Accident Prevention Plan

For Computech

Name:
Class Title:
Date:

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Table of Contents

Introduction............................................................................................................................4

Fire Emergency Evacuation Plan:.......................................................................................4

President’s Statement:.........................................................................................................7

Management Responsibilities.................................................................................................8

The Manager.......................................................................................................................8

The Supervisor....................................................................................................................9

Employee Orientation...........................................................................................................11

Emergency Action Plan:...................................................................................................11

Extended Power Loss........................................................................................................20

Electrical Safety:...............................................................................................................23

Environmental Policy:......................................................................................................25

Evacuation:.......................................................................................................................26

Fire Safety:........................................................................................................................27

Emergency Shutdown Procedure:.....................................................................................33

Injury and Illness Procedure.................................................................................................35

Accident Investigation Procedure.........................................................................................44

Accident Investigation Form............................................................................................46

Safety Guidelines..................................................................................................................48

Safety Inspection:.............................................................................................................49

Basic Safety Rules:...........................................................................................................50

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 Equipment Specific Safety:..............................................................................................50

Safety Disciplinary Policy....................................................................................................58

Safety Awareness Program...................................................................................................59

Safety Awards Program:.......................................................................................................63

Appendices...........................................................................................................................64

Appendix A: Safety Data Sheet........................................................................................65

Appendix B: Posters.........................................................................................................78

Appendix C: OSHA Forms...............................................................................................83

References............................................................................................................................86

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Introduction

The Accident Prevention Plan covers the foreseeable occupational risks and any related

hazards that may apply or occur to the employees of the industry. It defines and outlines the

measures and procedures, and the policies that are implemented to mitigate or even eliminate

these hazards. These employees’ pool includes the entire industry people such as engineers,

technical staff, domestic staff and as well as the upper hierarchy. This Accident Prevention

Plan applies to all the departments related to the company’s portfolio. So, to be effective, all

employees and departments must know where to find and how to use this Accident

Prevention Plan.

This Accident Prevention Plan is designed in such a way that it replaces the safety plans that

have been previously implied by all the departments. However, the various departments shall

continue to follow and address their previous safety plans that may not be covered in this

Accident Prevention Plan.

The Accident Prevention Plan does not replace the policies or rules laid by following plans or

manuals:

Fire Emergency Evacuation Plan: This includes the actions that need to be taken in case of

a fire or any such emergency situation. For this, we need to arrange some sort of evacuations

plans and the risk assessments. For example, in case of a fire, the immediate response of the

employees would be everyone escaping to a safer place and maintain safe distance from the

premises of the fire. This is known as simultaneous evacuation.

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`

Fire Emergency Evacuation Plan (SAMPLE)

Fire Emergency Symbols

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The goal of the Accident Prevention Plan is to provide essential health and safety guidance

that applies to all employees at the industry. To be operative, all employees should know

about the Accident Prevention Plan and become acquainted with the issues the document

covers.

Hierarchy of Hazard Control

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President’s Statement:

There’s no question as to the importance of safety to the way that Multi-million giant

Computech operates. All employees need to do is look at who the company’s chief safety,

health and environmental officer is - CEO and President of Computech.

Safety is the prior concern of our company. For us to have a really good and strong safety

environment, we must value the safety concerns of our employees. By integrating safe and

sound health and safety management, we can offer novel and innovative products to the

consumer market.

Computech goes all-out for consistent and continued betterment in the health safety

management systems. We, as a company, acknowledge that our company’s production line

and the products themselves have a direct impact on the environment, and thus, we are

striving to protect the environment as well as our own employees by providing them standard

operating protocols.

As an employer, Computech has been defining the standards in the Health and Safety of the

employees and all other staff that is involved in the success of Computech.

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Management Responsibilities

The success of an Accident Prevention Plan is directly related to the active participation of

the upper hierarchy that includes the managers and the supervisors as well. Many employees

work in the factories on various machines in varying working conditions. They meet with

accidents while working. Management must provide them adequate safety measures to reduce

accidents. Work comes to stop when accidents occur. It may injure the employee sometimes

seriously. A slight sloppiness on the part of the employee at the place of work may land him

in trouble. According to R.P Blake accidents are, “unplanned or unintended occurrences that

interrupt or interfere with work activity.” According to Factories Act 1948 industrial accident

is, “an occurrence in an industrial establishment causing bodily injury to person who makes

him unfits to resume his duties in the next 48 hours.”

The Manager is the one who is responsible for helping out the employees and saving them

from serious accidents. Goal of safety is easily achievable and thus, the manager should

encourage the employees for the safety protocols. The importance of health and safety is

covered in this Accident Prevention Plan and should be made accessible to the employees. A

manager should take sheer interest in directing the employees to follow the safety protocols.

Various types of workshops and seminars may be held in order to motivate the employees in

pursuing the managements proposed safety protocols. Employees should be encouraged to

participate in discussion on safety. All these activities manager should plan and coordinate

with the help of the people working under him.

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According to the International Labor Organization, the employer has an obligation to secure

the safety and health of all his/her employees.

These safety requirements include the appointment of qualified and competent persons to be

in charge of evacuation works, scaffolding, equipment and machinery maintenance and to

ensure such equipment and machinery are in good order and repair.

The Supervisor has, in addition to other things, responsibility for the following:

 Risk assessments of the jobs done by the employees

 Supervision of the development of Job Safety Analysis (JSA)

 Managing the changes in tasks and conditions

 Devising operating rules for the employees

 Educating the employees whether newly recruited or not

 Scrutiny of the work area, equipment & practices for the rectification of substandard

conditions

 Investigation of accidents (not only injuries alone) for the determination of causes

The activities listed above need special interest by the supervisors. It is the responsibility of

each and every supervisor to make sure that no employee in put in jeopardy and are kept from

engaging themselves in methods of working that are not safe for them.

This should be an essential part of a supervisor’s work schedule. His role is not only to make

job assignments but also to see that the job is done according to plan, according to established

instructions, without interference, without delay, and without increasing the cost of operation.

A supervisor should accept the fact that this is a mandatory part of his job and that he is not

being pressurized by the upper hierarchy to impose such protocols.

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Most accident causes are not of a great impact. They are common and frequent occurrences in

the daily operation of a company. Employees rarely try to defend deviations from the right

way of doing a job, but because accidents do not occur every time those instructions are

disregarded, they quickly develop a false sense of security. They feel that nothing serious will

happen when they follow poor safe practices. This false mindset of the employees needs to be

changes by introducing proper safety protocols and it is the duty of the supervisors to enforce

these protocols upon the employees for their own betterment.

The TRAP (Take Responsibility for Accident Prevention) program is an employee-driven

program of identifying, evaluating, and eliminating hazards in the workplace. This program

involves both the employees and the employers.

