University of Engineering and Technology, Lahore

Mining Engineering Department

Environment Health & Safety (EHS) Guide

Mineral Processing Laboratory
Author: Dr. M. Usman Khan
 CONTENTS
1. INTRODUCTION ........................................................................................................................... 1
1.1 Mechanical Hazard ....................................................................................................................... 1
1.2 Electrical Hazard .......................................................................................................................... 1
1.3 Physical Hazard ............................................................................................................................ 1
1.4 Chemical Hazard .......................................................................................................................... 1
2. SAFETY .......................................................................................................................................... 1
2.1 Attitude towards Safety ................................................................................................................ 2
3. GENERAL LABORATORY SAFETY RULES ............................................................................. 2
4. GENERAL ELECTRICAL SAFETY ............................................................................................. 4
5. SPECIAL WASTE .......................................................................................................................... 5
6. WORKING AFTER OFFICE HOURS ........................................................................................... 5
7. IN CASE OF ACCIDENTS ............................................................................................................ 6
8. CONTACT PERSONS .................................................................................................................... 6
9. EMERGENCY CONTACT NUMBERS ........................................................................................ 7
10. PENALTIES FOR VOILATING LABORATORY RULES ........................................................... 7
10.1 First Offense ............................................................................................................................... 7
10.2 Second Offense ........................................................................................................................... 7
10.3 Third Offense.............................................................................................................................. 8
11. MINERAL PROCESSING HEAVY MACHINERY LABORATORY .......................................... 8
12. MINERAL PROCESSING LIGHT MACHINERY LABORATORY .......................................... 10
13. EQUIPMENT SPECIFIC HAZARDS, EHS RULES AND GOOD WORK PRACTICES .......... 11
13.1 Crushing and Grinding Equipment (Jaw, Roll, Hammer, Disc and Impact) ................................ 11
13.1.1 Fly Rock ................................................................................................................................ 12
13.1.2 Dust Hazard ........................................................................................................................... 12
13.1.3 Electrical Hazard ................................................................................................................... 12
13.1.4 Direct Physical Contact with Machine....................................................................................... 12
13.1.5 Safety Precautions ...................................................................................................................... 12
13.2 Magnetic Separator ....................................................................................................................... 13
13.2.1 Electrical Hazard ................................................................................................................... 13
13.2.2 Safety Precautions ...................................................................................................................... 13
13.3 Screens .......................................................................................................................................... 13
13.3.1 Electrical Hazards .................................................................................................................. 13
13.3.2 Dust........................................................................................................................................ 13
13.3.3 Noise ...................................................................................................................................... 13
13.3.4 Safety Precautions ...................................................................................................................... 14
13.4 Gravity Spirals .............................................................................................................................. 14
13.4.1 Electrical Hazard ................................................................................................................... 14
13.4.2 Splash out Hazard ...................................................................................................................... 14
13.4.3 Safety Precautions ...................................................................................................................... 14
13.5 Heat and Heating Devices ............................................................................................................. 15
13.5.1 Oven and Furnace ...................................................................................................................... 15
13.5.2 Safety Precautions ...................................................................................................................... 15
13.6 Slip Falls Hazards ......................................................................................................................... 15
13.6.1 Safe Personal Practices .............................................................................................................. 16
13.7 Chemical Hazards ......................................................................................................................... 16
13.7.1 Toxic Chemicals ........................................................................................................................ 16
13.7.2 Flammable Materials ................................................................................................................. 17
13.7.3 Highly Reactive or Explosive Materials .................................................................................... 17
13.7.4 Generally Offensive Materials ................................................................................................... 17
13.7.5 Methods of Chemicals Absorption ............................................................................................ 17
13.7.6 Symptoms of Exposure .............................................................................................................. 18
13.7.7 Specific Chemical Hazards ........................................................................................................ 18
FORM I ................................................................................................................................................. 20
FORM II ............................................................................................................................................... 21
FORM III .............................................................................................................................................. 22
TIME-IN & TIME-OUT LOG BOOK FOR “AFTER OFFICE HOURS WORK” ............................. 23
OFFENSE BOOK ................................................................................................................................. 24
REFERENSES ...................................................................................................................................... 25
This document contains Environment Health & Safety (EHS) Guide for Mineral Processing
Laboratories of mining engineering department of UET, Lahore. Guidelines and procedures
laid down in this document will be used to train, educate, and prepare students and staff who
were involved in any kind of laboratory work. If reader/s have any questions regarding this
document please contact usman@uet.edu.pk for clarification.
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1. INTRODUCTION
Hazard is basically a danger or risk that sometimes can cause serious injuries or loss of life.
Hazards can be of many types, however in mineral processing laboratories the chances to have
mechanical, electrical, physical, and chemical hazards are more prominent.

