Gap1 PDF

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PRACTICAL CHEMICAL MANAGEMENT

TOOLKIT FOR YOUR COMPANY
TRAINER MANUAL TO BE USED WITH MODULE 2
MANAGING THE RISKS IN YOUR COMPANY - CONTROL
MEASURES AND GAP ANALYSIS
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Deutsche Gesellschaft für
Internationale Zusammenarbeit (GIZ)

GmbH
Internet: http://www.giz.de
Department 4 – Planning and

Development
Person Responsible for the Toolkit:
Dr. Alberto Camacho
Convention Project Chemical
Safety
Dahlmannstrasse 4
53113 Bonn
Germany
Tel.: +49 (228) 24934230
Fax: +49 (228) 24934215
Email: alberto.camacho-henriquez@giz.de
Internet: http://www.giz.de/chemical-safety
Authors: Dr. Alberto Camacho and Dr Jürgen Hannak
The Convention Project Chemical Safety is implemented by GIZ on behalf and with funding of
the German Ministry for Economic Cooperation and Development (BMZ).
Revised edition © GIZ, August 2011

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OVERVIEW OF TRAINING MATERIALS TO BE USED WITH MODULE

“CHEMICAL RISK MANAGEMENT AND CONTROLS”
GENERAL INTRODUCTION
About the trainer manual 6
Learning objectives 7
Overview Moderation plan “Chemical Risk Management and Controls” 8
AVAILABLE TRAINER INSTRUCTIONS

Session Code Description of training material Page
Gap analysis and HO 10a Exercise - Identifying control approaches 13

selection of risk
HO 10b Determination of control approaches for inhalation risks 14
control measures
HO 10c Determination of control approaches for dermal risks 15
Technical session
0201 HO 10d Inventory and health risk assessment table (completely filled) 16
HO 10e Gap analysis for control approaches in the BC company 17
HO 10f Checklist inhalation control approaches 18
HO 10g Checklist skin control approaches 27
Critical areas Prepare flip chart with definition of critical areas 30

/critical situations
Technical session
0202
Case Study Exercise HO 11a Story critical areas 34

Part 1 critical
HO 11b Ground plan 35
areas/situations
HO 11c Instructions for Exercise critical areas/gap analysis/costs 36
HO 11d Possible answers 37
HO 11e Using eco maps in chemical management 39
HO 12a Exercise BC cost assessment, basic data 41

Case Study Exercise
HO 12b calculation table empty form 42
Part 2 costs
HO 12c Calculation table solution 43
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assessment HO 13a Story gap analysis 44
Case study exercise HO 13b Instructions for the gap analysis exercise 45
Part 3 gap analysis of
control approaches HO 13c Inventory, risks assessment and health control approaches 46
table BC company printing section
HO 13d Suggestion for presentation of findings on controls gap analysis 47
Case study Part 4 HO 14 Decision matrix 48

presentation of
findings
Safe storage of HO 15a Chemical storage layout 52
chemicals
HO 15b Compatibility check table for the storage of hazardous 53
Technical session chemicals
0203
HO 15c Solution to storage of compatibles chemicals exercise 54
HO 15d Separate solids from liquids, acids from bases 55
HO 15e Storage and handling of chemical: self assessment checklist 57
HO 15 f How to calculate net savings and payback period when you 64

implement an improvement measure in the storage
Selecting and Topic Setting up a Respiratory Protection Program

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using personal 4d
protection
Topic 4e Selecting the correct respirators
Technical session
0204
Topic 5d Select and use protective equipment for skins and eyes
HO 16 Glove material selection chart
Managing HO 17a Story a hot day in BC emergency

chemical
HO 17b Story fire and explosion(control banding)
emergencies
HO 17c Risk assessment table for fire and explosions (empty)
Technical session
0205 HO 17d Fire risk assessment using control banding
HO 17e Risk assessment table for fire and explosions (filled)
HO 17f Fire prevention checklist
HO 17g Emergency check list
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Topics to be found in the annex of the guide
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Safety data sheets from inventory exercise, module 1
Topic 4c Learning more about the four control approaches for

chemicals causing harm when inhale and for preventing fires
and explosions
Topic 6c Fire safety and extinguishers
Preparing for the HO 18a Preparation company application

company
WS 18b Observations of critical areas/ gaps in control approaches
application
Processing WS 18c Identification of hot spots

company
HO 19 Action plan module 2
application and
action planning
Anchoring Topic 8 Integrating chemical management in your company

chemical
management in
your company
Technical session
0206
PRESENTATIONS FOR USE WITH MODULE CHEMICAL RISK MANAGEMENT AND

CONTROLS PROVIDED IN A SEPARATE CD
PPP Number Description of presentation
PPP 13 Identifying control approaches
PPP 14a About control approaches
PPP 14 b Control guidance sheets
PPP 15a What are critical situations?
PPP 15b Examples of hot spots
PPP16 Eco maps
PPP 17 Safe chemical storage
PPP 18a Emergency management
PPP 18b Control banding for fire and explosions

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PPP Number Description of presentation
PPP 19 Cycle of change module 2
MSDS Storage exercise
MSDS Gap analysis exercise

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ABOUT THE TRAINER MANUAL
This trainer manual for the module “Chemical risk management and controls” contains instructions
and materials for the facilitators /consultants. The company guide “Chemical risk management and
controls” as well as this trainer manual module is complementary.
This trainer manual gives an overview of the different materials available for this module and makes
recommendations in form of trainer instructions on how to best use the worksheets/handouts and
which power point presentations are available to support your training /coaching of enterprises. The
training materials are organized in technical sessions.
An overview of the training materials is given indicating the page in the trainer manual where you
can find them.
A training sequence indicates the main tasks that have to be fulfilled by the facilitators for each day
and unit.
The worksheets/handouts of this trainer manual will be distributed session wise during the training.
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LEARNING OBJECTIVES
At the end of module 2 Chemical Risk Management and Controls, the participants will be able to….
 carry out a gap analysis between recommended / required control approaches and actual
controls on-site
 identify priority areas in their company for improvement measures
 assess and arrange/reorganize the storage of chemicals in their company
 identify and select personal protective measure
 prepare for chemical emergencies
 develop and select control measures to mitigate critical situations / areas
 plan steps for the further dissemination of chemicals management within their companies
Expected output:
Action plan to implement and to document specific improvement measures in the company with
regard to chemical risk management control and anchoring of chemicals management elements,
based on a company specific gap analysis of recommended and existing risk control measures.
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TRAINING SEQUENCE FOR MODULE 2 – CHEMICAL RISK MANAGEMENT AN CONTROLS
Possible sequence and content of Hazardous Waste Management training for companies
Day 1 Day 2 Day 3 Day 4
Morning Welcome and Company Analyzing

progress review application results of
company
application
and action
planning
Selection of health Safe storage Selecting and

risk control chemicals of using
measures and gap personal
(Technical session
analysis 0203) protection
(Technical session (Technical

0201) session 0204)
Critical areas/ Managing chemical

situations emergencies
Afternoon (Technical session (Technical session
0202) 0205)
Case study
exercise – and Preparing for Review of company Anchoring
presentation of company application chemicals
findings application management

in your
company
(Technical
session 0206
Closing of
workshop
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Tasks for companies and consultants to be completed after module 2:
o Complete gap analysis in the company
o Prepare action plan to implement and to document specific improvement measures in the
company with regard to chemical waste
o Implement and document improvement measures
o Participate in Network Meeting

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TRAINER’S INSTRUCTIONS FOR PROGRESS REVIEW
At the beginning of the workshop, briefly recall together with the participants the subjects covered
during the last training. List the activities, the company teams were given to complete between the
last training and this one.
Start with a general reflection in the plenary on the challenges the company teams have faced during
the implementation of their actions plans as well as on the ways they have been able to overcome
the challenges.
Invite each company team to present their progress and results. Ask the teams to specifically refer to
the action plan, they had prepared during the last training.
Allow for about 60 min for the progress review.

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TECHNICAL SESSION GUIDE 0201– SELECTION OF HEALTH RISK CONTROL MEASURES

AND GAP ANALYSIS
Before using this session guide, read chapters Understanding the hierarchy and principles of controls
and Identify gaps between recommended and existing controls in your company in Practical Chemical
Management Toolkit for your Company, Module 2 – Managing the chemical risks.
Rehearse your session!
Respect the time limit: 170 minutes
SESSION DESIGN
This session introduces the concept of hierarchy and principles of controls for chemical risks and
explains how to systematically identify areas of interventions by assessing possible gaps between
recommended and existing controls of chemical risks on-site for given situations. At the end of this
session, the participants will be able to
 determine the recommended control approaches for environment, physical and health
hazards, in line with ILO Control Banding and BAUA methodologies
 relate the codes for control approaches used and identified in the inventory table to the
specific sets of control approaches for inhalation and skin exposure;
 identify and document gaps between existing and recommended controls in their respective
companies.
The session is divided into following steps:
Step Time available
Introduction on control approaches ppp 12 20 min
Presenting the different control approaches PPP 13a 25 min
Exercise – Identifying control approaches 20 min
Control approaches and hierarchy of controls 30 min
Case study exercise – Identifying and analyzing the gaps in BC 60 min
Conclusion 15 min
Materials required:
- PPP 13, PPP 14a, PPP14b

- HO 9f, HO 10a,10b,10c,10e,10f,10g
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DESCRIPTION OF STEPS
INTRODUCTION (20MIN)
Quickly review with the participants the process of identifying recommended control measures when
preparing the chemical inventory (See HO 9f, module 1; PPP 13). Explain that the codes used in
column 12 of the inventory table related to predefined groups of control approaches for the different
hazards and risk identified.
PRESENTING THE DIFFERENT CONTROL APPROACHES (25 MIN)
Provide an overview of the different control approaches and how they are linked to the coding of the
control banding tool in the inventory table, using PowerPoint presentation No 14a (about control
approaches. Encourage participants to give examples from their companies and experience.
For more specific guidance on recommended control approaches for given situations, refer to the ILO
control sheets at: http://www.ilo.org/legacy/english/protection/safework/ctrl_banding/toolkit/icct/sheets.htm
EXERCISE – IDENTIFYING CONTROL APPROACHES (20 MIN)
Request the participants to form groups of 4 - 5 persons. Referring to HO 9f (module 1) ask the
groups to identify the full description of the recommend control measures for the different codes in
column 13.
After 15 minutes of group work, review the results in the plenary. After discussion distribute HO 10d
CONTROL APPROACHES AND HIERARCHY OF CONTROLS (30 MIN)
Referring to the result of the exercise, explain that the different control approaches are structured in
a priority for risk management approaches, ranging from simple good housekeeping measures to
complex engineering solutions. Point out that the control approaches as such in turn consist of a
number of different interventions. Distribute HO 10f and HO 10g and review the questions together
with the participants.
Point out that the general objective in the control of chemical hazards is to reduce to the lowest
possible level of the risk that a hazardous chemical can pose, for example by coming in contact with
the worker or by contributing to a fire or an explosion when ignited by a possible source of ignition.
To eliminate or minimize risks in general, usually a four-point strategy of controls can be used to
prevent and reduce the possibility and thus the risk of accidents, health impacts, fire or explosion
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and adverse effects on the environment. Better than reducing the risk would be eliminating the risk
altogether by simply avoiding or substituting the hazardous chemical with a non-hazardous one.
While this may not be possible in the short run, it still should be considered as long-term option.
You can easily demonstrate the concepts of the four point strategy in the classroom:
 Use a water bottle as hazardous chemical and choose one volunteer to represent the worker,
position away from the bottle.
 For the strategy 1 “substitution” simply remove the bottle and place a distinctively different
bottle there, indicating that this would represent a non- or less hazardous substance;
 For strategy 2 “engineering control”, place the earlier bottle representing the hazardous
chemical again in front of the participants, but with any open cover or put some water into
an open cup and ask the volunteer to come closer to the bottle or cup. Place the cup on the
bottle to show an engineering solution such as enclosure. Move the bottle and volunteer to
an area with a ventilation.
 For strategy 3 “administrative controls”, simple advice the volunteer to step back as the area
around the bottle is declared an area for authorized personnel only.
 Finally hand over a personal protective device (e.g. mask, goggles, gloves) to the volunteer
and ask him to handle the bottle, representing the strategy 4 “personal protective measures”
After finishing your demonstration of the 4 control approaches with a bottle, distribute HO 10 e
and give instructions to the working groups.
CONCLUSION (15 MIN)
Summarize the hierarchy of controls and point out that all relevant information can be found in the
Chemical Management guide as well as further information can be retrieved from the ILO Control
Banding website. Mention that the participants will have an opportunity of using the different
checklist tools during the next company application. Present PPP14b control guidance sheets (10min)
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HO NO 10A „BEAUTIFUL COLOURS“– IDENTIFYING CONTROL APPROACHES

After inventorying the chemicals used and available in “Beautiful Colors” and determining their
hazards and hazard groups, you will now identify the recommended control approaches for these
chemicals to address possible risks to health from exposure by inhalation and skin contact.
Control approaches for hazardous chemicals that can be inhalated are gathering under 4 points
(control approaches from 1 to 4) and control approaches for hazardous substances for skin under 3
categories (low, medium and high).
In your group…
 Use the information available in HO No 9f (Inventory-risk assessment table) and complete

the table (columns 11 and 12) with the information provide here below.
 Use HO No 10b and HO No 10c to identify the control approaches for inhalation and skin
exposure and enter the respective code of the control approach into the inventory table HO
No 9f (column 13).
Duration: 20 minutes
Additional information:
(1) As you can observe in the dye kitchen of “Beautiful Colors”, small splashes of acetic acid fall
on to the hands and forearms of the concerned worker while pouring the acid. There is a
washbasin at the other side of the production area, where the worker washes his hands and
arms after preparing each batch. You estimate that in a day the total duration of exposure is
about 14 minutes.
(2) Reactive black 5 is manipulated for less than 10 min each time (4 times a day) but always
small quantities of powder are visible in the hands and forearms of the concern workers.
(3) In the printing section, you observe that the cloths of the worker are covered with some
kind of white dust for the whole day. He is wearing wrist-length gloves. But the worker is
frequently scratching and rubbing his bare forearms. He explains to you that this dust is
coming from the sodium hydroxide bags he has to carry from the trolley to the dosing point
in the printing section. He says that when he is washing off the dust in the evening the
itching usually stops.
(4) Once you have identified the recommended control approaches, follow the instructions in
HO 10e and use check lists in HO No 10f and 10gf to verify what each control approach
contain
Duration 60 min
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HO 10B DETERMINATION OF CONTROL APPROACHES FOR INHAL. RISKS, ILO 2001