In an article titled “Fatal Accidents on the rise in 1997: A Cause for Concern”

 Near misses need to be considered as warnings, analyzed, and used to prevent more

serious accidents from occurring

 Near misses are incidents which usually indicate the presence of a hazard - or in other

words a “TRAP”

TRAPS come and go in the workplace daily, depending on the work activities and the

employees. Some are simple, such as a cord stretched across a walkway. Some are more

complex, such as a poorly designed set of controls on a mining machine.

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Employee Orientation

It is the policy of Computech that all of its employees should be educated and provided with

sufficient knowledge about health and safety. This policy does not replace formal or required

training but provides a basic overview of the health and safety program to let it policies and

essential information in need you to assist employees in making good choices.

The following orientation topics may be covered during the initial orientations of the

employees that work in the company:

 Emergency Action Plan

 Electrical Safety

 Environmental Policy

 Evacuation

 Fire Safety

 First Aid / CPR / BBP

Emergency Action Plan: It is provided not only as a guide to support the entire work

force of a company to follow the Occupational Safety and Health Administration’s (OSHA)

Emergency Action Plan standard, 29 CFR 1910.38, as well as to gather and make use of other

beneficial information.

A sample template for the Emergency Action Plan is given on the next page including all the

necessary details. Tables are also included to fill out the information of the responsible

people and the respective authorities.

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The objective of the Computech Emergency Action Plan is to comply with the Occupational

Safety and Health Administration’s (OSHA) Emergency Action Plan Standard, 29 CFR

1910.38, and to prepare employees for dealing with emergency situations. Designed to

minimize injury and loss of human life, this plan trains the employees to procuring and

maintaining necessary equipment, and taking responsibilities. This plan applies to all

emergencies that may be anticipated to occur at Computech.

An Emergency Plan Manager shall manage the Emergency Action Plan for Computech.

The plan manager shall also maintain all training records relating to this plan and must take

the responsibility of conducting routine tests for the emergency warning system with the

relevant authorities. The Emergency Plan Manager shall also coordinate with local public

resources, such as fire department and emergency medical personnel, to ensure that they are

prepared to respond as detailed in this plan.

Emergency Plan Coordinators are responsible for starting the procedures in this emergency

plan in their designated areas in the event of an emergency.

Alternate Alternate
Section/ Primary Name Contact
Name and Contact
Department and Position Number
Position Number

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We may list individuals in the following table that shall be responsible for assisting

employees with disabilities and/ or who do not speak the native language during the

evacuation process.

Name of Assigned
Assistant’s
Section/ Person Contact Assistant’s
Contact
Department requiring Number Name
Number
assistance and Position

All emergency situations must be reported as soon as possible to the responsible authorities

by one of the following means:

 Verbally; or

 Telephonically

Only responsible authorities are authorized to contact the emergency response team so that

there is no confusion and to eliminate the risk of false alarms.

The telephone numbers and contact information for the emergency response team for are

given below:

 Fire: ___________________________________________

 Police/Sheriff: ___________________________________

 Ambulance/EMS: ________________________________

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Emergency Evacuation Escape Routes must be displayed and posted in the designated areas

such as hallways, galleries, tool rooms, storage rooms etc. In the event of any emergency

alarm, all employees should leave their work and exit the buildings through the designated

escape routes.

In such dire emergency situations, some items may need to be kept in a safe place so that any

further detriment to the company may be avoided. Only the following individuals may remain

in the building for the set amount of time to secure the property and equipment to which they

have been assigned.

Equipment to Location of the ETA to complete

Name
secure equipment the procedure

As soon as the equipment is secured by the responsible persons, they must use the escape

routes and meet the remainder of the personnel/ employees at the designated Assembly Area.

Another important aspect of this Emergency Action Plan is the training of the employees. All

of the employees should receive instructions on this plan during the orientation. And,

additional trainings or workshops should be conducted:

 When a change is made to the plan

 When an employee's responsibility changes

 And, semi-annually for better understanding

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Items that should be reviewed during the trainings include:

 Proper housekeeping

 Fire prevention practices

 Threats, hazards, and protective actions

 Names of emergency action plan manager and coordinators

 Individual responsibilities

 Alarm systems

 Escape routes and procedures

 Emergency shut-down procedures

 Procedures for accounting for employees and visitors

 Emergency Action Plan availability

An example of an Emergency Action Plan is shown below and the standard OSHA checklist

has also been tabulated.

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 Emergency Personnel Names and Phone Numbers

DESIGNATED RESPONSIBLE OFFICIAL (Highest Ranking Manager)

Name: ______________ Phone: ______________

EMERGENCY COORDINATOR:

Name: ______________ Phone: ______________

AREA/FLOOR MONITORS (If applicable):

Area/Floor: ______________ Name: ______________ Phone: ______________

Area/Floor: ______________ Name: ______________ Phone: ______________

ASSISTANTS TO PHYSICALLY CHALLENGED (If applicable):

Name: ______________ Phone: ______________

Name: ______________ Phone: ______________

Date ____/____/____

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 Emergency Phone Numbers

FIRE DEPARTMENT: ________________

PARAMEDICS: _______________

AMBULANCE: _______________

POLICE: ________________

FEDERAL PROTECTIVE SERVICE: ________________

SECURITY (If applicable): _________________

BUILDING MANAGER (If applicable): ________________

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 Utility Company Emergency Contacts

(Specify name of the company, phone number and point of contact)

ELECTRIC: _____________________

WATER: _______________________

GAS (if applicable): __________________________

TELEPHONE COMPANY: _______________________

Date: ___/____/_____

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 Medical Emergency
Call medical emergency phone number (check applicable):

 Paramedics

 Ambulance

 Fire Department

 Other

Provide the following information:

 Nature of medical emergency,

 Location of the emergency (address, building, room number),

 Your name and phone number from which you are calling.

Do not move victim unless absolutely necessary.

Call the following personnel trained in CPR and First Aid to provide the required assistance

prior to the arrival of the professional medical help:

Name: _______________________ Phone: _______________________

Name: _______________________ Phone: _______________________

If personnel trained in First Aid are not available, as a minimum, attempt to stop the bleeding

with firm pressure on the wounds.

Date___/___/___

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Extended Power Loss

In the event of extended power loss to a facility certain precautionary measure should be

taken depending on the geographical location and environment of the facility:

 Unnecessary electrical equipment and appliances should be turned off in the event

that power restoration would surge causing damage to electronics and effecting

sensitive equipment.

 Facilities with freezing temperatures should turn off and drain the following lines in

the event of a long-term power loss.

· Fire sprinkler system

· Standpipes

· Potable water lines

· Toilets

 Add propylene-glycol to drains to prevent traps from freezing

 Equipment that contain fluids that may freeze due to long term exposure to freezing

temperatures should be moved to heated areas, drained of liquids, or provided with

auxiliary heat sources.

Upon Restoration of heat and power:

 Electronic equipment should be brought up to ambient temperatures before energizing

to prevent condensate from forming on circuitry.