1.1 Mechanical Hazard

The term mechanical hazard refers to the any type of injury or loss of life or damage to any body
part caused by machines or their moving parts. As mechanical hazards are present near machinery,
therefore these hazards exists in rock mechanics and core sampling laboratories.

1.2 Electrical Hazard

The term electrical hazard refers to any type of injury or loss of life due to anything involving
electricity. Electrical hazards are present almost everywhere in homes, workplace, offices, roads,
laboratories, etc.

1.3 Physical Hazard

Physical hazard is a wide-ranging term that means any agent, factor or circumstance that can cause
harm with contact or without contact. These are the most common source of injuries or loss of life
in all workplaces. Physical hazards are difficult to avoid. That is why appropriate preventive
measures should be adopted. Physical hazards can be caused by many things i.e. bad ergonomics,
pollution, vibrations, temperature conditions of workplace etc.

1.4 Chemical Hazard

A chemical hazard is a type of occupational hazard caused by exposure to chemicals in the
workplace. Exposure to chemicals in the workplace can cause acute or long-term detrimental
health effects. Chemical hazards and toxic substances pose a wide range of health hazards (such
as irritation, sensitization, and carcinogenicity) and physical hazards (such as flammability,
corrosion, and explosibility).

2. SAFETY
Safety being opposite of hazard is a condition of being protected against any harm, injury or loss
of life. Safe and protective environment is the right of every individual as well as duty of every
induvial to keep his environment safe. No matter how safe the working environment is, if
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individuals shows carelessness or non-seriousness, they will invite troubles. So, everyone should
follow all the safety rules to avoid and mitigate all types of hazards.

2.1 Attitude towards Safety

 Act sensibly at all time.
 Use common sense.
 Develop safety consciousness.
 Ask yourself - is it safe?
 If in doubt, if you hesitate, STOP and seek advice.

3. GENERAL LABORATORY SAFETY RULES

1. Although you may be admitted into a laboratory you are NOT allowed to commence
work unless authorized to do so by a laboratory supervisor.
2. You MUST wear a safety shoes and proper workshop attire in the laboratory areas. Soft
contact lenses should not be worn in a laboratory where hazardous chemicals are in
use.
3. Be aware of the available safety equipment, its location and method of use, i.e. fire
extinguishers, fire blankets, eyewash stands, telephone, etc.
4. Observe and obey all safety signs and warnings posted in laboratories.
5. Familiarize yourself with the layout of the laboratories and their fire escapes.
6. Do not eat or drink in laboratory.
7. Smoking is prohibited in the laboratory.
8. Sleeping is prohibited in the laboratory.
9. Keep your work space clean and tidy.
10. Use common sense and do not rush in the laboratory.
11. Horseplay of any sort is absolutely prohibited in the laboratory.
12. Do not store any food in laboratory.
13. Do not use food containers to store chemicals or laboratory samples.
14. No operating equipment will be left unattended or notify the staff if the experiment is
to be continued or equipment is to be ‘ON’ after office hours. A status signboard must
be displayed prominently near the experiment/equipment if it is still running.
15. Do not overload the laboratory coat.
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16. Do not wear loose clothes.