Quantity Metric units
SMALL Grams or milliliters
MEDIUM Kilogram or liters
LARGE Tones or cubic meters
Volatility Boiling point

LOW Boiling point above 150oC
MEDIUM Boiling point between 50 and 150oC
HIGH Boiling point below 50oC
Dustiness Appearance
LOW Pellet-like solids that do not break up.
Little dust is noticed during use (e.g. PVC pellets, waxed
flakes)
MEDIUM Crystalline. Granular solids
Dust settles quickly (e.g. detergents)
HIGH Fine, light powders
When used, dust clouds form and remain in the air for
several minutes (e.g. cement dust, carbon black, chalk dust)
Amount used Low Medium Medium High

dustiness or volatility dustiness dustiness or
low high
volatility volatility
Hazard Group A
grams or milliliters 1 1 1 1
kilograms or liters 1 1 1 2
tons or cubic meters 1 1 2 2
Hazard Group B
Hazard Group C
Hazard Group D
Hazard Group E
For all substances in hazard group E control approach 4 is required
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HO 10C DETERMINING CONTROL APPROACHES FOR DERMAL RISKS, BAUA 2009
Skin Hazard Affected area Duration Control

group of contact approach
Skin A Small Short Low
Small Long Low
Large Short Low
Large Long Medium
Skin B Small Short Low
Small Long Medium
Large Short Medium
Large Long Medium
Skin C Small Short Low
Small Long Medium
Large Short Medium
Large Long High
Skin D Small Short Medium
Small Long Medium
Large Short Medium
Large Long High
Skin E Small Short High
Small Long High
Large Short High
Large Long High
Quantity of substance on skin Criteria

Small quantity Splashes
Large quantity Immersion and/or large-area wetting of hands and forearms
Duration of skin contact Criteria

Short Duration 15 minutes or less per day
Long Duration More than 15 minutes per day
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HO 10D INVENTORY AND HEALTH RISK ASSESSMENT TABLE (COMPLETELY FILLED)
11 12
2 3 4 5 6 7 8 9 10 13
Area/ Process Name Price/ SDS R-phrases/ Hazard Hazard Hazard Amount per Dustiness/ Quantity Duration of
Hazard type* Control approach
Suppli Yes/ statements group group skin batch/task volatility on skin exposure
er No P H E Inhalatio on skin Inhale Skin
Dye kitchen Acetic Acid Yes R 10, R35 C E 8l Liquid Small Short 3 high
Medium Medium
Dye kitchen C.l Basic Yes R22, R41, R50/53 B - 7 kg Liquid 2 -

Yellow Medium Medium
Dye kitchen C.l Reactive Yes R42/43 C C 3kg Medium Solid Small Long 3 medium
Black 5 Medium
Printing 2-Naphthol Yes R20/22 R50 B - 85 kg Solid 1 -

Medium Low
Printing Sodium Yes R35 C E 10 kg Solid Small long 2 high

Hydroxide Medium Low
Storage Aniline Yes R20/21/22 D D 10 l Liquid Low - -

R40, R48/23/24/25 Remaining
R50 stock
Yard Citric Acid Yes R36/37/38 A - Medium Solid 1 -

250 g Medium
Printing Unknown 1
Storage Unknown 2
HO NO 10E GAP ANALYSIS FOR CONTROL APPROACHES IN “BEAUTIFUL COLOURS”
You have now completed your inventory list for the company “Beautiful Colours”.
You know all chemicals existing in the company; you have collected all MSDS for each chemical. You
have done a risk assessment for each chemical and now you have determined which is the best
control measure for each chemical (See HO No 10d completed Inventory / Risk assessment / Control
Approach Table)
Tasks.( 30 min)
1) Use completely filled inventory control table (HO 10d)
Unfortunately the manager of the company “Beautiful Colours” has not yet participated in training
on chemical management and there are no special control measures for any chemical in his
company.
2) Make a gap analysis for each chemical
Use the checklists HO No 10f (for knowing more details about what needs to be undertaken to
control the effects of chemicals harmful through inhalation) and HO No 10g of chemicals affecting
the skin.
Filling these checklists will allow you to do a gap analysis of what is recommended and what exists in
the company. In the Case of BC is easy since not a single control approach exist!
3) Make recommendations to the manager of BC
Work in five groups. Each group choose one chemical and one control approach listed below using
the corresponding checklist.
 Basic yellow use checklist Control approach for inhalation: 2

 Acetic acid use checklist Control approach for inhalation: 3
 2-naphtol use checklist control approach for inhalation: 1
 sodium hydroxide use checklist control approach for skin: high
 reactive black 5 use checklist control approach for skin: medium
You can also refer to the SDS of the 5 chemicals
4) Prepare your presentation of recommendations
Presentations 5 min per group (25 min)
19/95
HO 10F – CHECKLIST „CONTROL APPROACHES“- INHALATION CHEMICALS
Control approach 1 - General ventilation/Housekeeping
Name of the chemical…………………………………………….
In the case of controlling airborne chemicals and other

contaminants, general ventilation is regarded as one of the
best forms of control. The measures under control approach 1
provide good practice advice on the application of general
ventilation at the workplace.
General ventilation is suitable for a range of small, medium and large-scale tasks involving
solid and liquid chemicals. This control approach identifies minimum standards you need to
apply to protect you and your workers’ health. These recommendations should not be used to
justify a lower standard of control than that which may be required for process control or
control of other risks.
20/95
Individual control measures Yes2 No Comments
Access
Do you keep people away from the work area, whose
presence is not required in the work process?
Do you ensure that no one is working close by or
downwind to the source of contaminants?
Design and equipment
Do you ensure that there is unrestricted access to fresh
air? For example, this can be done by working outdoors.
When working indoors, doors and windows may need to
be opened or fresh air supply can be ensured by using
powered fans.
If you work inside a factory building, does a wall mounted
fan remove the dirty air and airbricks or louvers or ceiling
vents allow fresh, clean air into the workroom?
Is the release of dirty (exhaust) air near the clean air
intake avoided?
Do you ensure, where possible, that clean air firstly flows
past the worker and then past the work area?
In the open, do you make sure that the wind blows dirty
air away from you (upwind)?
For factories, do you ensure that the size and number of
fans is sufficient to remove the dirty air from the
workplace (more than one fan may be needed)?
Note: A minimum of 5 air changes per hour is
recommended.
Maintenance
Do you keep fans and/or extractors in good working
order?
Examination and testing
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How to use these lists:
These checklists should be used for each chemical where its control approach has been already identified. You go directly to
the corresponding control approach number (1, 2, 3 or 4) and apply only this number of the list.
You will find three columns with no, yes and comments.
 Yes: means the condition described in the list is fullfilled.

 No: means the condition described in the list is not fullfied; you need still to implement an improvement action.
 Comments: here is recommended to fill specific elements that clarify how the situation is and what kinds of actions
are still needed.
21/95
Individual control measures Yes2 No Comments
Do you check every day that the fans are working when
they are switched on?
Note: A ribbon strip attached to the exhaust side of the
fan cage can be used as an indicator that the fan is
working.
Cleaning/Housekeeping
Do you clean the work equipment and work area on a
daily basis?
Do you clean up spills immediately when they occur?
Do you avoid cleaning up dust with a brush/ broom or
compressed air, instead using a damp cloth or vacuum
where possible?
Do you put lids on containers immediately after use or
when not in use?
Do you store containers/bags in a safe place where they
will not get damaged?
Do you store volatile liquid containers away from direct
sunlight or sources of high temperature?
Training and supervision
Do you tell your workers about the harmful nature of the
substances they are working with and why they must use
the controls provided?
Do you teach and instruct the workers how to handle
chemicals safely?
Do you teach and instruct the workers how to check that
controls (e.g. fans) are working?
Do you teach and instruct the workers about what to do if
something goes wrong?
Do you have a system in place to check that the
precautions you have put in place are being followed?
22/95
Control Approach 2: Local exhaust ventilation (LEV), the most common form of engineering
control
The measure gives good practice advice on the application

of local exhaust ventilation, which is the most common
form of engineering control. The trapped contaminants are
conveyed by ducts to a collector (cyclone, filter house,
scrubbers or electrostatic precipitators) where they are
removed before the air is discharged into the outside
environment. This is accomplished by a special exhaust
system or by increasing the general ventilation.
Local exhaust ventilation can be applied to a range of
small, medium and large scale tasks involving solids and
liquids.
This measure identifies the minimum standards you need to apply to protect your health. lt
should not be used to justify a lower standard of control than that which may be required for
process control or control of other risks.
Individual control measures Yes No Comments

Do you consider the importance of the appropriate design
for an exterior hood?
Do the contaminants flow into the hood and are removed
before they escape into the general workplace
atmosphere?
Do take into consideration other forces (e.g. cross drafts)
and the distance between source and hood may be
hindering the contaminant‘s proper extraction by the
hood?
To control the contaminant, is the velocity of the air
flowing past the source high enough to overcome these
influences and to capture the contaminant with the
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moving air?
Do you apply the local exhaust ventilation (LEV) at the
source of the exposure?
3
This velocity is referred to as the capture velocity. Thus, the proper design of an exterior hood not
only needs considerations of local exhaust ventilation such as shape of the hood, unobstructed
ductwork and fan capacities but also the determination of the required capture velocity (m/s).
23/95
Is there a sufficient airflow to capture the dust or vapour
before it disperses in the workplace?
Have you measured the airflow at the origin of the dust or
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vapour with an anemometer?
Do you contain the source of dust or vapour as much as
possible to stop it from spreading?
Do you prevent workers from getting in between the
source of exposure and the LEV? (Note: Otherwise he or
she will be in the path of the contaminated air)
Where possible, do you locate the work away from doors
and windows to stop draughts from interfering with the
LEV and spreading dust or vapours?
Do you keep extraction ducts short and simple and avoid
long sections of flexible duct?
Do you provide an easy way of checking that the LEV is
working (such as a ribbon strip attached to the output
side)?
Do you discharge extracted air in a safe place away from
doors, windows and air inlets? (Note: Be careful that
extracted air does not affect neighbours.)
Do you keep the hood as close as possible to the source
of exposure?
Maintenance
Do you keep the LEV system in good working order?
Do you check every day that the extraction system is
working when it is switched on before starting work?
Do you check ducts once a week for signs of damage
and repair when necessary?
Do you have the system thoroughly examined and tested
at least once a year?
4
For dust, airflows greater than 1 m/s will generally be needed and for vapours, airflows greater than
0.5 m/s.
24/95
Control Approach 3: Putting distance or shielding/containment between the substance and the
worker
Containment involves enclosing processing equipment in order

to restrict spread of air contaminants to the workplace
environment and isolating sources of heat (e.g. from open
flames, from fuels). It is ideal for processes in which the
worker has minimal chances of coming into contact with the
chemical in question. Contact with hazardous chemicals can be
reduced by isolation, which entails moving the hazardous
process or operations to a remote location in the plant or
constructing a barrier to separate them from other processes.
An example of isolation is separating a spray painting process from the other processes of the
plant by means of a barrier or wall. A similar isolating effect can be obtained by the safe
storage of hazardous chemicals and by restricting the amounts of these chemicals in the
workplace to that required in a day or a shift. Such restriction is useful if the process can be
carried out by a very small number of workers and when control by other methods is difficult
or impossible. The workers engaged in this process however, should be given adequate
personal protection.
The measure gives good practice advice on containment and describes the key points you
have to follow to reduce exposure to an adequate level. Containment can be applied to a range
of small, medium and large scale tasks involving solids and liquids. This control approach
identifies the minimum standards you need to apply to protect your health. lt should not be
used to justify a lower standard of control than that which may be required for process control
or control of other risks.
25/95
Access
Is the work area and equipment clearly marked?
Is entry to the work area controlled?
Are only workers actually needed and trained for that
work process allowed into hazardous work areas?
Is the material handling taking place in a closed system
that separates the worker from the hazardous material by
a solid barrier?
In case limited breaches of the close system are
permitted under controlled conditions, is the exposure
times limited to a few minutes and the quantity of material
handled small (for example for quality control sampling)?
Is the design of the closed system so that it can be easily
maintained?
Where possible, do you keep equipment under negative
pressure to reduce leakage?
Do you vent any exhaust air in a safe place away from
doors, windows, walkways and air inlets?
Do you take care that the exhaust air does not affect
neighbours or other work areas?
Do you provide a sump or separate drainage system to
prevent leaks and spills from contaminating communal
drains and waterways?
Maintenance
Do make sure that all equipment used is well repaired if
necessary and maintained in good and efficient working
order?
Do you adopt a ‘permit to work’ system for all
maintenance work?
Do you document and follow any special procedures that
are needed before the system is opened or entered, e.g.
during purging or washing?
Do you prevent entry into any closed vessel until it has
been checked for hazardous, toxic or flammable
substances and sufficient oxygen (between 19.5% and
23.5%)?
Do you check all the equipment once a week for signs of
damage and repair when necessary?
Do you have the system thoroughly examined and tested
at least once a year?
Cleaning/Housekeeping
Do you clean the work equipment and work area on a
daily basis?
26/95
Do you clean up spills immediately when they occur?
Do you avoid cleaning up dust with a brush/broom or
compressed air, but use a damp cloth or vacuum where
possible, instead?
Do you put lids on containers immediately after use or
when not in use?
Do you store containers in a safe place where they will
not be damaged?
Do you store volatile liquid containers away from direct
sunlight or sources of high temperature?
Personal Protective Equipment (PPE)
Do you avoid using Respiratory Protective Equipment
(RPE) for routine tasks except for cleaning and
maintenance activities and when dealing with spills?
Are you aware that some maintenance tasks may involve
entry into confined spaces where Supplied Air
Respiratory Protective Equipment may be needed?
Do you use such equipment in such situations?
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Control Approach 4: Special advice