 Fire and potable water piping should be checked for leaks from freeze damage after

the heat has been restored to the facility and water turned back on.

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EAP Sample

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Emergency Action Plan Checklist
Occupational Safety and Health Administration (OSHA)
General Issues
Does the plan consider all natural or man-made
 emergencies that could disrupt your Common sources of emergencies identified in emergency action plans include - fires, explosions, floods, hurricanes,
workplace? tornadoes, toxic material releases, radiological and biological accidents, civil disturbances, and workplace violence.
Does the plan consider all potential internal
 sources of emergencies that could disrupt your Conduct a hazard assessment of the workplace to identify any physical or chemical hazards that may exist and could
workplace? cause an emergency.
Does the plan consider the impact of these
internal and external emergencies on the
 Brainstorm worst-case scenarios asking yourself what you would do and what would be the likely impact on your
workplace’s operations and is the response
operation and device appropriate responses.
tailored to the workplace?
Does the plan contain a list of key personnel
with contact information as well as contact Keep your list of key contacts current and make provisions for an emergency communications system such as a cellular

information for local emergency responders, phone, a portable radio unit, or other means so that contact with local law enforcement, the fire department, and others
agencies and contractors? can be swift.
Does the plan contain the names, titles,
departments, and telephone numbers of
 individuals to contact for additional List names and contact information for individuals responsible for implementation of the plan.
information or an explanation of duties and
responsibilities under the plan?

Unless you are a large employer handling hazardous materials and processes or have employees regularly working in
Does the plan address how rescue operations hazardous situations, you will probably choose to rely on local public resources, such as the fire department, who are

will be performed? trained, equipped, and certified to conduct rescues.

Most small employers do not have a formal internal medical program and make arrangements with medical clinics or
Does the plan address how medical assistance facilities close by to handle emergency. If an infirmary, clinic, or hospital is not close to your workplace, ensure that
 onsite person(s) have adequate training in first aid. Treatment of a serious injury should begin within 3 to 4 minutes of
will be provided?
the accident.

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Electrical Safety: Just like every other workplace, Computech also operates on the

electricity, so electrical hazards are omnipresent. All electrical systems used in offices have

the potential to cause serious harm, especially if improperly used or maintained.

Humans are good conductors of electricity. This means if the open electric circuit comes in

contact with our body, we’ll get a shock. The electric current will pass through our body from

one point to another causing great pain, burns, damage to the tissues, nerves and muscles.

This could even lead to death.

Types of Workplace Electrical Injuries:

 Electric shock

 Burns

 Falls

 Electrocution

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Possible reasons of Electrical Hazards:

 Direct contact with electrical circuits

 Electricity arcs

 Poor electrical wiring

 Overloading of extension cables

 No ground wiring

 Using equipment with damp hands

Proper employee training plays a crucial role in preventing such hazards. Electrical safety

signs are of great use as they provide key information to the visitors and the employees which

keeps them safe and sound.

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Environmental Policy: It is a company’s declaration to commit to the environment. The

environmental vision of all the company stakeholders should be unanimous. This abets in

reducing the environmental footprint of the company.

Educate the employees regarding this policy and ask them to commit to it. The environmental

policy will improve employee morale by showing the company’s commitment to the

environment. The policy will also augment the company’s public image by signifying

corporate social responsibility and the company’s commitment to reducing its impact on the

environment.

As a part of the Accident Prevention Plan, Computech will:

 Incorporate environmental concerns into all of our decision-making and activities

 Promote environmental awareness among our employees and encourage them to work

in an environmentally responsible manner

 Train, educate, and inform our employees about environmental issues

 Starting recycling programs within the company to reduce waste – including the

recycling of plastic, cardboard, electrical components, sheet plastics, etc.

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 Example of an evacuation plan

Evacuation: Many typical situations in an industry result in some sort of emergency or

urgency. Little mistakes made by the employees often lead to a disaster. But this does not

mean that every emergency situation requires evacuation. Whether or not we need to

evacuate, it depends upon several factors. A term called Shelter-In-Place is often used in

industries which means, in simple words, there is no need to evacuate the building or some

place, but just take a shelter or sanctuary somewhere safer within the building. For such

conditions, there may be rooms designated with no windows and very strong construction

material used for the room so that in any sort of dire situation, employees can find shelter in

there. For an effective evacuation plan to work, Computech makes sure to mark all the

locations and emergency routes and make sure that these areas are clear of any obstructions.

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Fire Safety: A fire safety plan is a detailed document that covers all aspects of fire safety

for a specific building or property. This AAP discusses all of the necessary steps required to

overcome any type of fire that may take place in the company.

It is very much important tot cover this factor in

the AAP due to the fact that according to the

NFPA, approximately 13.5million fires were

reported in the United States in 2015, causing

$14.3billion in property damage. As such, it's

important that employers and building maintenance

managers prepare for fires - and have plans for what

to do if a fire breaks out.

One of the major parts of the fire safety procedure is

getting everyone out safely without any harm.

OSHA requires that every company should have emergency exits at suitable places so that

everyone can be evacuated safely. These exits need to be located at places where there is no

rush of any sorts. For example, Computech has 350 employees and to account for their

security, wide and airy hallways are constructed in the industry so that evacuation may be

done without any problem.

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Before any further ado, we shall first discuss the major factors that contribute towards fires in

the industries:

Components that produce fire: Without the following three components, the fire cannot

take place.

 Fuel (anything combustible, gasoline, wood etc.)

 Heat (raise the fuel to its ignition temperature)

 Oxygen (keeps the fire alive)

 Air Compressors (Computech uses these)

Three components of fire (Fire Triangle)

Any existing fire can be extinguished by removing at least one of these components. In

Computech’s APP, the following SOPs are to be followed:

 Remove any type of fuel within the fire’s vicinity

 Remove the heat by the help of water

 Cut off the oxygen supply by either using Carbon Dioxide or a blanket to cover the

fire

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First Aid Firefighting: This technique is the best method to prevent the widespread of the

fire. Employees may use first aid fire extinguishers that prevent the fire from spreading.

These are present in almost every industry as they are portable and easy to use.

First aid fire extinguisher kit

Classes of fire: Fire can be divided into 5 groups: A, B, C, D and K. Each type of the fire

tells us about the fire extinguisher that needs to be used in order to extinguish the fire.

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Types of Fire Extinguishers: Like all other industries, Computech also has a number of

portable fire extinguishers hinged along the hallways and emergency exit points. These are

divided in to the following categories:

 Water Extinguishers

 Dry Chemical Extinguisher

 Wet Chemical Extinguisher

 CO2 Extinguisher

Although most of these extinguishers may be used on one or more than one class of fires, but

mostly the water-based extinguishers are used on Class A fires. For Class B and Class C, dry

chemical extinguishers are used. The same goes for the wet chemical extinguishers. CO 2

extinguishers are the most commonly used extinguishers. Although it is less effective than the

dry chemical one, it has the plus point of not leaving any residue behind that needs to be

taken care of.