17. Report all accident/spillages to laboratory supervisor/teacher in-charge.
18. Unauthorized persons are not allowed to enter in the laboratory.
19. All students must inform laboratory supervisor when they are about to commence work.
20. No work can commence without prior permission from the laboratory
supervisor/DSO/head of the laboratory/department chairman.
21. No materials/equipment/laboratory property may be removed from the laboratory
without the prior permission from laboratory supervisor/DSO/head of laboratory/
department chairman.
22. Approval for working space, casting and storage of test specimens should be obtained
from the laboratory supervisor/head of laboratory/department chairman.
23. Replace tools in their original place after use.
24. Waste should be disposed of properly to appropriate container/bin.
25. Always ensure that the laboratory is clean and tidy both during and after use.
26. Advice and assistance must be sought by student before operating any machine which
they are not familiar with.
27. Always ensure all electrical tools are switched off before leaving the laboratory i.e.
lights, fans, machines, grinders etc.
28. Any damage to the equipment or tools must be reported immediately to the laboratory
supervisor/head of laboratory/teacher in-charge.
29. No materials or equipment in the laboratory can be used without prior permission from
the laboratory supervisor/head of laboratory/teacher in-charge.
30. Miscellaneous items i.e. hammer, spirit level, hand drill, small grinder, etc. can be
signed out on the day of use and to be returned on the same day.
31. Ensure that all electrical equipment appear to be in good working order. If in doubt,
consult laboratory supervisor/teacher in-charge.
32. Ensure that hands are dry when handling electrical equipment and that all sources of
moisture are kept away from electric plugs and sockets.
33. Always observe all necessary safety measures when operating any equipment i.e.
goggles, gloves, safety boots, ear plugs, face shields, etc.
34. Slippers, sandals, and open shoes are prohibited in the laboratory.
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35. When operating moving or turning machines, students with long hair must tie their
hairs.
36. Students should never work alone. Always make sure that concerned laboratory
officials know that you are working in the laboratory.
37. If there are strong reasons for the students to carry out their projects after office hours,
approval must be obtained from the project supervisor and other authorities as
designated in “FORM I”.
38. Special attention should be paid when using the following potentially dangerous
facilities:
- Crushers and grinders
- High temperature ovens and furnace.
- Hydraulic & motorized sample extruders.
- Automatic compactors.
- Grinder & mixer.
- High air pressure systems.
- Other mineral processing equipment.

4. GENERAL ELECTRICAL SAFETY

1. Adequate electrical outlets should be provided in the lab to prevent circuit overloading.
2. Examine all electrical cords periodically for signs of wear and damage, if damaged
electrical cords are discovered, report to the laboratory supervisor/teacher in-charge.
3. All equipment must be properly grounded.
4. Do not run electrical cords along the floor as they may form a tripping hazard and are
subject to wear. If a cord must be run along the floor, protect it with a cord cover.
5. If sparks are noticed while connecting electric equipment or if the cord feels hot, do
not use this equipment and report laboratory supervisor until it can be
serviced/examined by an electrician.
6. Do not run electrical cords above the ceiling. The cords must be visible at all times to
ensure it is in good condition.
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7. Do not plug too many items into a single outlet. Cords which enable you to plug more
than one item in at a time should not be used. Multi-plug strips can be used if they are
protected with a circuit breaker and if they are not over-used.
8. Do not use extension cords for permanent wiring. If you find that you must use
extension cords all over the laboratory, then it may be time to have additional outlets
installed.

5. SPECIAL WASTE
1. Any kind of laboratory waste including chemical waste should be discarded in an
appropriate manner.

6. WORKING AFTER OFFICE HOURS

1. No students are permitted to work outside the office hours without prior permission of
their supervisor, director of laboratory/DSO/chairman of the department.
2. Student should must fill in the “FORM I” for working after office hours and work can
only be started after approval from the designated officials.
3. Students are not allowed to hold the lab keys unless approved by the designated
officials.
4. Student are responsible for their safety and they should take extra precautions in
laboratory.
5. Unless approved by the designated authority, no student under any circumstances can
work alone in the lab. There should be a staff member or a faculty member.
6. While working after office hours, fill out the log book for time-in and time-out. Never
ignore to fill in the log book.
7. A file containing Form I, FORM II, FORM III, log book, offense book, and penalty
form should be maintained in each laboratory by the laboratory supervisor for record.
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7. IN CASE OF ACCIDENTS
1. Report all the accidents as soon as possible, no matter how trivial, on the day of
occurrence to the director of laboratory/DSO/laboratory supervisor/teacher in-charge.
2. First aid kits are available in the department, familiarize yourself with their locations.
3. Familiarize yourself with the location of fire extinguishers.
4. Personal safety is most important. If a person’s clothing catches on fire, he/she needs
help. He/ she should not run. If possible put him/her under a safety shower. If not
possible than lie him/her down and smoother the flames by rolling, wrapping with lab
coats or any other possible thing.
5. Never turn a CO2 extinguisher on a person.
6. When the fire alarm sounds, leave the building immediately. Try to collect your
belongings such as keys, wallets etc. only if it is safe to do so.
7. Shut the doors behind you ensuring no one is there. Go to the designated assembly
point and do not return unless is announced safe by the designated authority.
8. In addition to above mentioned procedures, please follow the instructions of
Department’s EAP in case of any emergency.

8. CONTACT PERSONS
In case of any assistance or problem contact:
 Your academic supervisor.
 Director or supervisor of the concerned laboratory.