Control approach 4 – special – means you have a situation where you need more specific and specialist advice
than provided in the other three control approaches.
Here we refer you to the electronic version of ‘COSHH Essential’ (www.coshh-essentials.org.uk) for further
details. The advice may come from a more detailed Health/Safety/Environment Guidance document, or you may
need to involve an expert, such as a qualified occupational hygienist. An occupational hygienist can give you
site-specific advice on your risk assessment or the possibility of substituting the chemical you are using for a
less hazardous one and control measures.
Some remarks on elimination or substitution
Try to reduce the risk by eliminating the chemical hazard or replacing the chemical with a less
hazardous one.
The most efficient way to reduce chemical hazards is to avoid using toxic substances or substances that pose a
risk of fire or explosion. The selection of the substituting chemical substance should be made at the design and
planning stage of the process. For existing processes, the substitution method should be used wherever
hazardous substances or processes may be replaced by others that are less hazardous. The choice of alternative
substances may be limited, especially where the use of that particular substance is unavoidable if specific
technical and economic requirements are to be met. It is always useful to look for alternative substances by
learning from experience in similar circumstances/processes, sectors.
Substitution is nothing else than a certain type of innovation!
Substitution unfortunately is not always chosen by enterprises. Main reasons for this are:
 No priority given at enterprise. Dealing with the existing problems is already too laborious.
 Companies want no additional problems which might occur with a new, innovative approach
 Uncertainty in risk assessment
 Substitutes are often less tested in practice integration in the production chain makes an innovation
beyond enterprise borders necessary
 Technological or economic difficulties
Try to be innovative whenever possible.
If you are really engaged in chemical management you will understand that sooner or later you have
to substitute your most hazardous chemicals.
Not substituting the hazardous chemicals means that you also will have problems when managing
their disposal. And disposal of hazardous chemicals is expensive and has implications on the
environment and on generations to come.
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HO 10G – CHECKLIST „CONTROL APPROACHES – SKIN“
Control approach “Low”
Name of chemical …………………….
Low control measures Yes No Comments

Is the workplace tidied up and equipment kept clean?
Are splashing of liquids, the release of dusts or mists as
well as skin injuries resulting from cuts or perforations
avoided by means of proper working techniques?
Are leaked or spilled chemical agents removed
immediately by suitable means?
Are chemical-agent residues on the outer surfaces of
containers or packaging removed, particularly in the
case of dust-forming, liquid or sticky products?
Are wastes and used cleaning cloths collected in the
containers provided for that purpose?
Do you/the workers use long-sleeved working clothes to
ensure the general protection against skin contact?
Are distinguishable cleaning cloths for machines and the
hands made available and used?
Are good washing facilities (including soap and clean
towels) provided, particularly in the vicinity of work place
where skin contact of chemical may occur?
Do workers wash their hands before and after eating,
drinking and using the lavatory?
Prior to using new chemical agents, are workers
instructed with regard to the necessary protection and
hygiene measures during their handling?
Does the information on the risk to skin and on the use
of skin-protection, skin-cleansing and skin-care products
form part of the work instructions?
If necessary, are these instructions repeated on a
regular basis?
Do you have a system in place to check that the
precautions and instructions you have put in place are
being followed?
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Control approach “Medium”
Name of the chemical……………..
Medium control measures Yes No Comments

Do you check the Material Safety Data Sheet
or ask your supplier to find out what PPE (type,
material, compatibility) is needed?
Do you ask your protective equipment supplier
for written recommendations on the PPE that
is suitable for your operations?
Do you ask the supplier to train you and your
workers in how to use, maintain and store the
equipment?
Does the information on the risk to skin and on
the use of personal protective equipment form
part of the work instructions?
Do you look after your personal protective
equipment?
When not in use, do you keep PPE clean and
store it in a clean and safe place?
Do you change your protective equipment at
recommended intervals or when it is
damaged?
Do you have a system in place to check that
the precautions and instructions you have put
in place are being followed?
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Control approach “High”
Name of the chemical……………..
In addition to the measures listed under control approach “low and medium” the following
measures should be implemented if a high level of control is needed (this is for instance true
for corrosive substances as well as for toxic substances which can be absorbed by the skin.
High control measures Yes No Comments

Have you considered elimination or
substitution of harmful substances?
Have you considered isolating the process, so
that the workers have no contact with the
hazardous chemicals?
If you cannot avoid exposure by substitution or
containment do you provide/use suitable tools,
instruments, devices or work techniques to
prevent or at least significantly reduce any
contact of the skin with the hazardous
substances?
If this is not possible, do you provide/use
personal protective equipment (e.g. chemical
protective gloves, protective aprons and
protection suits)?
Have you verified that you also have followed
all recommendations included in the checklists
for low and medium control approaches for
skin hazards?
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TECHNICAL SESSION GUIDE 0202– CRITICAL ARES/SITUATIONS
Before using this session guide, read chapters Understanding the hierarchy and principles of controls
and Identify gaps between recommended and existing controls in your company in Practical Chemical
Management Toolkit for your Company, Module 2 – Managing the chemical risks.
This session combines various concepts, which the participants have already used during previous
sessions, in particular non-product outputs (NPOs), inventory table/ risk sheet, control approaches and
gap analysis. Therefore this session, with its case study exercise, allows the participants to recollect
and deepen the understanding of these concepts.
Learning objective
At the end of this session, the participants will be able to
 identify and analyze critical areas/hot spots/ critical situations in a factory
 assess the chemical NPOs costs
 document the findings in such a way to use these as basis for further planning or
communication within their company, amongst others using visual documentation techniques
such as flowcharts and eco-maps
Visualize the following definition of Critical Areas/Hot Spots/ Critical Situations on the flipchart so that it
is visible during the whole exercise.
Critical Areas/Hot Spots/ Critical Situations are:
 Where economic losses can be identified, for example due to inefficient storage, handling, use
and/or disposal of chemicals
 Where improved practices can yield cost savings
 Where potential harm to the environment and outside neighborhood is possible due to the
release and emission of chemicals during use and disposal
 Where potential harm to the workers handling chemicals is possible, in particular when there
are existing gaps between recommended control approaches and existing control approaches
with regard to inhalation and skin exposure
Trainers instructions for Case study exercise – identifying and analyzing gaps in control approaches,
critical areas and costs
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SESSION DESIGN
This exercise deepens the concept of hierarchy and principles of controls for chemical risks and looks
into systematically identifying areas of interventions by assessing possible gaps between
recommended and existing controls of chemical risks on-site for given situations.
The exercise is divided into following steps:
Step Time available
Introduction 20 min
Exercise - Part 1 - Critical areas 50 min
Exercise - Part 2 - Costs assessment 30 min
Exercise – Part 3 – Gap analysis 40 min
Exercise – Part 4 – Management presentation 40 min
Wrap-up of exercise 20 min
Materials required:
 HO 11a, HO 11b, HO 11c, HO 11d, HO 11e, HO 12a, HO 12b, HO 12c, HO 13a, HO13b, HO 13c,
HO 13d, HO 14
PPP 15A, PPP 15B, PPP 16
INTRODUCTION TO THE EXERCISE (20 MIN)
Reiterate that the exercise is a continuation of the earlier case study of “Beautiful colours. It does not
really exist, but the situation described is typical of many medium-sized textile companies and similar
problems have already been identified in real cases. Explain that for this case study exercise, which
deals with the identification and analysis of gaps for critical areas in “Beautiful Colours”, the
participants will have to refer to different sources of information.
Present PPP 14a: What are critical areas and PPP 14b: Examples of hot spots
Referring to the stories “critical areas”( HO No 11a) and “gap analysis” (HO 13a) point out that some
changes have taken place in 'Beautiful Colours' since the first exercise.
Ask the participants to form groups of 4 - 5 persons each. Take care that the groups are mixed with
respect to the professional background of the participants, e.g. one entrepreneur, one
representative from an institution, one consultant etc.
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EXERCISE PART 1 – CRITICAL AREAS/SITUATIONS (50 MIN)
Distribute for the first step the following handouts to participants (the story HO No 11a, the ground
plan (empty) HO NO 11b, and the instructions for group work (HO No 11c)
Remind participants again that important information may need to be extracted from different hand-
outs, for example the inventory table/ risk table.
The working groups complete the tasks as per instruction Ho 11c (first part) on the story of the textile
company ‘Beautiful Colours’.
As facilitator control the time so that participants start to prepare their presentations after 30 min.
After discuss distribute HO 11d
EXERCISE PART 2 – COST ASSESSMENT (30 MIN)
Once every group has finished its presentation, distribute HO No 12a, 12b and second part of HO 11c
and ask the groups to do the exercise during the next 20 min.
Ask the groups to update the information by doing a final review of the findings they have gathered
so far for another 10 min and display their findings in the training room in form of an information
market.
EXERCISE PART 3 - GAP ANALYSIS (40 MIN)
Distribute and go through HO 13a Story gap analysis and instructions (third part of HO 11c and HO
13b). Go through the instructions (what to do, in what time frame and with what result) and
questions. Distribute HO 13c and explain how to fill the table.
Remind participants again that important information may need to be extracted from different hand-
outs, for example the inventory table/ risk table.
As facilitator control the time so that participants start to prepare their presentations after 30 min.
Request the participants to visit the stands of the other groups to review and discuss their findings
for about 10 min. Ask the groups to quickly compare these with their findings.
EXERCISE PART 4 – PRESENTING TO THE MANAGEMENT (40 MIN)
Explain that in most companies such work as done in the first part of the exercise may be entrusted
to a team or even a single person in the company. The implementation of improvement measures
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usually require the support from management (e.g. providing the necessary go-ahead and funding)
and cooperation from colleagues/co-workers).
Ask each group to take 15 min to compile the information on one single flip chart and in such a way
that it can be used for communicating the findings to all management of “Beautiful Colours”. Tell the
groups that they will be invited to make a (max 5 min) presentation to the management. In case of
more than three groups, randomly select 3 groups to present (e.g. select by drawing names).
Each of the selected groups has 5 minutes to make their presentation to the management (remaining
participants, alternatively a management body of 2 - 3 persons can be constituted from within the
participants, with the remaining participants being observers) on the key findings and the critical
areas. Each group should also briefly explain how they arrived at their priority list. Make sure that
each group presents its results in plenary visualized on flipchart paper in form of an “eco map”
indicating location of critical areas identified in the company BC.
After each presentation, there will be 5 min for clarifications, additional questions, different views;
the facilitator asks whether the results of the respective group are complete and correct, and assures
that a large part of the model solutions are covered by the discussion. The model solutions are only a
reference that should be handled with some flexibility.
Hand out the solution sheets (HO 11d, HO13c) and give all groups 15 minutes to compare their
results with the solutions sheets and raise questions for discussion in the plenum.
WRAP-UP OF EXERCISE (20 MIN)
Clarify any questions with regard to the solutions. Remind participants that sifting through all the
information and compiling the same in such a way to make easily comprehensible and a good basis
for further work, poses a great challenge. A systematic approach, such as by using standardized
forms, tools, visualization will help to overcome such challenges. Also point out that proper
preparation, breaking down the task in smaller and manageable parts and team work will make it
easier to accomplish this comprehensive task. Present PPP 16and distribute HO 11e and discuss HO
14 with participants after its distribution.
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HO NO 11A STORY CRITICAL AREAS
“Beautiful colors” a textile company is specialized in done as per an experience based recipe known to
dyeing fabrics that after washing and drying are sent the supervisor, but sometimes also by the workers.
to the printing section, where fancy designs and

The mixture is transferred into whatever empty
patterns are added using screen printing.
buckets, carried to the nearby coloring vessels and
In the general storage area, the dyes and chemicals then poured by the workers into the hot water in the
are received from the suppliers without further coloring vessels; the pre-treated fabric is added and
quality control. One of the workers recently pointed dyed under stirring in the coloring vessels at high
out the red symbol with the black exclamation mark temperature. Occasionally, when the coloring
on a chemical bag wondering about its meaning, but vessels are filled too much, liquids spill out of the
the supervisor did not know. vessels onto the floor. Once the process is
complete, the waste dye liquor is drained into the
All the dyes and chemicals are stored in bags and drainage.
containers next to the fabrics, directly on the floor.
Since the last rainy season the roof of the storage They keep a few open bags and containers of
area has been leaking. A few bags got wet and powdery dyestuffs and other chemicals in the mixing
were put aside in a corner. New materials have place. Sometimes, bags get spoilt when they have
already been ordered. John, the most skilled been lying on the wet floor for too long. To clean the
worker, is the only one who is able to identify dye kitchen from dust and spilt materials, the floor is
different chemicals even if labels or markings on swept by the cleaning personnel every week. They
many chemical containers are damaged or missing. also hose the floor, with the wash water flowing out
into the sandy factory yard.
Because of his long experience, John hands out the
chemicals needed in dyeing or printing process to The cleaning effluent goes directly into the nearby
each worker individually. In case of any questions drainage. Several times the drainage is blocked by
regarding the chemicals everybody checks with him. some old packaging and the cleaning effluent flows
into the yard.
When the chemical containers in the storage area
have been emptied, some of the workers take them The factory has a simple wastewater treatment,
home in order to use them as storage for drinking which has been built ten years ago. However, local
water. Before taking them home, they clean the farmers in the neighborhood are concerned about
empty containers by washing off the remainders the daily color changes of the river water. The
with tap water in the factory yard. Empty chemical treatment sludge from the wastewater treatment is
bags are thrown out into the factory yard and dried and stored in the factory yard. Some solid
burned from time to time together with other types of wastes, including some empty hazardous chemical
waste collected from the different parts in the containers, of the factory are collected every week
factory. by the local garbage collector.
Once the workers have received the chemicals they