As previously mentioned in the components of fire, Computech makes use of Air

Compressors; and these compressors may play a pivotal role in igniting a fire or even an

explosion. Electrical circuits within the compressors may spark due to some technical fault

creating a foreseeable risk of fire or explosion. Apart from this, compressors heat up when

they are running, so putting them in a place which is not very well ventilated explicitly

increases the risk. To counter this issue, Computech’s APP made sure that these compressors

are properly installed and train the employees so that they can help prevent that from

happening:

 Locate the compressor no closer than 20 feet from the spray area

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  Don't place objects on or against the air compressor that could block the ventilation

openings

Fire Prevention Measures: As noted above, fire is only possible where there is a supply of

combustible materials, oxygen, and heat. However, lack of caution, equipment failure, or

simple human error can cause ignition. Making sure of the following things can mitigate the

risk of fire:

 Keep all paper, plastic and wood products away from the things which susceptible to

catch fire such as those air compressors

 Oily cloths must be placed in some sort of metal bins and sealed afterwards. These

cloths are used at Computech for oiling and greasing of the Injection Molding

Machines, Plastic Sheet Forming Machines, Metal Punch Presses etc.

 Garbage may contain substances that are toxic when burned, and clutter may prove an

obstacle for those trying to evacuate the building

The last orientation topic that needs to be covered in the APP is the First Aid or CPR. CPR

is intended to keep the patient's organ systems and blood circulation regular while they are

yet to be examined by a medical professional. The most important reason for educating the

employees regarding the CPR is that is saves life. The fate of the worker suffering from a

health concern will depend on the steps taken seconds after he gets into trouble. According to

recent data, 90% of people who suffer from cardiac arrest die, whether at the workplace or at

home, before they reach a hospital or medical care facility. Looking at the long-term benefits

of CPR, it also provides the employees with the knowledge of avoiding accidents in the first

place. As a part of the training, educating them about cardiac arrests will enable them to

assure that no such incidences will happen again. Moreover, people are motivated to work for

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a company that consistently shows concern for its employees. Providing them with CPR

training is one of the ways to show the employee that the company cares for them.

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Emergency Shutdown Procedure: Emergency Shutdown System (ESD) is designed

to minimize the consequences of emergency situations by shutting the system down to protect

personnel, facilities, and even the environment. The control system of the shutdown

mechanism determines a cause and effect type analysis. It is not necessary that the

Emergency Shutdown completely shuts down the company’s machinery as it can be

detrimental for the company itself. But what this procedure will do is minimize the working

of the machinery in the company by shutting down parts of some machinery which are not

being used at all. For example, in case of a fire, the existing controls to open or close the

vents and/ or close the fire doors may be overridden by the Fire Damper System.

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Example of how an emergency shutdown works 34
Injury and Illness Procedure

Injury and Illness Prevention

Procedure is a readily available

program that enables the employers to

find and fix any anticipated workplace

related hazards. Just like other

industries and businesses, Computech

has also adopted such approaches e.g.

OSHA’s program. By including this program in the APP, not only the employers experience

a dramatic decrease in the workplace injuries, but they often find out their workplace as a

newly reformed and a highly productive one. In an article by OSHA, In the four decades

since the Occupational Safety and Health Act (OSH Act) was signed into law, workplace

deaths and reported occupational injuries have dropped by more than 60 percent. Yet the

nation's workers continue to face an unacceptable number of work-related deaths, injuries and

illnesses, most of them preventable:

 Every day, more than 12 workers die on the job – over 4,500 a year.

 Every year, more than 4.1 million workers suffer a serious job-related injury or

illness.

Management responsibilities and employees’ wit, both combined, can prevent many major

types of accidents in any industry. And for the workers part, they need to be properly trained

regarding the working of the program and the program itself shall be reviewed at least semi-

annually.

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The most important goal of this program is to prevent injuries and illnesses which eventually

eases the financial hardships on the company if any serious injuries occur beforehand.

Combined with insufficient workers' compensation benefits and inadequate medical

insurance, workplace injuries and illnesses can not only cause physical pain and suffering but

also loss of employment and wages, burdensome debt, inability to maintain a previous

standard of living, loss of home ownership and even bankruptcy. In a 2010 research by

Liberty Manual, the direct cost of the most disabling workplace injuries in 2008 was

approximately $53 billion which for sure has increased in recent times considering the rate of

inflation that we are incurring today.

Numerous studies have examined the effectiveness of injury and illness prevention programs

at both the establishment and corporate levels. For example, the successes of these state

programs, which lowered injury and illness incidences by 9 percent to more than 60 percent

is shown in the pie chart below.

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 Employee Statement

Employee: ____________ DOB: ____________ SSN: xxx-xx

Supervisor: ____________ Date / Time: ____________ / ____________

Work Area: ____________________________________________________________

Details:

What were you doing just before the injury occurred?

___________________________________________________________________________
___________________________________________________________________________

What happened or went wrong?

___________________________________________________________________________
___________________________________________________________________________

Describe the injury?

___________________________________________________________________________
___________________________________________________________________________

What specific object/thing/action caused the injury?

___________________________________________________________________________
___________________________________________________________________________

Was anyone else injured? Yes/ No

Did anyone witness the injury? Yes/ No

Statement/Release: I certify that these facts are true and correct to the best of my

knowledge. I hereby authorize the full release of all medical records or other information

related to this incident, to my employer or their designated representative.

________________________ ___________________________
Signature of Employee Date of Report

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 Witness Statement

Name: ________________________ Craft: ___________ Level: _________

Work Area: ________________________ Supervisor: _______________________

Incident: ___________________________________________________________________

Details:

Did you personally witness the injury? Yes/ No

Who else was in the immediate area?

___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

What did you see/hear/observe?

___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

Did you wish to remain anonymous? Yes/ No

Statement: I certify that these facts are true and correct to the best of my knowledge.

________________________ ___________________________
Signature of Witness Date of Report

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 Supervisor Statement

Employee: ________________________ Craft: ______________________

Supervisor: ________________________ Date / Time: ______________/______________

Work Area: _________________________________________________________________

Details:

What was the employees work assignment? (Location, activities, tools in use, etc.)

___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

What factors may have contributed to the event?

___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

What could be done to prevent future events like this?

___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

Did you witness the incident / injury? Yes/ No

If this is an injury report, do you question the validity of how it occurred? Yes/ No

Statement: I certify that the above facts are true and correct to the best of my knowledge.