Laboratory Director Contact Supervisor Contact

Laboratory
Heavy Machinery Engr. M. 0301- Mr. Waqar 0333-4073342
Shahzad 4751913 Ahmed
Light Machinery Engr. M. 0301- Mr. Waqar 0333-4073342
Shahzad 4751913 Ahmed
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 If you cannot contact director or supervisor of the laboratory, or if you are not satisfied
by their response then contact or reach.

Department Safety Officer (DSO) Dr. Shahab Saqib 0333-4337406

Department Chairman Dr. Zulfiqar Ali 0300- 4541810

9. EMERGENCY CONTACT NUMBERS

UET Chief Medical Officer (CMO) ........... 0333-4288824
UET security office ..................................... 042-99029400
UET Gate No. 3 .......................................... 042-99029403
Recue Service.............................................. 1122
Fire Fighting................................................ 16
Ambulance .................................................. 115
Edhi ............................................................. 7847050, 7847060
Bomb Disposal ............................................ 9212111
Counter Terrorism Department ................... 0800-111-11
Insdad-e-Dehshat Gardi Force .................... 1717
Police Emergency ....................................... 15, 6309108
Local Police Station .................................... 042-36880300
City Govt. Lahore ....................................... 9211657

10.PENALTIES FOR VOILATING LABORATORY RULES

If anyone fails to abide by the laboratory rules he/she will be punished as following:

10.1 First Offense

Verbal Warning from laboratory director/chairman/teacher in-charge or any other punishment
suggested by these officials.

10.2 Second Offense

Written warning from laboratory director/chairman/teacher in-charge or anything else as suggested
by these officials.
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10.3 Third Offense

Suspension from the laboratory by laboratory director/chairman/teacher in-charge until further
notice. Student need to appeal by writing to chairman of the department.
 In case of any offense, it is mandatory for laboratory supervisor to keep a record of
each student or person working in the laboratory in the offense book.
 Form III is to be filled in case of any offence.

11. MINERAL PROCESSING HEAVY MACHINERY LABORATORY

Mineral processing heavy machinery laboratory consists of the following equipment, a flow chart
of the laboratory is given in Figure 1.
1. Denver Jaw Crusher (Blake Type).
2. Denver Roll Crusher.
3. Disk Mill Pulverize.
4. Hammer Mill (Impact Crusher).
5. Ro-Tap Sieve Shaker.
6. High Intensity Wet Magnetic Separator.
7. Low Intensity Wet Magnetic Separator.
8. Mineral Jig.
9. Centrifugal Hydro Classifier.
10. Shaking Table.
11. Dyno Cone.
12. Centrifugal Hydro Classifier (Industrial Scale).
13. Air Classifier.
14. Cylindrical-Conical Ball Mill.
15. Denver Dillon Vibratory Screen.
16. Humphrey’s Spiral Concentrator (For metals and non-metals).
17. Gyratory Screen Shaker.
18. Hummer Screen.
19. Davies Disk Magnetic Separator.
20. Drum Filter Station.
21. Bowl Type Classifier.
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22. Ball Mill.

23. Rod Mill.

Mineral Processing Heavy Machinery Laboratory Layout

Figure 1. Mineral Processing Heavy Machinery Laboratory Layout

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12. MINERAL PROCESSING LIGHT MACHINERY LABORATORY

Mineral processing light machinery laboratory consists of the following equipment, a flow chart
of the laboratory is given in Figure 2.
1. Induce Role Magnetic Separator.
2. ISO Dynamic Magnetic Separator.
3. Vibratory Mill.
4. Sample Divided.
5. Ultrasonic Sieve Cleaner.
6. Scale Platform.
7. Woodland Wing Balance.
8. High Tension Electrostatic Separator (Screen Type).
9. High Tension Electrostatic Separator (Plate Type).
10. High Tension Electrostatic Separator (Drum Type).
11. Chemical Cupboards.
12. Denver Floatation Machine.
13. Fisher Oven (Capacity 220° C).
14. Fisher Oven (Capacity 250° C).
15. Fisher Oven (Capacity 220° C).
16. Lindberg Furnace.
17. Distillation Operator.
18. Agitator.
19. Raymond Mill.
20. Hard Groove Grind Ability Testing Machine.
21. Ring Mill.
22. Dodge Type.
23. Cylindro-Conical Ball Mill.
24. Rod Mill.
25. Vibro Sieve Shaker.
26. Sampling Platform.
27. Stand.
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Mineral Processing Light Machinery Laboratory Layout