carry these in open and unmarked buckets. In the
dye kitchen the color baths are prepared by mixing
water with dyes and auxiliary chemicals. This is
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HO 11B GROUND PLAN OF BC
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HO NO 11C CASE STUDY EXERCISE 'BEAUTIFUL COLOURS' – CRITICAL AREAS
Instructions
During the next 160 minutes complete the following 5 tasks in your group, based on the story of the
textile company 'Beautiful Colours':
First part (50 min) “identification and mapping of critical areas/situations”
1. Read the story (Ho 11a).
2. Indicate on the ground plan of the factory (Ho 11b) where chemicals can be found. In
particular, indicate where in the factory input chemicals and chemical NPOs (Non-Product-
Outputs) are present/ used, and how these move into, in and out of the factory.
3. Identify and indicate (on a separate copy of the ground plan) possible critical areas with
respect to
a. costs - describe the situations where chemicals are used in considerable quantities,
lost or spoilt
b. risks to environment - describe the possible effects of chemicals on the environment
4. Discussion in plenum of the results (30 min). Afterwards distribute HO 11d
Second part (30 min) “costs assessment” exercise: review the additional material provided
Having analyzed the cost of chemical inputs and chemical NPOs, use the information from
the story (HO 12a) and the filled cost assessment table (HO No 12b) to inform when
communicating yours recommendations to the management. Discuss with the other
groups the findings and distribute HO No 12c
Third part (40 min) “gap analysis between existing and recommended control approaches”
exercise: review the additional material provided
Add all the information you have already produced during the work
 BC health control approaches (HO No 10d)
 Ground plan (HO 11b)
 Information you generated during the gap analysis between the recommended and actual
control approaches in the printing area of BC (HO No 13d)
Fourth part preparation for presentation of all results (20 min)
1. Compile the information in such a way, that it can be used for communicating the findings to
all relevant stakeholders within a company and as a basis for planning improvement
measures.
2. You will be invited to make a 5-minute presentation of your findings to the top management
of “Beautiful Colours”. The top management wants to know where the key problems are.
3. In order to prepare yourself for the meeting with the management, analyze the findings in your
group and try arriving at some kind of prioritization
Fifth part “Group presentations” each group 5 min (20 min) maximum 3 groups will present
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HO NO 11D POSSIBLE ANSWERS TO  Printing paste is washed off from screen
instead of being recollected/reused
‘BC’CRITICAL AREAS QUESTIONS FOR
 Remainders in the containers are washed off
GROUP WORK/MODEL SOLUTIONS (not fully emptied and used)
 Cost of medical treatment for workers who
1) Indicate on the factory’s ground plan where
regularly get sick due to exposure to chemicals
chemicals can be found
3) Identify possible hot spots with respect to risk
Incoming chemicals (transport from supplier)
– describe the possible effects of chemicals on
Storage (everything except for cloth)
workers’ health and/or the environment
Dye area
Risks for human health through exposure to
 In the mixing and coloring vessels
chemicals
 Chemicals spilled on the floor or dust coming
 Ingestion of chemicals by contamination of
from powdery materials
food/drinks by dirty hands or vapours in the air
 Bags of dyestuffs stored next to vessels
 Cigarettes are fire or explosion hazards
 Chemicals swept away/dust clouds caused by
 Inhaling of dust/powdery material/solvent
sweeping
vapors (open bags of powdery dyestuffs, wrong
Printing
cleaning method (risk for workers and cleaning
 Printing paste
personnel – effect on respiratory system and
 Printing paste washed off with water or solvents
the organism as a whole) – can be worsened
(cleaning of screens) going into drainage
by smoking
Wastewater
 Direct skin contact with certain chemicals (e.g.
 Chemicals in wastewater from dyeing and
dyestuffs and printing paste in manual printing
printing
causing skin irritations/ rash and harming the
 Chemicals in waste water from cleaning (floor
organism as a whole)
and containers)
 Chemicals in effluent (risk for everyone getting
Waste
in contact with this water: workers, neighbours,
 Remainders of chemicals in the containers (not
farmers, etc.)
completely washed out)
 Chemical containers used for water storage
 Remainders of chemicals in the textile sludge
(workers take containers home to their families)
 Other chemical waste produced in the factory
 Chemicals in the waste (workers, garbage
Product
collector)
Chemicals (colors and auxiliaries) in the cloth
 Chemicals in the product, e.g. carcinogenic
2) Identify possible hot spots with respect to
substances (workers, buyers and customers).
costs – describe the situations where chemicals
Risks for environment
used in considerable quantities are lost or spoilt
 Chemical emissions affect surface,
 Inappropriate storage (white cloth next to
groundwater and soil (e.g. chemicals washed
chemicals, stored directly on the ground not on
off the containers in the yard/chemicals washed
pallets, water leaking through the roof damages
off from printing screen/solvents, chemicals
chemicals, without labels everything depends
from cleaning etc.)
on one knowledgeable worker)
 Inadequate wastewater treatment
 Bags/containers transported into the dye
kitchen may get wet and spoilt
 age of chemicals in the work process
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 Storage of remaining chemicals (sludge, solid  Reduce the hazard to workers to bring down
stored in the yard, affecting groundwater and medical costs
soil)  Provide personal protection equipment (dust
 Effects from inadequate waste disposal, e.g. no mask, gloves, boots)
special treatment and inadequate handling of  Provide local exhaust ventilation
hazardous waste by local garbage collector  Install proper wastewater treatment
 Air emissions from vapours caused by  Do not let workers take home containers.
chemicals (e.g. solvent vapours). Instead, return them to supplier for re-use (for
4) What are causes of the identified hotspots? chemicals again)
Who is responsible/involved?  Training of workers
Possible causes  Test sludge for hazardous substances. If
 Convenience (e.g. bringing dyestuff bags into necessary, dispose of it on special landfill for
dye kitchen) hazardous waste
 Lack of knowledge of health risks/ environment  Separate waste and dispose hazardous waste
risks caused by chemicals (e.g. sickness is properly (on special landfill, etc.)
related to other causes)  Install collection tanks in order to re-use
 Lack of knowledge of proper handling (e.g. chemicals spilt in the processes.
sweeping the floor instead of using industrial
vacuum cleaner or damp cloth)
 No calculation of losses
 Working based on experience – no interest in
labelling (only one person knows what is what)
Who is responsible/involved?
 Suppliers
 Owner
 Second level management (production
manager)
 Workers
 Buyers, customers
 Garbage collector
 Farmers
5) What are possible measures to mitigate
critical areas/hot spots?
 Repair the roof/reorganize storage (e.g. pallets)
 Label all (!!) chemicals properly
 Do not allow anyone to bring open dyestuff
bags into the dye kitchen. Or use other (safer)
systems, such as small closed containers, etc.
 Do not sweep the floor but use the vacuum
cleaner or a damp cloth (and dispose of
contents as hazardous waste)
 Reuse printing paste as much as possible
(don’t simply wash it off)
 Always completely empty containers
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HO 11 E USING ECO- MAPS IN CHEMICAL MANAGEMENT
Eco-maps are simple and practical tools, designed to document and present complex information in a simple
and generally understandable way. As eco-maps are mostly present the information through graphics and
symbols, these tools are suitable for involving person with lower literacy skills.
Eco-maps are basically based on the ground plan(s) of a company and build up a picture of key environmental,
health, safety and other information by using symbols on a simple plan of the site. Information such as on
environmental, health and safety aspects, production set-up (inputs, outputs), production flow, etc. can be
gathered through observations or discussions on-site and are then systematically entered into the map as per
the specific needs.
The visual approach of the method makes it a useful and powerful support tool for raising the awareness of
employees and stakeholders of the environmental, health safety and other impacts of an organization’s
activities. It also enables you to get more people involved at an early stage without needing huge amounts of
special know-how.
You can use several maps in order to facilitate and visualize different problems (“critical situations/hot spots”)
within a company. The different maps (e.g. chemicals, water, energy, air, wastes) create a useful multi layer set
of graphical information and form a readily available fundament for further analysis, planning of action,
monitoring and reporting.
In the context of the chemical management, you can use eco-maps to record flow of chemicals within a
company, their location, chemical NPOs and critical situations such as where money is lost on chemicals, where
specific risks exist for workers, where significant gaps exist between recommended and actual
controls/practices, or where these pose a hazard to neighborhood population and the environment.
A step-by-step approach:
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1. Prepare the basic map
As a first step prepare a map of the company site, seen from above, including car parks, access areas, roads and
the surrounding environment. What is the big picture? Think also about your transport, subcontractors,
procurement policy and the impact of your products and services! In case a ground plan already exists, refer to
the same.
As a second step get an idea of your chemical flows (what is going in and out and where) and their very nature.
This will help you to pay more attention later in the work to some aspects like storage, health risk, resource
use, emergency preparedness and waste management. The material flow is also useful to get a feeling about
associated costs. You can add other maps (chemicals, storage, production, control approaches, energy,
water,…) according to your needs
2. Observe and evaluate the situation on-site

The maps should show the real situation - they should be simple, recognizable and in proportion. They should
have a date, a name and a reference. You will have to integrate one or two significant objects which will enable
you to orient yourself straight away in the site (e.g. machines, boilers, etc.).
3. Enter the information into the map
Before you start entering the information, decide on standardized symbols, colors which need to be
consistently used for all further maps.
Do not overload the eco-maps, otherwise their usefulness will be reduced.

In the context of chemical management, you can use eco-maps for several different purposes functions:
 Making an inventory of environmental, health & safety and production practices and problems
 Using it as a systematic method of conducting an on-site review and audit
 Encouraging employee involvement and participation
 Using it as a support for training and awareness, and to assist with internal and external communication
 an easy way to document and track (environmental) improvements
 a catalogue of immediate small positive actions
During the process you will discover information deficits but also decide on which environmental steps and
actions to implement.
Be aware of the following limitations:
1. They are less strong on determining risks and future challenges and trends
2. The method is more difficult to use for a site that covers a large area.
3. It focuses on site premises and so may be difficult for organizations that work at multiple sites or in a more
diverse set of places
For further reading on eco-maps and the scope of their application, please visit following website:
www.ecomapping.org
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HO NO 12A EXERCISE 'BEAUTIFUL COLOURS' – COSTS ASSESSMENT, BASIC DATA
While checking the different chemical NPOs during the walk-through and discussing with the
responsible staff in “Beautiful Colours”, we were able to gather the following additional data:
(1) In the storage area
 150 kg of screen printing ink has already expired and can no longer be used.
 Further 300 kg of Reactive Black 5 got wet and spoilt due to the leaking roof and can no longer be
used (during the rainy season earlier this year).
Both chemicals have to be replaced in the coming year.
(2) In the production process

 About 5 % each of Reactive Black 5 and Basic Yellow is spilled on the floor every day due to
inadequate handling of bags or overflowing dye baths.
 On average 1% of Acetic Acid is spilled every day. According to the production manager they use
about 100 liters per day.
 Furthermore, every day 10% too much of Basic Yellow and Reactive Black 5 is used. It appears it
is because of wrongly adjusted pH value and temperature in the coloring bath as well as poor
measuring in the dye kitchen.
 Every day about 20% of left-over screen printing ink is being removed while cleaning the screens.
 It is being estimated that about 15% of Acetone is used in excess during cleaning of printing
screens. The supervisor in the printing area informs that they use up about two cans of 10 litres
each every day. The empty cans are thrown out into the yard for further disposal.
Additional information for cost assessment

For daily quantities, check with column 3 in HO 13b The company is operational for 300 days a year.
Assess the cost of chemical inputs and chemical NPOs, using the cost assessment table (Ho 13b). In
particular, you will need to calculate:
 annual chemicals cost (column 5)
 additional cost of chemicals spoilt/expired (column 6)
 losses due to chemicals spills (column 7)
 losses due to chemicals overuse (column 8)
 total annual cost of chemical NPOs (column 9)
 percentage of NPO costs in relation to the overall annual cost of the respective chemicals
(column 10)
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HO 12B CALCULATION TABLE COST ASSESSMENT
Calculation table – cost assessment
Additional
costs caused Losses per Losses per
Amount used Total cost of NPO as % of
Price (kg or Value of Costs per by spoilt or year from year from
Chemical per day (kg chemical NPO total annual
l) in $ daily input year ($) expired chemicals chemicals
or l) per year ($) input
($) chemicals per spilled ($) overuse ($)
year ($)
1 2 3 4 5 6 7 8 9 10
Acetic acid 5 100 l 500
Acetone 10 20 l 200
Basic Yellow 20 70 l 1.400
Reactive black
20 30 kg 600
5
Screen
10 50 l 1.000
printing ink
Total 3.700
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HO 12 C CALCULATION TABLE SOLUTION
Calculation table – cost assessment solution
Additional
costs caused Losses per Losses per
Amount used Total cost of NPO as % of
Price (kg or Value of Costs per by spoilt or year from year from
Chemical per day (kg chemical NPO total annual
l) in $ daily input year ($) expired chemicals chemicals
or l) per year ($) input
($) chemicals per spilled ($) overuse ($)
year ($)
1 2 3 4 5 6 7 8 9 10
Acetic acid 5 100 l 500 150.000 0 1.500 0 1.500 10%
Acetone 10 20 l 200 60.000 0 9.000 1.500 10.500 18%
Basic Yellow 20 70 l 1.400 420.000 0 21.000 42.000 63.000 15%
Reactive black
20 30 kg 600 180.000 6.000 9.000 18.000 23.000 13%
5
Screen
10 50 l 1.000 300.000 1.500 60.000 0 61.500 21%
printing ink
Total 3.700 1.100.000 7.500 100.500 61.500 159.500 15%
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HO 13A GAP ANALYSIS OF INHALATION AND SKIN CONTROL APPROACHES IN THE
PRINTING SECTION
We are back in 'Beautiful Colours', the responsible person some time back to hand
medium-sized textile factory with its 150 out more chemicals at a time. They keep a few
workers. During our previous visits, we have open bags and containers in the mixing place
collected basic information on the main in one corner of the printing section. Since the
production flows, the chemicals in use and all mixing table is not big enough many of these
other chemicals in the company. Based on this chemicals “are stocked” at the floor. They put
information we were able to prepare an together all liquids under the table like acetic
inventory sheet of these chemicals and carry and nitric acid, hydrogen peroxide and caustic
out an assessment of their potential risks and soda. They have also under the table a big
determine the control approaches (see HO No metal container of around 40 liters filled with
11c). acetone that is not always tightly closed.
Sometimes they are spills of acetone and they
After dyeing the fabrics, they are washed and are clean with a cloth and used cloths are
dried. The dried colored cloth is taken to the collected in a bucket in the corner.
printing area.
There is no control for the access of workers
Printing is done manually by applying a printing from other sections to the printing section so
screen ink for a colorful pattern on the cloth. that during the breaks, other workers come
Since it is very hot in the printing area, the here.
workers do not like to wear gloves.
The production manager recently complained
Several times a day the screens are sprayed to the owner, about the low productivity of work
off with water and cleaned with acetone for caused by regular absenteeism due to coughs,
some minutes. The effluents go directly into head-aches and skin rash. The workers do not
the drainage. always leave the production areas during the
breaks but eat, drink and sometimes even
Two wall-mounted ventilators are installed in
smoke at their workplaces.
the printing area of which only one is working.
The printing area has no windows and a typical In the printing section there is a pressurized
smell (a mixture of odors from acetic acid/ water fire extinguisher.
acetone/ printing ink) can be perceived by the
visitors but apparently not by the workers. In An old and very faded signboard with a hardly
the middle of the printing section there is a visible picture of a face mask is hanging near
hood but since the motor makes big noise it is the entrance to the dye kitchen but none of the
all the time switch off. workers know why it is there. The last training
of workers in chemical safety has been
As the workers do not like to walk back and organized by the production manager some
forth between storage and printing section too years ago.
often, they have convinced the storage
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HO 13B INSTRUCTIONS FOR THE GAP ANALYSIS EXERCISE
Group work: Time 30 minutes