________________________ ___________________________
Signature of Supervisor Date of Report

43
Studies suggest that workers believe the actions of their supervisors reflect how the company

values them. Showing empathy, concern and a willingness to work with an injured worker to

adjust the workplace to accommodate the injury sends the message that the worker is valued

by the employer. This study shoes that supervision not just a mere job of assigning tasks, it is

a huge responsibility of handle and live up to the expectations of the employees. It's the

supervisor’s responsibility to enforce safe work practices and procedures; failure to do so is

an invitation for accidents to occur. Their responsibility of conducting accident investigations

and making sure that all the injured employees report to the medical emergency service as

soon as possible. Apart from these duties, a supervisor must take immediate steps to correct

unsafe and unhealthy workplace conditions which may promote or allow in-future accidents

to take place.

44
Accident Investigation Procedure

Whenever an accident or a mishap takes places in an industry, it is mandatory to determine

the root cause of the event. Computech, as per the Accident Prevention Plan, carries out the

investigation not to put a blame some employee but to uncover the major reason that lead us

to this point in the first place.

There are certain steps to conducting this investigation:

1. Immediate action: In the event of an incident, immediate action to be taken may

include making the area safe, preserving the scene and notifying relevant parties. The

investigation begins even at this early stage, by collecting perishable evidence, e.g.

CCTV tapes, samples.

45
2. Planning the investigation: What resources will be required? Who will be involved?

How long will the investigation take? For severe or complex incidents, an

investigation team will be more effective than a single investigator.

3. Data collection: Information about the incident is available from numerous sources,

not only people involved or witnesses to the event, but also from equipment,

documents and the scene of the incident.

4. Data analysis: An incident is never a fruit of a single event; it is due to a chain of

events. While most of the accidents occur due to human error, this does not mean that

there aren’t other factors involved in the accident.

5. Corrective actions: Unlike some other small industries, Computech does not take

actions which only deal with the direct causes and ignore the root and underlying

causes of the accident.

6. Reporting: At last, the investigation is concluded when all the outstanding issues have

been resolved and a formal investigation report is generated.

46
 Accident Investigation Form

A. Injured Employee Data

Employee Name Position Personnel Number

Work Location

Date of Accident Time of Accident Claim Number (if known)

Home Telephone Work Telephone Other/Cell Number

Supervisor Supervisor Telephone Number

B. Accident Description
Where did the accident happen and who was involved? Provide a full description of the

surroundings of the location and the individuals involved.

What was happening at the time of the accident and why was it taking place?

What were the events leading up to the accident? Describe the sequence in order and when

they took place.

What exactly caused the injury and how did it happen? What were the mechanics, equipment

or tools involved?

Describe the injury or injuries incurred. What body part and what kind of injury? (Indicate if
no injury occurred.)

If a physical injury was avoided, what could have happened to cause an injury?

C. Accident Findings

47
 After review of all facts, what was the hazardous condition, unsafe work practice, or other
causal factors (procedure, equipment, people, and environment) that contributed to the accident
/ injury?

D. Corrective Action
What is recommended to prevent this type of accident from occurring again?

Actions taken to ensure recommendations are considered:

Signature of Supervisor Date Time

E. Distribution Instructions
Original: County Clerk/Human Resources
Copies: Employee’s Supervisor & County Commission

Safety Guidelines

Computech has formed a

safety committee to aet

employees and management

to work together for

identifying the safety-

related problems, find out

solutions to them,

reevaluate the incident

reports and analyze the efficacy of the safety program. The committee is made up of

48
management-designated representatives and one employee-elected representative each from

the office, factory and outside sales divisions of our company.

 A representative will be elected from the employees’ pool to be on the committee.

This can be done either by voting or by volunteering.

 The representative from the employees will be elected for a year before being re-

elected or replaced.

 The committee is made up of management-designated representatives and one

employee-elected representative each from the office, factory and outside sales

divisions of our company.

 The committee will have to elect a chairperson for a single year which will then be

decided upon either by voting or by volunteering.

 In addition to the committee responsibilities explained above, duties of safety

committee members include:

o Inspection of the area on monthly basis

o Communicating with the employees they represent on safety issues and

o Safe work practices being ensured in the workers

Apart from this committee, employees are required to attend a safety meeting organized at

the start of each month. This will help them identify the problems related to safety, find out

solutions to them, make reports and get themselves trained for any type of incident.

Safety Inspection: Computech is committed to identifying hazardous conditions due to

which any injury or illness may occur to the employees. Prompt and proper actions will be

taken to mitigate the detriment and eliminate any further risks.

49
  Annual Site Survey: Once in a year, a team of the safety committee will do extensive

inspection of the entire company. They will write down any (foreseeable) hazards and

plan to get rid of them beforehand.

 Periodic Change Survey: Any changes made to the safety issues; a supervisor will

take a look at them. Changes that are exclusive to Computech, include new

equipment, changes made to production process, injection molding processes and

sheet forming processes.

 Monthly Safety Inspection: Before the scheduled safety committee meeting,

inspections will be done at the start of each month. Committee members will report

any hazards to the whole committee for considerations.

 Job Hazard Analysis: Each type of job done by the employees will be evaluated. If

any changes are made for the sake of safety, the committee will approve it

unanimously. Employees will also be checked whether they need a PPE or not.

Basic Safety Rules:

 Never do anything that is unsafe in order to get the job done

 Do not remove or disable any safety device! Keep guards in place at all times on

operating machinery

 Obey all safety warning signs

 Do not bring firearms or explosives onto company property

50
  Smoking is strictly prohibited

Equipment Specific Safety:

1) Air Compressors

i. Wear safety goggles

ii. Use self-retracting cord

iii. Use and OSHA-Approved nozzle

iv. Check for oil and air leaks

2) Conveyers

i. Do not wear loose clothing

ii. Do not climb, step, sit or ride on the conveyors.

iii. Do not alter or remove guards or safety devices.

iv. Do not try to remove stuck items or debris until the conveyor is locked out.

v. Do not service the conveyor without following lock-out procedures.

3) Electric Forklift

i. They are powered by large lead-acid batteries, which must be routinely charged

ii. Ensure both forks are as far under the load as

possible before lifting

iii. Do not pass a forklift traveling in the same

direction if it is at a blind spot, intersection

or other dangerous location.

iv. Never drive a forklift up to anyone in front

of a bench or other fixed object.

51
 v. Never allow anyone to walk or stand under the elevated forks – even if the forks are

not carrying a load.

vi. Check that there is adequate clearance under beams, lights, sprinklers, and pipes for

the forklift and load to pass.

vii. Never engage in stunt driving or horseplay

4) Hoists

i. Know the safe load limit of the hoist. Do not exceed.

ii. Keep wire ropes and chains lubricated.

iii. Hoist from directly over the load. If not centred, the load may swing when lifted.

iv. Hang hoists solidly in the highest part of the hook area. Rigged this way, the hook

support is directly in line with the hook shank.