Figure 2. Mineral Processing Light Machinery Laboratory Layout

13. EQUIPMENT SPECIFIC HAZARDS, EHS RULES AND GOOD WORK

PRACTICES
Numerous physical hazards may be present in the laboratory, while not as exotic as chemical and
biological hazards, physical hazards are responsible for the majority of workplace injuries. It is
important to be aware of these hazards, pre-plan various scenarios, use personal protective
equipment, and follow basic safety rules in order to prevent accidents that involve physical
hazards.
13.1 Crushing and Grinding Equipment (Jaw, Roll, Hammer, Disc and Impact)
Crushing equipment presents various physical hazards that are discussed below.
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13.1.1 Fly Rock

When a crusher breaks rock samples, small pieces may become airborne. This is known as fly
rock, it can be quite damaging especially to the eye or face.
13.1.2 Dust Hazard
Crusher equipment produces little dust as this is a coarse crushing process (e.g. taking fist sized
samples down to fragments that are few cm across). Dust inhalation may cause damage to lungs.
13.1.3 Electrical Hazard
Electricity travels in closed circuits, and its normal route is through a conductor. Shock occurs
when the body becomes a part of the electric circuit. Electric shock can cause direct injuries such
as electrical burns, arc burns, and thermal contact burns. It can also cause injuries of an indirect or
secondary nature from involuntary muscle contractions from the electric shock. These injuries can
include bruises, bone fractures, and even death resulting from collisions or falls. Death may also
occur from damage to internal organs and cardiac arrest. Electrical shock generally occurs from
contact in one of three ways:
 Both wires of the electric circuit.
 One wire of the energized circuit and the ground.
 A metallic part that has become energized by being in contact with an energized wire,
and another part or ground.
13.1.4 Direct Physical Contact with Machine
During crushing operation, there is a chance that the worker’s hands may come in contact with the
machine due to negligence. So it is advisable to keep enough distance from the machine to avoid
such kind of hazards.
13.1.5 Safety Precautions
 Proper safety glasses or googles should be worn at all the times.
 When working with the crusher, stay behind the safety barriers.
 Never grab anything from a moving belt.
 No loose dress.
 Keep away from belts and motor.
 Wear mask to avoid dust inhalation.
 Wear Helmet.
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13.2 Magnetic Separator

Magnetic separators poses some of the following hazards:
13.2.1 Electrical Hazard
There is very high electrical hazard in magnetic separator as it requires high voltage of DC current
that is very dangerous and may result in worker’s death. These and all other electrical devices used
in the laboratory setting present a potential danger of injury due to electric shock, fires due to
poorly installed or maintained systems, and fires due to sparks serving as an ignition source for
flammable or combustible materials.
13.2.2 Safety Precautions
 Remove rings, watches and other jewelry, which may become part of an electrical
circuit when working around electricity.
 The accidental or unexpected start of electrical equipment can cause severe injury or
death.
 Wear gloves when handling larger magnets and always handle with care.
 Always keep a safe distance (at least 10 cm) between magnets and all objects that can
be damaged by magnetism.
 Avoid contact with energized electrical circuits.
13.3 Screens
Screens poses some of the following hazards:
13.3.1 Electrical Hazards
There is very high electrical hazard in screens as it requires high voltage of DC current that is very
dangerous and may result in worker death. Contact with live parts causing shock and burns and
faults which could cause fires.
13.3.2 Dust
With dust the sharp edges of the particles scratch the surface of the lungs and after a time scare
tissue will form. The scare tissue will prevent the lung oxygen processing ability from the air and
breathing will become harder and harder.

13.3.3 Noise
With noise things just become quieter and quieter until nothing is left. Even short-term exposure
to loud noise can cause a temporary change in hearing. Short-term effects such as feeling like your
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ears are "stuffed up" or ringing in the ears may go away after leaving the noisy area. However,
repeated exposure to noise hazards can lead to permanent tinnitus or hearing loss.
13.3.4 Safety Precautions
 Wear ear protector.
 Keep away from machine.
 Remove rings, watches and other jewelry, which may become part of an electrical
circuit when working around electricity.
 The accidental or unexpected starting of electrical equipment can cause severe injury
or death.
13.4 Gravity Spirals
Gravity spirals poses some of the following hazards:
13.4.1 Electrical Hazard
There is very high electrical hazard in spirals as it requires high voltage of DC current that is very
dangerous and may result in worker death. Workers may be exposed to electrical hazards including
electric shock, arc blasts, electro- cautions, fires and explosions. Potential exposures to electrical
hazards can result from faulty electrical equipment/instrumentation or wiring, damaged receptacles
and connectors, or unsafe work practices.
13.4.2 Splash out Hazard
When working with the gravity spiral, if the flow rate of the feed is very high as compared to what
is recommended, there may be high chances of splash out of feed from the spiral and it can have
damaging effects on the worker if contains hazardous chemicals.
13.4.3 Safety Precautions
 Use gloves.
 Keep away from machine.
 Wear lab coat.
 Remove rings, watches and other jewelry, which may become part of an electrical
circuit when working around electricity.
 The accidental or unexpected starting of electrical equipment can cause severe injury
or death.
 Wear googles.
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13.5 Heat and Heating Devices