Group 1
Make a gap analysis between the existing health control approaches and the recommended
health control approaches in the printing section for Screen Ink Color 110 as recommended in
the risk sheet (HO No 11c). Consult also the MSDS for ink for additional information. Use the
HO10f (Checklist for actions that guarantee an inhalation control according to the control
approach 1) and HO10g (Checklist for actions that guarantee a medium dermal control
approach)
Group 2
Make a gap analysis between the existing health control approaches and the recommended
health control approaches in the printing section for Acetone as recommended in the risk
sheet (HO No 11c). Consult also the MSDS for acetone for additional information. Use HO
No 10f (checklist for actions that guarantees an inhalation control according to control
approach 2) and HO 10g (Checklist for actions that guarantee a medium dermal control
approach)
Present your results in the market place using the form in HO 13d
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HO 13 C: INVENTORY, RISKS ASSESSMENT AND HEALTH CONTROL APPROACHES TABLE BC PRINTING SECTION
Control approaches
Name Cost per l or MSDS R-phrases Hazard type Hazard Hazard Amount per Dustiness/ Inhalation Skin
kg Yes/No group group batch/task volatility
skin
($) P H E Inhalat.
Acetone 10 Yes R11, A A 20 l Liquid 2 Medium
R36, Medium High
R66,
R67
Screen 10 Yes R20, B C Medium Low 1 Medium
printing
R21, 2l
Ink colour
R52
110
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HO 13 D SUGGESTION FOR PRESENTATION OF FINDINGS OF THE GAP ANALYSIS
Working process Chemical Actions already done according to Which other actions need to be done or
area used checklists completed according to checklists
Inhalation skin Inhalation skin
printing Washing Screen ink

the screen 110
“storage of Screen ink
screen ink” 110
printing Screen ink
110
Washing acetone
the screen
“storage of acetone
acetone”
printing Acetone
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HO NO 14 DECISION MATRIX 5
A Decision Matrix, also called an Evaluation Matrix, is used to achieve collective agreement among
members of a group in decision-making. It is obvious that decisions based on real data are ideal, but
in practice data are difficult to obtain in the initial stage of the project. However, this tool can be
bias if most members of the group give high ratings to a particular problem or option. Nevertheless,
Quality Circles or Project Teams still use the Decision Matrix to achieve consensus among the
members. In general, the steps to create a Decision Matrix are:
Problem Severity Frequency Cost implications Cost of inaction Score (1-10)

for resolving the 10 is top priority
problem
Productivity
Material High Always High High 9
consumption
Product quality Medium 82% success Moderate Moderate to High 6
Housekeeping High Always Minimal Moderate to High 10

Environment
Legal compliance Medium to High Occasionally on air, High High 7
always on effluents
Business
Number of rejects Maximal 5% Minimal High 4
from customers
(1) Decide on the objective of the Decision Matrix

(2) Select a list of criteria like cost, frequency, cost of inaction, time, benefit to team, frustration,
safety, environmental enhancement, delays, etc.
(3) Create the table for the Decision Matrix. Decide on the rating system
• Give scores of 1 (low) to 5 or 10 (high) for each criterion
• Evaluate the quantitative and qualitative parameters of each criterion
(4) Rate each problem or option against the criteria by giving scores objectively. It is important that
the team must not be bias towards any problem or option
(5) Select the problem or option with the highest total score
55
From Handbook on Green productivity (APO, 2006)
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TECHNICAL SESSION GUIDE 0202 – SAFE STORAGE OF CHEMICALS
Before using this session guide, read: Understanding the hierarchy and principles of controls and
Identify gaps between recommended and existing controls in your company as well as refer to tool 7
- Safe storage of chemicals in Practical Chemical Management Toolkit for your Company, Module 2
– Managing the chemical risks.
SESSION DESIGN
This session introduces the concept of safe chemical storage as part of the chemical risk
management process. At the end of this session, the participants will be able to
1. Identify and point out basic safety features and requirements of a chemical store
2. Correctly arrange different types of chemicals in a chemical store, while taking into
considerations aspects such as compatibility of chemicals, ergonomic requirements and
productive storage layout.
3. Understand the importance of referring to the safety data sheet on chemical storage
requirements.
Step Time available
Introduction 5 min
Exercise 30 min
Review exercise 20 min
Conclusion 15 min
Materials required (being prepared in advance):
 One sample storage layout for each group (see drawing in HO 15a)
 HO 15b - One compatibility chart for each group
 One set of cut-outs of chemical containers with name, symbol, indication of quantity for
each group
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 MSDS of each chemical
 One solution sheet for each participant (HO 15c)
 HO 15d chemical storage guidelines
 HO 15 e - Checklist on safe storage and handling
 Topic 7
 Pin boards
 PPP 17
 Optional exercise how to calculate net savings and pay back periods when implementing an
improvement measure in the storage ( see HO No 15f, 20 minutes)
INTRODUCTION (5 MIN)
Give the title of the session. Point out that organising the chemical storage is an important part of
the chemical risk management process. Usually many NPOs can be found in the storage area.
Emphasize the point that well-organised chemicals storage contributes to the reduction of chemical
risks in a company while also contributing to a higher productivity in the handling of chemicals.
Explain that the participants will now be given the task of organising a simple chemical store.
EXERCISE (30 MIN)
Divide participants in equal groups (ideally 4 - 5) and distribute storage layout, set of chemicals
containers and compatibility chart to each group. Explain that the objective of the exercise is to find
a suitable place for the different chemical containers in the storage, considering the information
available so to ensure safe storage and productive handling of chemicals. Give the groups 30
minutes to complete the exercise. During the exercise check correctness of layout, point out any
mistakes and ask group to verify and find out. At the end of the exercise each group should display
the completed storage layout.
REVIEW EXERCISE (20 MIN)
Choose one group to present their storage layout in the plenum and ask participants to comment or
ask questions. Ask guided questions in case shortcoming are not identified. Distribute the solutrion
sheet to the participants.
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Invite participants to point out the safety features displayed in the chemical store as well as
additional features (e.g. connection of emergency drain to effluent treatment plant, signboard
limiting access to chemical store for authorised personnel only, control of humidity and
temperature). Highlight the importance of considering the storage also from a possible angle with
regard to fire risk.
Alternatively, you can also refer PPP 14 at this point to review and summarise the important points
about safe storage of chemicals.
CONCLUSION (15 MIN)
Summarize the session by showing pictures of good chemical stores or the solution sheet. Remind
participants of the triple-win benefits of a well organized chemical storage (reduction of risk of fire
and explosion, reducing wastage of chemicals, better and faster overview of stocks in hand;
reduction of health and safety risks to workers,….).
Refer participants to the checklists on safe storage and handling of chemicals in HO 26 e for further
assessment of prevalent conditions and practices in the storage area. Explain that they will use this
checklist during the next company application. Ask the participants to go through HO 26e and clarify
any questions arising.
Point out that further information can be found in the company guidebook. Invite participants to
check the chemical stores in their respective companies using the compatibility chart and referring
to the storage requirements in the safety data sheets or supplier guidelines.
Distribute HO 15d (chemical storage guidelines) and HO 15e self assessment checklist storage and
handling.
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HO 15A SKETCH OF A CHEMICAL STORAGE
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HO NO 15B COMPATIBILITY CHECK FOR HAZARDOUS SUBSTANCES
C Xi, Xn T, T+ F, F+ O E
C   o   
Xi
X     o 
T,
T o   o  
F,
  o   
F+
O  o    
E      
C corrosive Are allowed to be stored together


Xi irritant
Xn harmful Are allowed to be stored together, subject to
o
T, T+ toxic, highly toxic special precautions
F, F+ flammable, highly flammable Are not allowed to be stored together

O oxidizing
E explosive
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HO 15C SOLUTION SKETCH CHEMICALM STORAGE
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HO 15D CHEMICAL STORAGE GUIDELINES
Solids: Low tendency for reaction (when dry) so most can be shelved alphabetically,
exceptions:
Sulfides should be stored away from acids
Cyanide compounds must be segregated from acids, especially liquid acids
Phenol crystals must be stored separately from oxidizers
Liquids: Store liquid chemicals below shoulder height
Acids:. Separate organic acids from inorganic acids, e.g., acetic from nitric
Perchloric acid should be stored alone
Flammable Liquids: The excess of 10 liters must be stored in safety cabinets or in safety cans
Oxidizers: Keep away from acids, bases, organics, and metals Store in cool place
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Incompatible Chemicals
The following list is to be used only as a general guidelin
Chemical: Incompatible with:

Acetic acid Chromic acid, nitric acid, hydroxyl compounds, ethylene glycol, perchloric acid, peroxides.
permanganates
Acetylene Chlorine, bromine, copper, fluorine, silver, mercury
Acetone Concentrated nitric and sulfuric acid mixtures
Alkali and alkaline earth Water, carbon tetrachloride or other chlorinated hydrocarbons, carbon dioxide, halogens
metals
Ammonia (anhydrous) Mercury, chlorine, calcium hypochlorite, iodine, bromine, hydrofluoric acid (anhydrous)
Ammonium nitrate Acids, powdered metals, flammable liquids, chlorates, nitrites, sulfur, finely divided organic
combustible materials
Aniline Nitric acid, hydrogen peroxide
Arsenic materials Any reducing agent
Azides Acids
Bromine See chlorine
Calcium oxide Water
Carbon (activated) Calcium hypochlorite, all oxidizing agents
Chlorates Ammonium salts, acids, powdered metals, sulfur, finely divided organic or combustible
materials
Chromic acid and Acetic acid, naphthalene, camphor, glycerol, alcohol, flammable liquids in general
chromium trioxide
Chlorine Ammonia, acetylene, butadiene, butane, methane, propane(or other petroleum gases).
hydrogen, sodium carbide, benzene, finely divided metal, turpentine
Chlorine dioxide Ammonia, methane, phosphine, hydrogen sulfide
Copper Acetylene, hydrogen peroxide
Cumene hydroperoxide Acids (organic or inorganic)
Cyanides Acids
Flammable liquids Ammonium nitrate, chromic acid, hydrogen peroxide, nitric acid, sodium peroxide, halogens
Fluorine All other chemicals
Hydrocarbons (such as Fluorine, chlorine, bromine, chromic acid, sodium peroxide
butane, propane,
benzene)
Hydrocyanic acid Nitric acid, alkali
Hydrofluoric acid Ammonia (aqueous or anhydrous)
(anhydrous)
Hydrogen sulfide Fuming nitric acid, oxidizing gases
Hypochlorites Acids, activated carbon
Iodine Acetylene, ammonia (aqueous or anhydrous), hydrogen
Mercury Acetylene, fulminic acid, ammonia
Nitrates Acids
Nitric acid (concentrated) Acetic acid, aniline, chromic acid, hydrocyanic acid, hydrogen sulfide, flammable liquids and
gases, copper, brass, any heavy metals
Nitrites Acids
Nitroparaffins Inorganic bases, amines
Oxalic acid Silver, mercury
Oxygen Oils, grease, hydrogen; flammable liquids, solids, and gases
Perchloric Acid Acetic anhydride, bismuth and its alloys, alchohol, paper, wood, grease, oils
Peroxides, organic Acids (organic or inorganic), avoid friction, store cold
Phosphorus (white) Air, oxygen, alkalis, reducing agents
Potassium Carbon tetrachloride, carbon dioxide, water
Potassium chlorate Sulfuric and other acids
Potassium Perchlorate see Sulfuric and other acids
also chlorates
Potassium permanganate Glycerol, ethylene glycol, benzaldehyde, sulfuric acid
Selenides Reducing agents
Silver Acetylene, oxalic acid, tartaric acid, ammonium compounds, fulminic acid
Sodium Carbon tetrachloride, carbon dioxide, water
Sodium nitrite Ammonium nitrate and other ammonium salts
Sodium peroxide Ethyl or methyl alcohol, glacial acetic acid, acetic anhydride, benzaldehyde, carbon
disulfide, glycerin, ethylene glycol, ethyl acetate, methyl acetate, furfural
Sulfides Acids
Sulfuric acid Potassium chlorate, potassium Perchlorate, potassium permanganate (similar compounds of
light metals, such as sodium, lithium)
Tellurides Reducing Agents
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HO NO 15E STORAGE AND HANDLING SELF ASSESSMENT CHECKLIST
Yes Further No
action action WHAT ACTION DO Y OU PROPOSE?
needed needed
Responsibilities assigned
1. Have you assigned a person
exclusively being in charge of the
chemical store(s)?
2. Do you know the qualification this Please specify for your own reference!
person?
3. Is the person regular employee?
Chemical supply:
4. Do verify that only properly labelled