52
 v. Lever operated hoists can be used to pull in any direction, but a straight-line pull must

be maintained. Side pulling or lifting increases wear and sets up dangerous stress

levels on hoist parts. Only one person should pull on hand, chain and lever hoists.

vi. When loading the lower hook, place the load directly in line with the hook shank.

Loaded this way, the load chain makes a straight line from hook shank to hook shank.

5) Metal Punch Presses

i. The most important element in eliminating accidents is to make sure that workers are

properly trained before they are allowed to operate presses

ii. Never place your hands in the sliding block working area while the punch press is in

operation

iii. When adjusting or repairing the machine, always hang a warning board

53
 iv. Use closed tools and static fixed guards

v. Fit interlock safety devices that prevent access and stop machinery movement

immediately when opened

vi. Use presence sensing devices

vii. Use light curtains with fixed guards on part revolution power presses

viii. Use two handed controls as a back-up system

6) Metal fabrication machine

i. A detailed training session regarding the equipment, occupational hazards, and

working conditions should be given to the personnel

ii. The tools should be checked for malfunctioning, and inspected to ensure that they are

in good working condition. This is because sheet metal fabrication workers use

various types of manual or hand operated tools.

54
 iii. This point encompasses handling raw materials, tools, and finished products. You can

utilize the right material handling equipment to transport big or heavy products.

iv. Any person handling sheet metal fabrication tools should be equipped with safety

gear. They should wear hard hats, goggles, gloves, and safety shoes at all times. Make

sure that when working or handling any product, your back and neck are supported

adequately. An injury to the back could result in long term pain.

7) Injection Molding machine

i. Do not operate the machine unless you have been instructed in its operation devices

ii. Be certain all safety devices are working properly before operating the machine

iii. If any safety equipment is missing, damaged, or inoperative, notify your supervisor

immediately and do not operate the machine

iv. Report any hazard to your supervisor, no matter how minor it is

v. Report any open receptacles, junction boxes, bare wires, oil leaks to your supervisor

55
 vi. Keep oil and water off the floor around the machine

vii. Keep the platform and work area clean

viii. Use safety devices provided and do not bypass, change, or otherwise make inoperative

any such safety device or equipment

ix. Shouting or horseplay is strictly forbidden

8) Plastic extrusion machine

i. Isolate hazardous processes that follow extrusion, such as heating, cutting or sealing

ii. Ensure that handling and storage processes minimise spills and dust

iii. Use temperatures low enough to avoid toxic vapour formation

iv. Clean plastic dust from surfaces where it lands. Blowing dust with compressed air is

not acceptable

v. Provide adequate ventilation

vi. Always wear PPE to cover face, hands, and body

56
 vii. Keep fire extinguishers readily available, and ensure staff know how to use them

9) Shearing machine

i. Assess your work area to make certain the area is clear of clutter that could potentially

cause you to fall, as well as has sufficient lighting

ii. Make certain you have all personal protective equipment (PPE) needed to operate the

machine safely including safety glasses and gloves

iii. Finally, set up a safety border to ensure others do not get into your way

iv.

57
 v. Make certain any available safety enhancements, such as light curtains or rear guards,

are in place

vi. Always keep a lookout for overheating or smoking. Turn the power off immediately if

this occurs

vii. If the machine stops functioning, ensure the power supply is turned completely off

viii. Make certain power to the machine is completely cut off

ix. Remove any trash and debris that has accumulated on the machine. Clean off the

machine per your employers’ protocol

Safety Disciplinary

Policy

Computech expects its

employees to use good judgment

when performing their tasks and

to follow the established rules and

58
regulations. We have established a disciplinary policy to provide appropriate consequences for

failure to follow safety rules. This policy is designed not so much to punish as to bring unacceptable

behaviour to the employee's attention in a way that the employee will be motivated to make

corrections. The following consequences apply to the violation of the same rule or the same

unacceptable behaviour:

 1st instance: verbal warning, notation in employee file, and instruction on proper

actions

 2nd instance: 1-day suspension, written reprimand, and instruction on proper actions

 3rd instance: 1-week suspension, written reprimand, and instruction on proper actions

 4th instance: Termination of employment

HR and managers should document every stage of company’s disciplinary procedure (except

the verbal warning.) If appropriate, include necessary information like evidence, testimonies

and employee’s progress or improvement.

Computech has the right to modify this policy or act in any other legal or reasonable way as

each case demands. But the company will always enforce discipline in a fair and lawful

manner.

Safety Awareness Program

Two of the major aspects of this program have been covered in the Safety Guidelines

section i.e. Safety Committee and Safety Meetings.

Safety Training: It is a program that enables the workers and employees of a company to

perform their tasks in a way which is safe for them as well as for the company. This is

made sure through proper trainings and workshops. Computech encourages a great

59
incident reporting culture so that we can effortlessly create a safer workplace and can

identify how our company can continually improve the workplace environment. Safety

training is an integral part of the employee onboarding process but it also requires

regular “refresher” courses for compliance (and effectiveness)

Beyond the obvious reasons – regulation and moral responsibility – there are plenty of

advantages to investing more time and thought in a well-planned workplace safety training

program. Here are a few:

 Lower insurance premiums

 Less productivity loss due to illness or injury

 Higher employee satisfaction

 Reduced worker compensation for medical leave due to work-related injuries

60
Apart from all of these measures, there are some safety courses such as:
 NEBOSH International General Certificate (IGC)

 NEBOSH Process Safety Management (PSM)

 IOSH Managing Safely

 IASP OSHA 30 Hours Standard Training

 ASHI Basic Life Support (First Aid, CPR & AED)

 HABC Level-4 International Award in Health and Safety at Work

NEBOSH International General Certificate: It is ideal for managers, supervisors and

anybody with health and safety management responsibilities. It’s also perfect for those

embarking on a health and safety career and gives you a stepping stone to success.

Trusted by many prestigious organizations such as Maersk, Shell, BP, Skanska, Nestle and

the Dubai World Trade Centre, it can help to:

 Minimize workplace injuries and illness

 Boost employee wellbeing

 Demonstrate your commitment to health and safety, which can win business

NEBOSH Process Safety Management: This process safety management qualification is

the result of the unique collaboration which combines the advanced technical ‘high hazard’

expertise of HSE with NEBOSH’s ability to deliver strong vocational OSH qualifications.

This qualification is designed to equip delegates with a broad understanding of the accepted

principles and recognized industrial practices for the management of process risk. This will

ensure that they can recognize and contribute to the control of process safety hazards.

61
IOSH Managing Safely: Designed to provide all managers with the confidence and

enthusiasm to apply knowledge to the workplace, this course is unlike any other.

Top 5 business benefits:

 Greater productivity fewer hours lost to sickness and accidents

 Improved organization-wide safety awareness

 Active staff involvement to improve the workplace

 Internationally recognized certification for managers and supervisors

 Enhanced reputation within the supply chain

IASP OSHA 30-Hour Standard Training: The course is a comprehensive safety program

specifically designed for workers in the general industry safety training as an orientation to

occupational safety and health for employees as covered in OSHA 29 CFR 1910. Workers

are required to get additional training on the specific hazards of their work. 