Heat hazards within laboratories can occur from a number of sources (Microwave oven and
furnace); however, there are some simple guidelines that can be followed to prevent heat related
accidents.
13.5.1 Oven and Furnace
Oven and Furnace in laboratory scale can have fire, explosion and fumes hazards. Lab ovens
having temperature 250 degree Celsius while furnace with temperature 1400 degree Celsius can
pose a fire hazard if not used or maintained properly.
13.5.2 Safety Precautions
 Inspect the oven prior to each use and ensure it is in good operating condition.
 If the oven is not operating within normal operating parameters, it must be taken out of
service and not used until repairs are made.
 Regularly check oven calibration to ensure the temperature read-out is accurate.
 Use the correct oven for the work intended. Consider the maximum temperature needed
and the temperature range of the oven. Do not use an oven that will significantly exceed
the maximum safe working temperature.
 Ensure that the oven is set to the proper temperature required for the experiment. This
includes the high temperature shut-off set point.
 The oven should remain clean and free of chemical spills and residues.
 Do not use materials in the oven that are flammable or can create flammable vapors.
This presents a fire or explosion hazard.
 Ensure that the heating process will not create any hazardous fumes. If there is a
possibility of generating fumes, the oven must be connected to an approved ventilation
system.
13.6 Slip Falls Hazards
According to OSHA, slips, trips and falls constitute the majority of workplace accidents. Slip-fall
accidents include falls incurred in buildings and on the grounds, but are usually falls on the same
floor level or simple falls to the ground, floor, and stairs. Most of these types of accidents can be
prevented with improved housekeeping, utilizing appropriate handrails and guardrails,
maintenance of walking surfaces, and remaining alert to the work surroundings.
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13.6.1 Safe Personal Practices

 Wear the proper footwear for your work and environment and weather conditions.
 Walk at a reasonable pace and be aware of your surroundings.
 Avoid poorly lighted travel paths.
 Be especially cautious when in unfamiliar territory.
 Do not try to carry loads that are too heavy or that obstruct your view.
 Use handrails when on stairways. Take stairs at a safe pace and only one at a time.
 Whenever possible, avoid carrying heavy or bulky objects which obscure your vision
and/or require the use of both hands.
13.7 Chemical Hazards
Acids, bases, etching solutions, and solvents are commonly used in materials chemistry and device
fabrication. These are "hands on" hazards which are hard to control by engineering controls only.
These chemicals can cause severe
 Burns.
 Tissue damage.
 Organ damage.
 Asphyxiation.
 Genetic damage if used improperly.
In addition, improper use of solvents can result in a major fire. These chemicals even if they look
ordinary, are not hazard free.
The hazards associated with chemicals can be classified under the general headings:
1. Toxicity.
2. Flammability.
3. Explosibility.
4. Generally offensive.