chemical containers are being
allowed into your factory?
5. Do you use mechanised means of
unloading the chemicals? (e.g.
forklift, crane) If not, do you use an
elevated unloading platform with a
ramp?
6. Are the chemicals being unloaded by
your own workers?
7. Are the workers being supervised by
an experienced supervisor or person
in charge of chemical store while
handling chemicals?
8. Are the workers unloading the
chemicals experienced and trained in
handling the substances?
9. Are the workers (regardless your own
or external) provided with personal
protective gear when unloading the
chemicals?
10. Do the workers use the personal
protective gear while unloading the
chemicals?
Storage organization and inventory
11. Do you keep track of the chemical
movement and shelve lives of all the
chemicals in your storage in a
separate chemical inventory?
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Yes Further No
needed needed
12. Are the chemical requisitions from
the various workplaces being
recorded in the chemical store and
the respective workplace?
13. Does your supplier provide you with
the chemical/ material safety data
sheets for all the chemicals?
14. Do you keep the chemical safety data
sheets in a separate file for easy
reference?
15. Do the workers have access to this
information?
16. Have you or your supervisor
informed the workers unloading or
handling chemicals on the hazardous
nature of chemicals?
17. Do all the chemical containers/bags/
drums/ barrels have proper labels
attached - clearly indicating the
following:
 content
 trade name
 name/ address/telephone
number of the supplier
 hazard symbols
 specials risks associated
 Safety and emergency
procedures
18. Do you or persons assigned by you
take samples to check whether the
chemicals comply with your quality
specifications?
19. Do have access to and use facilities to
analyses quality/purity of chemicals?
Storage layout
20. Is the storage area being locked?
21. Do you keep incompatible chemicals

in different storage places? (Criteria:
incompatible chemicals have to be
stored in separate storage places)
Check with your compatibility chart or with section 10
in respective MSDS.
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Yes Further No
needed needed
22. Do you store chemicals chemical-
wise in separate places/on separate
pallets?
23. Are the heavier chemical containers
stored on the lower racks?
24. Are the hazardous liquid chemicals
stored on the lower racks?
25. Are the designated storage places
clearly indicated by separate boards
or labels?
26. Do you store sulphide containing
chemicals in air tight containers?
27. Does the supplier take the
containers/barrels/drums back?
28. Do you dispose empty chemical
containers, barrels as per clearly
established procedures or legal
requirements?
29. Do you clean/rinse all
container/barrels before disposing?
30. Is the storage building isolated from

the factory workplace, welfare
installations, power house, water
supply system?
31. Does the chemical storage have
separate emergency drainage and
collection system? (Please note: Also
this drainage should be connected to
a treatment facility!)
Chemical storage emergency
procedures:
32. Do you have facilities in place to deal
with chemical spillage and/or
leakage? (e.g. do you keep one spare
container/ barrel/etc. for each
hazardous substance, bucket of
sand,..)
33. Does the storage area have separate
firefighting equipment?
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Yes Further No
needed needed
34. Do you know which chemicals are
being considered hazardous? (Please
note: Mixing of different chemicals
can generated even more hazardous
combinations!)
35. Have you listed out and displayed
hazardous chemicals in the store?
36. Are the workers dealing with
chemicals trained in safe handling
them?
37. Do the workers use special tools for
taking out chemicals from original
storage container? (spatula, spoons,
taps, etc.)
38. Do use a separate
space/room/location outside
chemical storage for preparing
chemicals (mixing, diluting,…)?
39. Do you prepare correct chemical
mixes/dosages before transporting to
workplace?
40. Are proper containers used for
transferring chemicals from storage
to workplaces?
41. Do you transport the chemicals on a
special trolley/cart instead of carrying
by hand?
42. Have the workers handling the
chemicals at each stage been
informed and trained about the
hazards involved in handling the
chemicals?
43. Are these workers trained and
capable to take necessary emergency
measures to cope with chemical
hazards?
44. Have you conducted a refresher
training during the last six months?
Personal protection and hygiene
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Yes Further No
needed needed
45. Do the workers wear all the
protective gear (goggles, gloves,
footwear, apron, face mask,..) as
prescribed on the chemical safety
data sheets while handling hazardous
chemicals?
46. Are washing facilities provided to the
worker in the staking yard?
47. Is a separate first-aid box provided in
the storage area?
48. Are relevant emergency procedures
visibly displayed and understood by
each worker in the storage area?
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HO NO 15F HOW TO CALCULATE NET SAVINGS/PAYBACK PERIOD?
Chemicals in the company BC are disorderly ‘stored’, directly on the floor. This leads
to losses due to chemicals getting wet and being spilled/spoiled. After a company
visit and an analysis of causes and formulation of an action plan you find that an
improvement measure in the storage area has been proposed.
In the table here below is explain which information is necessary to calculate the net
savings and the payback period of the identified measure and how do you calculate
the net savings and the payback period.
The identified measure is the organization of the storage and installation of shelves
Calculation of measure: Organization of storage and installation of shelves in a company in South Africa
Required
Criteria Formula Result Information
information
Total cost of Amount chemicals - supplier of
1t per month x
chemicals per year in stored per year and 7560$/year chemicals
630 $/t
the storage costs of chemicals - Accounting
Losses due to Estimated by
inappropriate storage 5% 5 % of total 378$/year country team during
(estimation) the workshop
Yearly gross savings 5 % =- 1 %
through the Reduction of losses (378$ =- 75.6$) Estimation and
302.4$ /year
implementation of the from 5 % to 1 % Equivalent to 80% calculation
measure reduction in losses
Additional operational
costs caused by the
None --- --- ---
implementation of the
measure per year
Net saving per year (Gross saving –

302.4$/year
(USD /year) additional costs)
Costs of shelves
Investment in USD 215$ Supplier
and installation
Payback period (in (Investment / net

8.5 months
months) saving) x 12
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TECHNICAL SESSION GUIDE 0203 - SELECTING AND USING PERSONAL PROTECTION
Before using this session guide, read chapter personal protection and hygiene, and go through topics
4d (setting a respiratory protection program) 4e (selecting the correct respirators), 5d(select and use
protective equipment for skin and eyes) and 5e (special guidance on selection of protective gloves) in
the annex of Practical Chemical Management Toolkit for your Company, Module 2 – Managing the
risks in your company – control measures and gap analysis.
SESSION DESIGN
This session introduces the important aspects of personal protection and use of personal protective
equipment as a means of controlling exposure to chemical hazards. At the end of this session, the
participants will be able to
1. Assess the requirements of personal protective measures in their company

2. Specify the requirements of personal protective equipments (e.g. to supplier, purchase
department, etc.)
3. Understand the basic elements and requirements for a personal protection programme
Step Time available
Introduction 5 min
Exercise 30 min
Conclusion 5 min
Materials required:
 Safety data sheets from Inventory exercise, Module 1

 HO 16
 Topic 4d, Topic 4e, Topic 5d, Topic 5e
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At the beginning of the session, refer back to module 2 (chapter hierarchy of controls). Point out that
one of the four strategies presented has been the use of personal protective measures, which
includes the use of different personal protective equipment. Emphasize that personal protective
equipment should also be considered as the last choice for exposure protection. If this last barrier
between a hazardous chemical and the person fails, the person will be fully exposed to the chemical.
Similarly wrongly chosen personal protective equipment will create the illusion of protection for its
user.
EXERCISE (30 MIN)
Ask the participants to form groups of 4 - 5 persons. Distribute the safety data sheets from the
inventory exercises, Module 1. Each groups is given 15 min to identify and extract different
recommendations on personal protective measures from the safety data sheets and to group this in
terms of different types of exposure they control (e.g. inhalation, skin contact).
Quickly review the findings of the groups in the plenum. Ask whether they would be able to prepare
a specification for the purchase of personal protective equipment such as gloves, masks etc. Explain
that not all types of PPE are suitable for all types of chemicals and further clarification needs to be
sought.
Distribute HO 16 and ask the groups to use the information and instructions to further specify the
type of gloves they would have to order for the situation in “Beautiful Colours” (10 min).
REVIEW THE EXERCISE (30 MIN)
Point out that further information on the selection of PPE for skin and eye protection is available in
topic 5d.
Explain that similar guidelines exist for the selection of respiratory protecive equipment. Distribute
topic 4e. Referring to the following guiding questions and to the information from the safety data
sheets used in “Beautiful Colours”, go through the questions in the plenum to demonstrate how to
select the correct respirator:
 What are the contaminants?

 What are their concentrations?
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 What is the applicable Occupational Exposure Limit (OEL)?
 What is the protection factor of the respirator?
 Are the contaminants gaseous or particulate or a combination of both?
 Do the contaminants have adequate warning properties such as smell and/or taste?
 Are the contaminants immediately dangerous to life and health?
 Does the atmosphere contain enough oxygen?
Make some assumptions about concentrations in order to be able to proceed with the
demonstration.
CONCLUSION
Re-emphasize that personal protective equipment should only be considered as the last choice for
exposure protection. PPE is more intended to be used in case where exposure is unavoidable (e.g.
sampling, maintenance). Remind the participants that wrongly selected PPE can do more harm.
Furthermore, point out that provision of PPE always needs to be accompanied by training which
familiarizes the user in the proper wear and care.
Finally, encourage the participants to use the topics in the annexes of the guide when they have to
prepare specifications for PPEs required or when interacting with a potential supplier. A good PPE
supplier would ask similar questions.
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HO NO 16 GLOVE MATERIAL SELECTION CHART
Selecting the proper chemical protection glove is a process that requires examining the
chemicals used, the processes and exposure times. Not all "rubber" type chemical protection
gloves are the same. You cannot determine the applicability of a specific chemical protective
glove without knowing the exact material and the materials resistance to decomposition for
specific chemicals. In the table the following abbreviations are used:
S - Superior
E - Excellent
G - Good
F - Fair
NR - Not Recommended
*Not recommended for Acetaldehyde, use Butyl Rubber
BUTYL Polyvinyl NATURAL
CHEMICAL FAMILY NEOPRENE NITRILE
RUBBER chloride LATEX
Acetates G NR NR NR NR
Acids, inorganic G E E E E
Acids, organic E E E E E
Acetonitrile, Acrylonitrile G E G S E
Alcohols E E NR E E
Aldehydes E G NR S* NR
Amines S NR NR F NR
Bases, inorganic E E E E E
Ethers G F NR E NR
Halogens (liquids) G NR F E NR
Inks G E E S F
Ketones E G NR NR G
Nitro compounds
(Nitrobenzene, G NR NR NR NR
Nitromethane)
Oleic Acid E E F E NR
Phenols E E NR NR G
Quinones NR E G E E
Solvents, Aliphatic NR NR F G NR
Solvents, Aromatic NR NR F F NR
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TECHNICAL SESSION GUIDE 0204 – MANAGING CHEMICAL EMERGENCIES
Before using this session guide, read chapter Emergency preparedness and response in Practical
Chemical Management Toolkit for your Company, Module 2 – Managing the chemical risks.
SESSION DESIGN
This session familiarizes the participants with the key elements of managing chemical emergencies.
At the end of this session, the participants will be able to
 Identify possible chemical emergency scenarios in their company, such as fire/explosions

chemical leaks, medical emergencies involving chemicals
 Assess the status of emergency preparedness in their company
 Plan and prepare for different emergency situations
Step Time available
Introduction 15 min
Exercise 60 min
Exercise control banding for fire and explosions 60 min
Conclusion 5 min
Materials required:
- Topic 6c: Fire prevention and extinguishers