Training course offered at Certifications will fulfill the requirements to receive the 30-hour

general industry completion card from IASP.

ASHI Basic Life Support (First Aid, CPR & AED): In this course, employees learn how to

recognize a life-threatening emergency, how to provide basic life support and what to do in

case of an airway obstruction or choking.

HABC Level-4 International Award in Health and Safety at Work: The Level 4 Award

in Health and Safety in the Workplace is a qualification aimed at Supervisors and Managers

with a direct responsibility for health and safety management. The qualification is intended

62
for learners already working in the capacity of supervisor or manager and those who are

preparing to start work at this level. Employees gaining this qualification will know that

supervisors and managers have legal and moral obligations to ensure health and safety within

a business and that this includes obligations to employees, contractors, visitors and suppliers.

Safety Awards Program: The achievement of safety goals, completion of safety training,

and successful implementation of safety practices are excellent reasons to recognize

Computech’s employees with awards. Safety Awards send strong messages to employees on

the importance of maintaining a safe workplace and the value that the company places on a

healthy environment. Safety awards can be given monthly, quarterly, annually, or for major

milestones. Some of the typical awards we see are given to individuals, facilities, and

departments.

63
Appendices

64
 Appendix A: Safety Data Sheet

The SDS includes information such as the properties of each chemical; the physical, health,
and environmental health hazards; protective measures; and safety precautions for handling,
storing, and transporting the chemical. The information contained in the SDS must be in
English (although it may be in other languages as well). In addition, OSHA requires that SDS
preparers provide specific minimum information as detailed in Appendix D of 29 CFR
1910.1200. The SDS preparers may also include additional information in various section(s).

A SAMPLE of standard SDS taken from the internet for batteries is provided below.

SECTION 1—PRODUCT AND COMPANY IDENTIFICATION

Product Name:
Product Use:
Chemical Family:

Emergency Telephone Number:

Manufacturer's Name:

Other Information Calls:

Address:

Revision Date:
Person Responsible for Preparation:

SECTION 2 – GHS HAZARD IDENTIFICATION

Do not open battery. Avoid contact with internal

components. Internal
components include lead and liquid electrolyte.
Electrolyte - Electrolyte is corrosive and contact may cause
Signs and skin irritation and chemical burns. Electrolyte causes
Symptoms of 1. Acute severe irritation and burns of eyes, nose and
Exposure Hazards throat. Ingestion can cause severe burns and vomiting.
Lead -Direct skin or eye contact may cause local irritation.
Inhalation or ingestion 0f lead dust or fumes may result in
headache, nausea, vomiting, abdominal spasms, fatigue,
sleep disturbances, weight loss, anemia and leg, arm and
joint pain.

Electrolyte - Repeated contact with sulfuric acid battery electrolyte fluid may cause
drying of the skin which may result in irritation, dermatitis, and skin burns.
Repeated exposure to sulfuric acid mist may cause erosion of teeth, chronic eye
2. Sub-chronic and
irritation and/or chronic inflammation of the nose, throat and lungs.
Chronic Health
Lead - Prolonged exposure may cause central nervous system damage,
Effects
gastrointestinal disturbances, anemia, and wrist-drop and kidney dysfunction.
Pregnant women should be protected from excessive exposure to prevent lead from
crossing the placental barrier and causing infant neurological disorders.
Medical If battery is broken or material is spilled, then persons with the following medical
Conditions conditions must take precautions: pulmonary edema, bronchitis, emphysema, dental

65
Generally
Aggravated by erosion and tracheobronchitis.
Exposure

Health Physical Environmental

Acute Toxicity
(Oral/Dermal/Inhalation)
Category 4
Skin Corrosion/Irritation
Category 1A
Eye Damage Aquatic
Category 1
Reproductive Explosive Chemical, Chronic 1
Category 1A
Carcinogenicity (lead compounds) Division 1.3 Aquatic
Category 1B
Carcinogenicity (arsenic) Acute 1
Category 1A
Carcinogenicity (acid mist)
Category 1A
Specific Target Organ
Toxicity (repeated exposure)

GHS LABEL
Health Physical
Hazard Statements
DANGER! Precautionary Statements:
Causes severe skin burns and eye Wash thoroughly after handling.
damage. Do not eat, drink or smoke when using this product.
Causes serious eye damage. Wear protective gloves/protective clothing, eye protection/face
May damage fertility or the protection.
unborn child if Avoid breathing dust/fume/gas/mist/vapors/spray.
ingested or inhaled. Use only outdoors or in a well-ventilated area.
May cause cancer if ingested or Causes skin irritation, serious eye damage.
inhaled. Contact with internal components may cause irritation or
Extremely flammable gas severe burns.
(hydrogen). Avoid contact with internal acid.
Explosive, fire, blast or projection Irritating to eyes, respiratory system, and skin
hazard.

SECTION 3 – COMPOSITION/INFORMATION ON INGREDIENTS

PRINCIPAL HAZARDOUS
COMPONENT(S)
C.A.S. Hazard Category % by Wt:
(Chemical & common
name(s))
Lead/Lead Oxide/Lead
7439-92-1 Acute-Chronic 60 - 97%
Sulfate
7440-36-0 Antimony Chronic 0.5 - 2%
7440-38-2 Arsenic Acute-Chronic < 0.2%
Sulfuric Acid Reactive-Oxidizer
7664-93-9 5 - 38%
(Battery Electrolyte) Acute-Chronic
7440-70-2 Calcium Reactive < 0.15%
7440-31-5 Tin Chronic < 1.0%

SECTION 4 -- FIRST AID MEASURES

INHALATION:

66
Sulfuric Acid: Remove to fresh air immediately. If not breathing, give artificial respiration. If

breathing is difficult, give oxygen. Consult a physician.

Lead: Remove from exposure, gargle, wash nose and lips; consult physician.

INGESTION:

Sulfuric Acid: Give large quantities of water; Do NOT induce vomiting or aspiration into the

lungs may occur and can cause permanent injury or death; consult physician.

Lead: Consult physician immediately.

SKIN:

Sulfuric Acid: Flush with large amounts of water for at least 15 minutes; remove

contaminated clothing completely, including shoes. If symptoms persist, seek medical

attention. Wash contaminated clothing before reuse. Discard contaminated shoes.

Lead: Wash immediately with soap and water.

EYES:

Sulfuric Acid and Lead: Flush immediately with large amounts of water for at least 15

minutes while lifting lids; Seek immediate medical attention if eyes have been exposed

directly to acid.

SECTION 5 - FIREFIGHTING MEASURES

Flash Point: Not Applicable

Flammable Limits: LEL = 4.1% (Hydrogen Gas in air); UEL = 74.2%

Extinguishing media: CO2; foam; dry chemical. Do not use carbon dioxide directly on cells.