13.7.1 Toxic Chemicals

It is advisable to find out if a safer substitute can be used. Personal cleanliness reduces the
possibility of ingestion and wearing of personal protective equipment eliminates absorption of the
material through skin. Protective clothing and gloves should always be examined carefully before
use, for example pinholes in gloves can cause serious injury by allowing chemicals to enter through
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gloves and by attacking the skin. All chemicals must be handled inside the extracted wet bench.
Any antidotes required should be prepared and made readily available for instant use.
13.7.2 Flammable Materials
These materials should be kept to minimum quantity, source of ignition excluded and correct type
of fire extinguisher placed nearby. Materials with a flash point below ambient temperature require
very careful consideration. The vapor pressure/temperature curve should be carefully examined to
check whether an explosive concentration of the substance in air can develop. All possible sources
of ignition should be removed.
13.7.3 Highly Reactive or Explosive Materials
These require very careful handling and reactions involving them should be kept to the smallest
possible size. Exothermic reactions should be classified in this category; particular care being
taken to ensure that cooling systems do not fail with the result that reaction get out of control.
Extra care should be taken when handling substances which may react violently when mixed. This
should also be borne in mind when storing chemicals.
13.7.4 Generally Offensive Materials
These produce unpleasant working conditions and frequently the chemicals are toxic too. The best
way to minimize unpleasant smell is to handle these chemicals in extracted wet bench. These cause
intense eye pain and copious flow of tears. Their effects on the eyes and air passages can be serious
but the symptoms and pain may disappear after few minutes in the open air. These materials should
always be handled in the extracted wet bench.
13.7.5 Methods of Chemicals Absorption
There are three main routes by which individuals can be exposed to chemicals:
1. Direct Contact with body
2. Oral Ingestion.
3. By Inhalation.
Direct Contact with Body: Certain parts of the skin are more active than others, namely sweat and
sebaceous glands, hair follicles, etc. Areas against which clothing rubs are particularly vulnerable.
Localized irritation is most common form of complaint and is enhanced by chemicals which absorb
moisture and dehydrate the skin. Corrosive chemicals cause varying degrees of injury from
relatively mild attacks to severe burns. Toxic chemicals may be absorbed into the bloodstream
after passage through the skin. Eyes are particularly sensitive area of the body and are irritated by
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the physical pressure of even the smallest object. When the material is corrosive and toxic pain
and injury can be serious.
Oral Ingestion: Oral ingestion of chemicals, apart from the deliberate act, is mainly due to
accidental occurrence and can be easily avoided.
Inhalation: Inhalation is the most common method of absorbing materials into body. A very large
volume of air inhaled by an average person per day means that even the very small amounts of
toxic material become important and very large surface area of the lungs increases the chances of
the material being absorbed rapidly. Some even may be absorbed into the mucous lining of the air
passage and be brought up in the sputum and swallowed, thereby presenting additional method of
absorption.
13.7.6 Symptoms of Exposure
May include irritation, burning sensation and coughing, wheezing, laryngitis, shortness of breath,
headache, nausea, and vomiting.
Acute Effects: Harmful if swallowed, inhaled or absorbed through skin. Exposure may be
extremely destructive to eyes, skin, respiratory tract, mucous membrane, nausea, headache,
vomiting, and convulsion. Inhalation may be fatal as a result of spasm, inflammation and edema
of the larynx and bronchi, chemical pneumonitis and pulmonary edema.
Chronic Effects: Prolonged exposure can cause lung irritation, chest pains, pulmonary edema,
damage to blood, kidneys, liver, lungs and mucous membranes or irreversible tissue damage,
impair self-rescue, reduce work efficiency, effect on central nervous system, and risk of
irreversible effects.
13.7.7 Specific Chemical Hazards
Acetone and Flammable Solvents: Acetone is widely used throughout the facility. It is a very
flammable solvent with a low flash point, (i.e. it can be ignited at a low ambient temperature).
Because of this, it presents a significant fire hazard. A spill of a gallon bottle of acetone could
cause a catastrophic fire or explosion. It should not be transported except in chemical buckets.
Solvents should also be handled with care in the hoods and not used near hot plates. Spilled solvent
can be ignited by the hot plates. The resulting fire could easily be drawn up into the exhaust ducts,
again with catastrophic consequences. Spilled solvents can react explosively with chemical
oxidizing agent present, e.g., peroxides, nitric acid. Spilled solvents should be contained
immediately with chemical spillage absorbent.
 P a g e | 19