- HO 17a, 17b, 17c, 17d, 17e,m17f and 17g
- Safety data sheets from inventory exercise, module 1
- PPP 18a emergency management
- PPP 18b control banding for fire and explosions
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Start the session by asking the participants to list different emergency situations they might have
experienced or heard of. Cluster the replies in groups (e.g. fire/explosion, accidental releases, and
medical emergencies). Add some examples, if not mentioned (e.g. Seveso, Bhopal, Hungary, Golf of
Mexico, Basle,...). Ask the participants to identify those emergencies which directly or indirectly
involve chemicals.
Explain that chemical emergencies are a special category of emergencies. One role of chemical risk
management includes the prevention of such chemical emergencies. However, as part of the overall
emergency management in a company, chemical risk management also comprises steps of preparing
for and being able to respond to chemical emergencies. Point out that even after taking preventive
and precautionary measures in the storage and handling of chemicals, there is still a chance that
emergencies involving chemicals may occur. As with the preventive and control measures, the key to
being able to respond to an emergency lies with sound knowledge of the chemical substances and
waste used or present in your company.
Explain the objectives of this session.
PREPARING FOR AN EMERGENCY – EXERCISE (60 MIN)
Before specifically looking into chemical emergency, briefly explain import elements of general
emergency management. You can use PPP 18 (Emergency management, 15 min).
Ask the participants to form groups (4-5 persons each) and distribute HO 17a “A hot day at Beautiful
Colours” – quickly review the tasks given. Remind the participants to refer to the safety data sheets
for further information and guidance on emergency requirements. Ask participants to also use topic
6c /fire safety and extinguishers) for completing the exercise. The groups have 45 min to complete
the task and compile their findings.
REVIEW OF EXERCISE (30 MIN)
Ask the participants what information sources they used to complete the tasks given (e.g. How useful
was the information in the safety data sheets? What other information did you use for example
inventory table, flow chart, floor plan?). to
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Ask selected groups make a short presentation (not longer than 5 min) of the preventive and
preparedness measures identified, followed by discussion in the plenary to discuss or complement
the results.
Conclude the review of the exercises by pointing out that the provision of the emergency facilities is
not sufficient to ensure a good response to an emergency. Preparedness also means to have an
emergency plan which lays down procedures for
- Evacuation of workers, including a system of accounting for all workers outside the premises
- Methods of notifying outside assistance such as fire brigade, ambulance, hospital, spill control
experts, local and national emergency focal points
- Role of different persons on site (management, supervisors, company’s own emergency services
e.g. company doctor, trained fire fighters)
- Role of selected workers
- Location, use and maintenance of emergency equipment in the company
In case the participant’s company do not have an emergency plan, encourage them to prepare and to
communicate a simple emergency plan for every workplace giving clear and easily understandable
instructions what to do in a case of an emergency. In case there is already an emergency plan,
suggest that the participants review the same and check whether the workers in their company know
what to do.
FIRE AND EXPLOSION CONTROL BANDING EXERCISE (60 MIN)
Using the same control banding methodology presents PPP18b (fire and explosions) as an
introduction to the following exercise. Distribute HO No 17b, 17c, 17d and by using control banding
make a fire risk assessment and determination of the appropriate control approach for the different
chemicals. At the end of the exercise distribute the completely filled table (HO 17e)
CONCLUSION
Summarise that one will find immediate guidance on how to respond to emergency situations such
as fire, explosion, spill and accidental exposure in the safety data sheets. From this information one
can easily derive what measures you might have to take to be prepared for such emergencies; for
example what type of fire extinguisher do you need, what fire fighting techniques are suitable what
type of material you can use to absorb or clean spilled or leaked material, what first aid provisions do
you need (e.g. any antidotes, special cream, ointments).
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Distribute HO 17f fire check list and HO 17g Emergency Checklist and explain that the participants
will assess the emergency preparedness in their respective companies as part of their next company
application, identifying gaps between recommended good practices and situation and requirements
in the workplace with regard to emergency prevention and preparedness.
EMERGENCY EXERCISE (ALTERNATIVE) 60 MIN
Referring to the initial brainstorming on different types of chemical emergencies, select following
scenarios for the exercise: (1) fire/explosion, (2) spillage and accidental release (including release of
toxic gases), (3) medical emergency involving chemicals).
Form mixed groups with 3 to 4 persons (in each group: one representative of a company, institution,
one consultant and/or one person with good knowledge and experience with chemicals)
Distribute – Merck MSDS Acetone and HO No 17g Emergency Checklist.
Then ask the groups to identify relevant recommendations on emergency procedures and measures
as listed in the safety data sheet, referring to the different emergency situations selected. Time
given: 15 min
As a second step, ask each group to review the recommendations in the assigned sections of the
emergency checklist and prepares a 5 min plenary presentation on the key recommendations, also
referring to information found in the safety data sheet.
Review the exercise in the plenary (30 min). Ask selected groups to make a short presentation (not
longer than 5 min) of the preventive and preparedness measures identified, followed by discussion in
the plenary to discuss or complement the results.
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HO 17A A HOT DAY AT „BEAUTIFUL COLOURS“
It is a hot summer day and work in “BC” is in full swing. One of the workers has noticed that in the store room
of “BC” one of the barrels containing cleaning solvent has developed a leak. As it is only a small wet batch on
floor, he does pay any more attention to it. It seems that one of the other workers in the store had accidentally
hit the barrel with the newly acquired forklift when reversing in the storage area.
The sun is shining onto the roof of the store room. The small wall mounted fan hardly makes a difference to
easy the hot air inside. The store-in-charge has placed an old stand fan in the store to increase the air
circulation. As he had not found a proper plug point, he had plugged the blank wires into a socket, near the
chemical containers. Unknown by the store-in-charge, the barrel’s side has been cracked quite severely and
more liquids are spilling out and collecting near the stand fan. Due to the heat the solvent is quickly
evaporating.
Suddenly, there is a flash and the floor around the stand fan is on fire. Quickly the fire makes it ways to the
barrel with the solvent, which blows up in flames with a loud crackling sound. The store-in-charge rushes out
into the open yard in panic. There is a fire extinguisher somewhere, which has been installed by the
management some months ago. So far, he had not received any training on how to use it. Shouting loud he
runs into the production areas to alert the other workers. Confused the workers try rushing to different exits
from the work area. Eventually the production supervisor alerted by all the running around emerges from his
office. Somehow is able to extract the information from the store-in-charge an about what has happened.
Quickly he runs back into the office and calls the fire brigade. Then he joins the other workers who have
gathered outside the factory building in different locations. It appears that somebody is still inside the
building…..
This is what might happen at “Beautiful Colours”. To prepare for possible chemical emergencies at “Beautiful
Colours”, the management has called your team to a meeting to discuss how “Beautiful Colours” could prepare
for possible emergencies.
Your tasks as a group:
1. Identify possible chemical emergency scenarios in “Beautiful Colours” – use the different documents
you have prepared so far, in particularly floor plans, flow charts, inventory table
2. Decide what and where emergency equipment may be required in the company, in particular in terms
of
 Active and passive fire fighting facilities (e.g. type of fire extinguishers)
 Emergency leak control kits and provisions (e.g. dyking, clean-up)
 Emergency vessels and containers to hold leaking material
 Medical first aid provisions
 General and special personal protective equipment for emergency personnel
3. Compile your group’s findings for presentation in the plenum.
Time: 45 min
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HO NO 17B STORY FIRE AND EXPLOSION IN BC
BC is located in a residential area and has around 150 workers. Many different workshops are group
together in great proximity to the storage. The storage room has roof ventilation and can be closed
by key. Very near to the storage room is a vast workshop where in case of fire or explosion smoke
can propagate easily due to lack of division of the workshop sections.
Three propane gas cylinders are stored in one corner of the storage room close to an extinguisher.
On the other corner in a wood container are stored around 50 kg of clean cloth (to be used as
wipers).
In the storage of BC you find additionally the following chemicals and materials:
 50 litres of Acetic acid

 200 litres of Acetone
 100 litres of Toluene
 a 200 litres barrel full with diesel
Task:
Form 3-4 company groups and make a fire and explosion risk assessment for BC by filling HO 17c
(consult SDS) and determine the appropriate control approach for each chemical
Time: 30 min
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HO NO 17C RISK ASSESSMENT TABLE FOR FIRE AND EXPLOSION (EMPTY)
Area/ Name SDS R-phrases/ Hazard Physic Boiling Liberation Dustiness Quantities Duration Level of Potential Control
Process Yes/ Flash point type al point/ group for for solids in use of use hazard extend of approach
Hazard vapor liquids (I,II,III) damage
No P H E
group pressur
Storage Acetone Yes R11, R36, C 56.2°C medium 200 l Long III high 3
R66, R67
24 kPa medium
-20°C
Storage Acetic
acid
Storage Toluene
Storage Diesel
storage Propane
gas
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HO 17D FIRE RISK ASSESSMENT USING CONTROL BANDING
According to BAuA, 2011 you can determine the control approach for fire and explosion for a specific
chemical after you have considered the 3 following parameters:
1. Physical hazard group

2. level of flammable or expolsive atmosphere formation
3. potential extent of damage
Physical hazard group
Physical hazard Risk(R-) Phrases
group
Physical A No R-Phrases, flammable
substances
Physical B R 10
Physical C R5,R6, R7, R8, R9, R11, R12,
R14, R15, R16, R18, R30, R44
Physical D R1, R2, R3, R4, R17, R19
 Table 1 classification of physical hazard groups according to BAuA 2011
The level for the formation of 3 different flammable or explosives atmospheres (mixtures of air
with other chemical substances that may lead to fire or explosive conditions) can be determined by
considering the following parameters: the boiling point, the vapor pressure, the dustiness, the
quantity and the time in use.
Level of (flammable or explosives) atmospheres (I,II, and III)

Liberation group for liquids Dustiness for solids Quantities in use Duration of use
Short Medium Long
LOW Small sized e.g. pellets, Low I I I
Boiling point: >150°C granulates, wax medium I II II
Vapor pressure: < 0.5 KPa high II II III
MEDIUM Dust that settle down after Low I I II
Boiling point: 150°-50°C short time e.g. sugar, medium II II III
Vapor pressure: 0.5 - 25 KPa detergent high II III III
Pellet and granular grit
HIGH Dust clouds that remain Low I II III
Boiling point: < 50°C some minutes in the air medium II III III
Vapor pressure:< 25 KPa e.g. toner, flour high II III III
 Table 2 - Determination of the level of (flammable or explosive) atmosphere, BAuA 2011
Parameters to be considered for determining the level of formation of flammable or explosive

atmospheres I, II or III:
(1) Quantity in use
Low ml or g
Medium l or kg
High m3 or t
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(2) Duration of use:
Short < 15 min sporadically
Medium < 15 min in series
Long >15 min
By combining the two parameters in Table 2 you obtain the level of hazard atmospheres (I, II or III)
for the chemical in question.
Determining the control approach6:
Influence of the working activity and the

surroundings
Hazard group Level of Potential extent of damage
hazard
flammable or
explosives Normal High
atmosphere
formation
Physical A I 1 1
II 1 2
III 1 2
Physical B I 1 1
II 1 2
III 2 3
Physical C I 1 1
II 2 3
III 2 3
Physical D Independent 4
 Table 3: Determining the control approach for fire and explosions according to BAuA, 2011
Now you need to determine if the potential extent of damage is normal or high.
A normal potential extent of damage has to be assumed when one of the following conditions is
fulfilled in the work area/ field of activity
-Many persons (>10) are active / present in the area
-There is public access (e. g. patients or students are present)
-There are technical facilities / equipment or closed systems on-site, especially problematic if
they are under high pressure and / or operate under high temperatures
- Many different workplaces are grouped together in close proximity
- There is a high density of buildings in the immediate surroundings of the enterprise,
especially problematic if the enterprise is located in a residential area
- The possibility /danger of a high smoke generation is given due to the hazardous substances
at hand (e g. petroleum products like diesel, synthetics / plastics, turpentine substitutes,
detergents / cleaning agents or also wood potentially leading to smouldering fires), as well as
the danger of a quick spread of the smoke due to the local conditions (e. g. vast factory
workshop without divisions into sections for the smoke)
- A danger of severe (irreversible) injuries or even fatal accidents is given (e. g. due to
containers under high pressure with a raised temperature)
A high potential extent of damage has to be assumed when at least three of the above mentioned
conditions are fulfilled in the work area /field of activity..
6
These control approaches 1-4 are the same as the ones recommended for control chemicals that causes harm to human health through
inhalation
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HO NO 17E RISK ASSESSMENT TABLE FOR FIRE AND EXPLOSION (FILLED)
Area/ Name SDS R-phrases/ Hazard Physic Boiling Liberation Dustiness Quantities Duration Level of Potential Control
Process Yes/N Flash point type al point/ group for for solids in use of use hazard extend of approach
o Hazard vapor liquids (I,II,III) damage
P H E
group pressur
Storage Acetone Yes R11, R36, C 56.2°C medium 200 l long III high 3
R66, R67
24 kPa medium
-20°C
Storage Acetic Yes R10, R35 B 118°C medium 50 l long III high 3
acid
38°C 15,5 kPa medium
Storage Toluene Yes R11, R38, C 3-3.5 kPa medium 100 l long III high 3
R48/20, medium
R63, R65,
R67
Storage Diesel R40, R65, A > 160 - Low 200 l long II high 2
R66, 385°C
medium
R51/53
< 0.04
Min 56°C kPa
storage Propane Yes R12 C - 42.1 °C high Medium long III high 3
gas
830 kPa
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HO NO 17F SAMPLE CHECKLIST FIRE PREVENTION FOR SUPERVISORS
Supervisors' Safety Checklist – Fire Prevention
Supervisor:
Date: Department/Area
Yes No Checklist Area
Area Safety Check
all flammable liquids are stored in approved, vented storage lockers
oily rags are disposed of in approved containers
electrical motors are checked daily for overheating
trash is not allowed to accumulate in work areas
flammable material is not stored under stairs
no storage allowed in electrical utility rooms
waste dumpsters are not located next to buildings
smoking is allowed only in designated areas - waste containers provided
flammable storage areas are posted with No Smoking signs
combustible gases are properly stored
bonding & grounding of flammable liquid containers is enforced
incompatible chemicals are stored in separate areas
Hot Work permits are used for all welding and spark producing operations
access to utility & equipment rooms is restricted to authorized employees
combustible & flammable material is not stored near gas fired equipment
Worker Training - workers are trained to
recognize and report fire hazards
to activate fire alarms
understand proper storage of flammable liquids
(supervisors) properly use fire extinguishers
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HO NO 17G EMERGENCY CHECKLIST
Point to consider Your assessment

Contingency analysis been conducted to determine what emergencies
might arise?
Emergency plans and procedures developed for potentially
catastrophic events such as
 Fires
 Blasts and explosions
 Leaks and spills
 Floods
 Tsunami
 Earthquake
 Civil unrest (mob attack)
Emergency plans provide for procedures for extinguishing different
types of fires, which might occur in the factory/office?
Emergency plans include evacuation and recovery procedures for

