaches, with respect to chemicals used during production. It implement these measures in a systematic way and is especially relevant for companies where chemi- finally monitor and evaluate the results obtained. cals represent a major portion of their running costs. By improving the management of chemicals, The guide was developed as part of a modular train- companies can lower production costs, improve ing approach for small and medium sized enterpris- product quality, reduce the environmental impact es. This interactive training program is designed of chemicals used and improve the health & safety for technical staff, employees and/or management conditions for workers. In doing so, the workers’ of companies, for representatives of intermediary motivation and productivity can be substantially institutions and for consultants/trainers. The work increased. with groups of participants/companies has proved to be very efficient by sharing experiences and sup- This guide describes a step-by-step approach to porting each other through the whole process. identify risks and reduce costs related to the use of chemicals. The approach is based on identify- A typical chemical management training program is ing ‘hot spots’ and making a ‘chemical inventory’. outlined in figure 1: The two steps provide the necessary information The duration of a complete training program/cycle to observe and calculate potential losses, assess is about 6 months, foreseeing about one month’s risks, consider substitutes (in terms of form and/or Figure 1: Programme ‘Arrow‘ Chemical Management Training Network meeting Network Improved meeting Network Chemical meeting Management 0.5 day Presentation of results Multiplication Event Continuous improvement in the company 3 day workshop, including 1 day company visit Chemical Inventory Group of 3 day workshop, participants including 0.5 day company visit Hot Spot Identification