Hydrofluoric Acid: Hydrofluoric acid (HF), presents a significant hazard for personal injury. It is
widely used in the semiconductor processing. It is only allowed in two designated wet benches,
one in staff clean room and other in the chemistry lab. It is available in 40% concentration, diluted,
and as the active component of buffered HF, Buffered Oxide Etch. It is used for etching silicon
dioxide and for stripping the native oxide prior to further processing. HF is a very hazardous
chemical, much more so than any other acids we use. Its danger comes from its colorless, odorless
appearance and its systemic poisoning. At the concentrations used in the laboratory, a HF "burn"
is initially painless. You may not even know that you have gotten a splatter on your hands, arms,
face, or in your gloves. The acid however, will silently eat away at your flesh. The fluoride ion is
not consumed in this process and is soluble in tissue, so the damage penetrates deeper and deeper,
until it comes to the bone. About this time the excruciating pain begins. It is too late, however, to
reverse the considerable tissue damage. At some point, it enters your blood stream and goes
everywhere scavenging Ca ions, totally messing up the ionic chemistry of your nervous system.
At some point, if left untreated, you die. Simple washing of HF splash is not sufficient to prevent
damage. It does not wash off; it is already dissolving you and will continue to do so until you
receive medical attention specific to HF burns (including deep injections to neutralize the
penetrated acid). Be sure that medical personnel know that it is HF burn and know that it requires
specific treatment different from a common acid burn. HF etches silicon dioxide as well as glass.
It must not be kept in a glass bottle, used in a glass beaker or disposed in a glass waste bottle.
Plastic laboratory ware is available for this purpose. HF must only be used in the designated
extracted wet benches (chemistry laboratory and staff clean room). It is not acceptable to use HF
or HF containing solutions in any other areas.
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FORM I
PERMISSION TO WORK AFTER OFFICE HOURS

Serial No: _________________

Name: ____________________________________
Registration: _______________________________
Degree: ___________________________________
Laboratory: ________________________________
Contact: __________________________________
Date/Duration: _____________________________
Project/Job Title:
______________________________________________________________________________
________________________________________________________________________
Purpose: ___________________________________________________________________
Project Supervisor: ___________________________________
Assigned Faculty/Staff Member: ________________________________________________
Student’s Signature: ___________________________________

Approved By:
Comments: ________________________________________________________________
Project Supervisor: ___________________________________

Comments: ________________________________________________________________
Lab In-Charge/DSO/Division Head: ___________________________________

Comments: ________________________________________________________________
Chairman of Department: ___________________________________
Date of Approval: ___________________________
 P a g e | 21

FORM II
COMMITMENT FORM

I _______________________________, Registration No. ____________________________ commit that I have

attended the laboratory safety lecture. Now I am aware of all the laboratory safety rules and ensure that I must abide
by all the rules and safety precautions in future.
Signature: ________________________
Date: ________________________

Teacher In-Charge: ________________________

 P a g e | 22

FORM III
PENALTY FORM

Serial No: ____________

Name: __________________________________________
Registration: _____________________________________
Date: ___________________________________________
Laboratory: ______________________________________
Offence: ___________________________________________________________________________
Level of Offence:
1st
2nd
3rd
Other: ___________________________
Penalty: ___________________________________________________________________________

Chairman/DSO/Head of laboratory/Teacher in-charge: _______________________________

 P a g e | 23

TIME-IN & TIME-OUT LOG BOOK FOR “AFTER OFFICE HOURS

WORK”
Sr. Registration/ Date Project Supervisor Purpose Form Time Time Sign.
No Name Serial. -In -out (Initials)
No.
 P a g e | 24

OFFENSE BOOK
Sr. Registration/ Date Offence Penalty Penalty/Remarks Sign.
No Name Level Form Sr. (Initials)
No.
 P a g e | 25

REFERENSES

American Chemical Society, Safety in Academic Chemistry Laboratories, 7th edition, 2003.

Fawcett, H.H. and W.S. Wood, Safety and Accident Prevention in Chemical Operations, 2nd
edition, Wiley-Interscience, New York, 1982.

Flury, Patricia A., Environmental Health and Safety in the Hospital Laboratory, Charles C.
Thomas Publisher, Springfield, IL, 1978.

Green, Michael E. and Amos Turk, Safety in Working with Chemicals, MacMillan Publishing
Co., NY, 1978.

Kaufman, James A., Laboratory Safety Guidelines, Dow Chemical Co., Box 1713, Midland, MI
48640, 1977.

National Institute of Health, NIH Guidelines for the Laboratory Use of Chemical Carcinogens,
NIH Pub. No. 81-2385, Government Printing Office, Washington, DC 20402, 1981.

National Research Council, Prudent Practices for Disposal of Chemicals from Laboratories,
National Academy Press, Washington, DC, 1995.

https://www.osha.gov/SLTC/hazardoustoxicsubstances/p.show_document?p_table=STANDAR
DS&p_id=9863

Engineering, D. o. (2014). Laboratory Safety Handbook. Univrsiti PUTRA Malaysia. Faculty

engineering.

Faculty. (2005). Safety in the science manual. Broock University. Department of methemetics and
science safety committe.

Hertzog, c. (2017). Laboratory Safety Manual. UTEP. envronmental health and safety department.

Malta, U. o. (2011). Safety Manual. Biult Environment Laboratory.