each type of emergency?
Roles and responsibilities assigned in the plan to specific persons
during emergencies?
These persons aware of their responsibilities?
Persons are qualified/ have been trained to carry out necessary
actions? Records available?
Is emergency personnel qualified, designated and on station during
and after office hours?
Different communication channels assigned to support emergency
measures?
Emergency phones available in all relevant sections, with important
numbers clearly displayed?
Plans to evacuate personnel from each factory/office area in the event
of emergencies?
Evacuation routes and warning signals information posted in each
factory/office area?
Evacuation routes and exits marked?
Emergency plans and procedures posted in prominent areas?
All personnel received training in emergency procedures
Drills on simulated emergencies being conducted periodically (at
least once a year) for all personnel? Lessons learned documented?
Procedures available to ensure that all personnel has been alerted to
the emergency and those who will not combat it have been
evacuated?
Existing escape provisions adequate (doors, stairways, elevators) for
the evacuation?
All doors open in the proper direction (in direction of escape) to
facility escape of personnel?
Procedures to preclude obstructions to personnel or access routes or
areas prepared and communicated?
Can personnel follow escape routes from factory/office areas in the
dark or in smoke?
Emergency assembly points established and clearly marked
Procedure for post evacuation head-count in place
Emergency equipment required as per the emergency procedures
available at the facility and operational?
Emergency equipment can be reached easily, if an emergency
occurs?
Self-contained warning systems installed (sirens, loudspeaker, etc.)
and tested periodically?
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Point to consider Your assessment
All personnel familiar with the meaning of warning signals and the
required action to be taken?
Procedure in place to make outside persons (visitors, contractors,
suppliers, customers) aware of the emergency procedures?
Is there fire-fighting equipment located near flammable or hazardous
areas (e.g. generator area, fuel storage tank, transformer)?
Location of the fire fighting equipment easily accessible and in
clearly marked locations?
Firefighting equipment provided in the locations appropriate to
control the respective type of fire in these locations?
First-aid kits available in designated and clearly marked areas
Procedure established and maintained to check and replenish content
of first aid kits (e.g. designated persons in-charge of first aid box)
Certified first aiders available in each section/agency during office
hours
Names and locations of first aid personnel indicated on first aid boxes
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PREPARE FOR COMPANY APPLICATION
After the participants have familiarised themselves with the basic steps of the gap analysis as
systematic approach to identifying differences between recommended and existing controls , the
participants will have the opportunity to practically carry out a first approximated gap analysis in
their company and apply different assessment tools in their respective companies. This will be done
in form of a “company application”. Some days later when all tables have been filled and all pendinhg
information has been collected a second approximation of a control approaches gap analysis should
be undertaken.
Respect the time limit: maximum 60 minutes
SESSION DESIGN
During this session, the participants will prepare the work plans for accomplishing the tasks assigned
to them for the company application. This will be done in company teams. Here often confusion
arises, as participants assume that everybody will visit all companies. This should be clarified to the
management of the participating companies in advance as companies often are reluctant to allow
external visitors into their premises.
Each company team will consist of the company representatives (those who are participating in the
training, plus additional company representatives assigned to the company’s change team). Each
team may be accompanied by one – two consultants who participate in the training (as part of TOT).
During the company visit the trainers are expected to visit each company to review the ongoing work
on site and to provide assistance to the company teams.
The preparatory session is divided into following steps:
Step Time available
Introduction to company application 5 min
Preparation of work plan and distribution of tasks in teams 45 min
Logistical arrangements 10 min
Materials required:
- HO 18a, HO 18b and HO 18c
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INTRODUCTION TO COMPANY APPLICATION (15)
Explain that after the participants have familiarised themselves with the basic concepts of NPOs,
preparation of an inventory and the assessment of hazards and risk using the control banding
methodology, they will have the opportunity to practically apply these tools in their respective
companies. This will be done in form of a “company application”. The purpose of this session is to
help them with guidance from the trainers to prepare for the tasks which will be assigned to them.
Point out that the work will be done in company teams only.
Distribute HO and go through the task to be performed by the company teams. Explain that each
company team is expected to complete the following tasks:
1. Select one work area in the company and carry out a gap analysis
2. Assess the storage of chemicals (conditions, practices)
3. Identify possible chemical emergency situations and assess the emergency preparedness of
the company
4. Collect other data and information which will the company teams to prepare an action plan
5. Prepare a short presentation of your visit on a flipchart for the next day of training.
PREPARATION OF WORKPLANS (45 MIN)
Ask the participants to break up in company teams and start with the preparation of their work plans
for completing the tasks on-site. In case TOT participants are present, assign these to different
company teams to assist with the preparation of the work plans as well as the completion of tasks
on-site.
Advise the teams that before starting, they should consider points such as what information they
would need, from whom and where they can get it. They should also decide who will coordinate the
group work, distribute the responsibilities, etc.
At the end of this session, each company team should have a draft work plan for the company
application. Time allotted is 45 minutes.
LOGISTICAL ARRANGEMENTS (10 MIN)
Briefly clarify the organizational aspects of the visit to the company.
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Ask the participants to make sure that they have the following information/materials with them
when they go to the companies
 Checklists
 Camera for documentation
Before completing the session, remind the participants that each company team is expected to
present the results of the visit in the plenary (for about 5 – 10 min), also dealing with organizational
issues such as where did you find the information, how did it go, transport, lunch, etc., challenges,
surprises…)
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HO NO 18 A PREPARATION OF COMPANY APPLICATIONS MODULE CONTROL
MEASURES
Clarification of organizational aspects
All participants should be clear on the following points:
 Who is going to which company?
 Time and place to meet for each group
 Transportation
 Time to be back at plenary
 Selection of responsible persons in the team for collecting specific data and ticking checklists.
During the visit the group prepare a ground plan of the company and fill Ho No 18b with names of
chemicals used and area they are used in, observation of critical situations, identified gaps, new
NPOs with the help of an Improved updated flow chart of a selected process
Checklists to be taken to the companies (Items to be ticked)
o Inventory and risk assessment table (filled) HO 10d for verification of existing control
approaches
o Checklist for supply, storage, handling HO No 15e
o Checklist for hot spots HO 18c
o Checklist fire prevention HO 17c
o Emergency checklist HO 17d
Take pictures and collect further information like:
o What about effluents?
o How is the waste disposal organized?
o Other important aspects?
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WS NO 18 B FOR OBSERVATIONS OF CRITICAL SITUATIONS/ IDENTIFICATION OF
CONTROL GAPS DURING COMPANY VISIT
Area in the Other aspects

Observations/critical Quantities used
factory/ or persons to
situations/identified in production if Possible hazard
chemicals in contact for
gaps /NPOs available
use more details
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HO 18 C IDENTIFICATION OF “HOTSPOTS“
For identifying potential opportunities for cost savings and for reducing risks
Do you notice… Comments
 Places where you see chemical substances spilled on the floor or

where you smell strong odour of chemicals
 Places where you see dust clouds created during transfer or

handling of chemicals
 Lids of chemical containers that are not tightly sealed and the
contents are exposed to air and humidity
 Chemical containers that are partially or completely uncovered

where vapours may escape
 Chemical containers such as bags, drums, bottles, tins or others

that are dented, damaged or defective
 Chemical packaging that is deteriorating due to leakage, damage,

floor water, humidity
 Containers that have no labels or where labels are damaged
 Chemical containers that are used for other purposes than storing
the original chemical, e.g. for storing water, storing and
transferring other materials
 Situations where workers have created and/or use makeshift

personal protective devices (e.g. a towel or handkerchief wrapped
around face, plastic bags for covering hands and arms,..)
 Places in the factory where workers complain about health effects

(e.g. loss of consciousness, coughing, burning eyes or throat,
headache)
 Situations where the skin of workers is contaminated with

chemicals
 Incidents of fire, explosion or accident in the past year
 Presence of ignition sources (e.g. open flames, electrical

installations such as switches, open cable connections, plug
points) next to flammable liquids/gases/dust
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TRAINER INSTRUCTION – ANALYSING RESULTS OF COMPANY APPLICATION AND
ACTION PLANNING
This session reviews the results after the company application, helping the company teams to refine
and analyze their results. At the end of this session, each company team will have prepared a
detailed action plan to (a) deal with the gaps in the selected work area and in the chemical store and
(b) initiate steps to improve the company’s ability to respond to emergency situations
The processing and planning session is divided into following steps:
Step Time available
Processing and presentation of results in company teams 30 min
Addressing critical areas and selected gaps 120 min - open
Materials required
Information and photos collected during company application.
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GENERAL REVIEW OF COMPANY APPLICATION (15 MIN)
Start with a general review of the company application in the plenary. Invite the participants in the
plenary to share their experience with the company application, for example what went well, where
they faced challenges, how the completed the task, whether and in which the preparation of the
work plan in advance had been of use, etc. In case not mention, verify the availability of safety
information such as safety data sheets, labels, markings, how useful the HOs and checklists have
been to assess the situation on-site
Check whether any common issues have come and provide further clarification, in case required.
PROCESSING OF RESULTS IN COMPANY TEAMS (60 MIN)
Remind the participants that each team was expected to briefly present their results of
 selecting one work area in the company and carry out a gap analysis
 assessing the storage of chemicals (conditions, practices)
 identifying possible chemical emergency situations and assess the emergency preparedness
of the company and
 collect other data and information which will the company teams to prepare an action plan
Inform the participants that each company team will be given about 30 min to complete their
presentations and put them on display in an information market.
Allow for about 30 minutes for activity in the information market to learn about each other’s
experiences and results.
ADDRESSING CRITICAL AREAS AND SELECTED GAPS (120 MIN - OPEN)
Request the participants to reorganize themselves in their company teams. Start this part with
recalling the different steps to arrive from a problem to a solution (refer to action planning in module
1).
Ask each company team to select a gap identified, which they would consider as a priority, using one
of these guiding questions:
- Which situations (handling etc.) cause the highest losses/NPOs and present
- Which are the most critical chemicals in terms of impact on environment and health?
- Which are the most critical situations in terms of impact on environment and health
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Then request the company teams to proceed along the same line as during action planning in module
1 , by establishing the causes for the situation (e.g. Why do these situations occur?)
After completing the cause analysis, they should proceed with identifying possible ways of
addressing the situation. Ask the company teams to look at possible alternative measures, through
which they could deal with the different causes they had identified.
Distribute action planning sheet (HO 19) to the company teams and encourage them to proceed with
selecting the most promising/feasible measures with respect to reduce costs and/or risk linked to
chemicals and prepare an action plan for their implementation. Remind the participants that the
implementation of one measure can imply several actions!
At the end the company teams should document the action plan on pin board or flipchart paper and
present the results in the plenary (or on info market) (5 min per company).
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HO NO 19 ACTION PLAN FOR CHEMICAL RISK MANAGEMENT – CONTROL MEASURES
Hazardous chemical/ Proposed measure Objective of proposed Necessary action/ Responsible person(s) Deadline Results to be monitored
critical situation/loss/ measure activities for
identified gap implementing measure
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TECHNICAL SESSION GUIDE 0205 – ANCHORING CHEMICAL MANAGEMENT IN THE
COMPANY
Before using this session guide, read chapter Implement improvement measures in your company
and Evaluate and integrate your achievements and Topics 6 and 10 in annex to module 2 – Managing
the risks in your company –control measures and gap analysis.
SESSION DESIGN
This session summarizes the different elements of the chemical management process. At the end of
this session, the participants will be able to
 Assess where their company stands in terms of integrating the different chemical
management elements in their company
 Decide on the next steps to incorporate chemical management in their company
Step Time available
Introduction 5 min
Exercise 30 min
Conclusion 5 min
Materials required:
 Topic 6
 Topic 10
 PPP 18 chemical management cycle module 2
Referring to the chemical management cycle, indicate the different steps the participants have
completed in the two training modules. Point out that the different tools and approaches they have
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familiarized themselves with, would need to become an integral part of the way their company
works, so ensure the continuation of the efforts as well as to reaping the full benefits.
EXERCISE (30 MIN)
Request the participants to go into their respective company teams. Distribute Topic 10 or ask the
teams to look at topic 10. Explain that the 11 points of action listed will help the participants
towards integrating the chemical management into their company. Each action point provides a
short description and ends with a set of guiding questions, which allow assessing the situation in the
company.
Quickly go through the 11 action points (10 – 15 min) and highlight some of the crucial features.
Following this ask the company teams to go through the guiding questions.
Point out that as in the case of other improvement measures, they can prepare an action plan with
measures helping them to address relevant issues. For example, what steps to take to ensure that
the chemical inventory will be maintained in future, or what steps to take that also other staff
members of the company can familiarize themselves with the information they have acquired during
the training, or how to guarantee that for each chemical in the company a risk assessment has been
done.
REVIEW EXERCISE (20 MIN)
Ask each company team, which of the 11 action points has been already satisfactorily addressed in
their company and which points need to be addressed in due course.
CONCLUSION (5 MIN)
Clarify any questions with regard to the anchoring of the chemical management and close the
session.
93/95
CLOSING OF WORKSHOP
Time 30 Min
Close the workshop by summarizing the topics covered as well as the tasks to be completed until the
next workshop.
Confirm with participants the following dates:
Date of network meeting:
Date of the next workshop:
Distribute HO 17 to participants with request for their feedback.
Request the company teams to take all their flipcharts and materials they have prepared in course of
the training workshop back to their companies for further training and reference.
94/95
95
Deutsche Gesellschaft für
Internationale Zusammenarbeit (GIZ) GmbH
Dag-Hammarskjöld-Weg 1-5
65760 Eschborn
Germany
T + 49 61 96 79 - 0
F + 49 61 96 79 - 11 15
E info@giz.de
I www.giz.de

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1

PRACTICAL CHEMICAL MANAGEMENT

Deutsche Gesellschaft für

Internationale Zusammenarbeit (GIZ)

Department 4 – Planning and

Person Responsible for the Toolkit:

Dr. Alberto Camacho

Convention Project Chemical

Tel.: +49 (228) 24934230

Fax: +49 (228) 24934215

Authors: Dr. Alberto Camacho and Dr Jürgen Hannak

Revised edition © GIZ, August 2011

OVERVIEW OF TRAINING MATERIALS TO BE USED WITH MODULE

Overview Moderation plan “Chemical Risk Management and Controls” 8

AVAILABLE TRAINER INSTRUCTIONS

Gap analysis and HO 10a Exercise - Identifying control approaches 13

HO 10e Gap analysis for control approaches in the BC company 17

HO 10f Checklist inhalation control approaches 18

HO 10g Checklist skin control approaches 27

Critical areas Prepare flip chart with definition of critical areas 30

Case Study Exercise HO 11a Story critical areas 34

HO 11d Possible answers 37

HO 11e Using eco maps in chemical management 39

HO 12a Exercise BC cost assessment, basic data 41

Session Code Description of training material Page

assessment HO 13a Story gap analysis 44

HO 13d Suggestion for presentation of findings on controls gap analysis 47

Case study Part 4 HO 14 Decision matrix 48

HO 15d Separate solids from liquids, acids from bases 55

HO 15e Storage and handling of chemical: self assessment checklist 57

HO 15 f How to calculate net savings and payback period when you 64

Selecting and Topic Setting up a Respiratory Protection Program

HO 16 Glove material selection chart

Managing HO 17a Story a hot day in BC emergency

HO 17e Risk assessment table for fire and explosions (filled)

HO 17f Fire prevention checklist

HO 17g Emergency check list

Session Code Description of training material Page

Safety data sheets from inventory exercise, module 1

Topic 4c Learning more about the four control approaches for

Topic 6c Fire safety and extinguishers

Preparing for the HO 18a Preparation company application

Processing WS 18c Identification of hot spots

Anchoring Topic 8 Integrating chemical management in your company

PRESENTATIONS FOR USE WITH MODULE CHEMICAL RISK MANAGEMENT AND

PPP 13 Identifying control approaches

PPP 14a About control approaches

PPP 14 b Control guidance sheets

PPP 15a What are critical situations?

PPP 15b Examples of hot spots

PPP16 Eco maps

PPP 17 Safe chemical storage

PPP 18a Emergency management

PPP 18b Control banding for fire and explosions

PPP Number Description of presentation

PPP 19 Cycle of change module 2

MSDS Storage exercise

MSDS Gap analysis exercise

ABOUT THE TRAINER MANUAL

TRAINING SEQUENCE FOR MODULE 2 – CHEMICAL RISK MANAGEMENT AN CONTROLS

Day 1 Day 2 Day 3 Day 4

Morning Welcome and Company Analyzing

Selection of health Safe storage Selecting and