Avoid breathing vapours. Use appropriate media for surrounding fire.

Fire Fighting Procedures: Use positive pressure apparatus. Beware of acid splatter during

67
water application and wear acid-resistant clothing, gloves, face and eye protection. If

batteries are on charge, shut off power to the charging equipment.

Hazardous Combustion Products: Highly flammable hydrogen gas is generated during

charging and operation of batteries. If ignited by burning cigarette, naked flame or spark, may

cause battery explosion with dispersion of casing fragments and corrosive liquid electrolyte.

Carefully follow manufacturer's instructions for installation and service.

SECTION 6 — ACCIDENTAL RELEASE MEASURES

Procedures for Clean-up: Stop release, if possible. Avoid contact with any spilled material.

Contain spill, isolate hazard area, and deny entry. Limit site access to emergency responders.

Neutralize with sodium bicarbonate, soda ash, lime another neutralizing agent. Place battery

in suitable container for disposal. Dispose of contaminated material in accordance with

applicable local, state and federal regulations. Sodium bicarbonate, soda ash, sand, lime or

other neutralizing agent should be kept on-site for spill remediation.

Personal Precautions: Acid resistant aprons, boots and protective clothing. ANSI approved

safety glasses with side shields/face shield recommended. Ventilate enclosed areas.

Environmental Precautions: Lead and its compounds and sulfuric acid can pose a severe

threat to the environment. Contamination of water, soil, and air should be prevented.

SECTION 7 — HANDLING AND STORAGE

Handling: Unless involved in recycling operations, do not breach the casing or empty the

contents of the battery. Handle carefully and avoid tipping, which may allow electrolyte

leakage. There may be increasing risk of electric shock from strings of connected batteries.

Keep containers tightly closed when not in use. If battery case is broken, avoid contact

with internal components. Keep vent caps on and cover terminals to prevent short circuits.

Place cardboard between layers of stacked automotive batteries to avoid damage and short

68
circuits. Keep away from combustible materials, organic chemicals, reducing substances,

metals, strong oxidizers and water. Use banding or stretch wrap to secure items for shipping.

Storage: Store batteries under roof in cool, dry, well-ventilated areas separated from

incompatible materials and from activities that may create flames, spark, or heat. Store on

smooth, impervious surfaces provided with measures for liquid

containment in the event of electrolyte spills. Keep away from metallic objects that could

bridge the terminals on a battery and create a dangerous short-circuit.

Charging: There is a possible risk of electric shock from charging equipment and from

strings of series connected batteries, whether or not being charged. Shut-off power to

chargers whenever not in use and before detachment of any circuit connections. Batteries

being charged will generate and release flammable hydrogen gas. Charging space should be

ventilated. Keep battery vent caps in position. Prohibit smoking and avoid creation of flames

and sparks nearby. Wear face and eye protection when near batteries being charged.

SECTION 8 -- EXPOSURE CONTROLS AND PERSONAL PROTECTION

(a) As dusts/mists (b) As inhalable aerosol (c) Thoracic fraction (d) Potential occupational carcinogen

(e) Based on OEL’s of Austria, Belgium, Denmark, France, Netherlands, Switzerland, & U.K.

(f) Based on OEL of Belgium (g) Based on OEL of Netherlands

N.E. = Not Established

OSHA US Quebec Ontario EU

Ingredients: ACGIH
PEL NIOSH PEV OEL OEL

Lead, inorganic 0.05 0.05 0.05 0.05 0.05 0.15 (b)

Antimony 0.5 0.5 0.5 0.5 0.5 0.5 (b,d)
Tin 2 2 2
Copper 1 1 1 1 1 (a) 0.1 (e)

Arsenic 0.01 0.01 0.01

69
 Sulfuric Acid 1 0.2 1 1 0.2 0.05 (c)
Polypropylene N.E. N.E. N.E. N.E. N.E. N.E
Engineering Controls (Ventilation):

Store and handle in well-ventilated area. If mechanical ventilation is used, components must

be acid-resistant. Handle batteries cautiously, do not tip to avoid spills. Make certain vent

caps are on securely. If battery case is damaged, avoid bodily contact with internal

components. Wear protective clothing, eye and face protection, when filling, charging or

handling batteries. Do not allow metallic materials to simultaneously contact both the

positive and negative terminals of the batteries. Charge batteries in areas with adequate

ventilation. General dilution ventilation is acceptable.

Respiratory Protection (NIOSH/MSHA approved):

None required under normal conditions. When concentrations of sulfuric acid mist are known

to exceed PEL, use NIOSH or MSHA-approved respiratory protection.

Skin Protection:

If battery case is damaged, use rubber or plastic acid-resistant gloves with elbow-length

gauntlet, acid-resistant apron, clothing and boots.

Eye Protection:

If battery case is damaged, use chemical goggles or face shield.

Other Protection:

In areas where water and sulfuric acid solutions are handled in concentrations greater than

1%, emergency eyewash stations and showers should be provided, with unlimited water

supply. Chemically impervious apron and face shield recommended when adding water or

electrolyte to batteries. Wash Hands after handling.

70
SECTION 9 -- PHYSICAL AND CHEMICAL PROPERTIES

Properties Listed Below are for Electrolyte:

210 - 245° Specific Gravity
Boiling Point: 1.215 to 1.350
F (H2O = 1):
Vapor Pressure
Melting Point: N/A 10
(mm Hg):
Vapor Density
Solubility in Water: 100% Greater than 1
(AIR = 1):
Evaporation Rate: % Volatile by
Less than 1 N/A
(Butyl Acetate = 1) Weight:
Below room
temperature
pH: ~1 to 2 Flash Point:
(as hydrogen
gas)
UEL (Upper
4.1% 74.2%
LEL (Lower Explosive Limit) Explosive
(Hydrogen) (Hydrogen)
Limit)
Appearance and Odor: Manufactured article; no apparent odor. Electrolyte is a clear
liquid with a sharp, penetrating, pungent odor.

SECTION 10 -- STABILITY AND REACTIVITY

Stability: Stable X Unstable

This product is stable under normal conditions at ambient temperature.

Conditions to Avoid: Prolonged overcharge at high current; sources of ignition.

Incompatibilities: (materials to avoid)

Electrolyte: Contact with combustibles and organic materials may cause fire and explosion.

Also reacts violently with strong reducing agents, metals, sulfur trioxide gas, strong

oxidizers, and water. Contact with metals may produce toxic sulfur dioxide fumes and may

release flammable hydrogen gas.

Lead Compounds: Avoid contact with strong acids, bases, halides, halogenates, potassium

nitrate, permanganate, peroxides, nascent hydrogen, and reducing agents.

71
Arsenic Compounds: Strong oxidizers; bromine-azide. NOTE: Hydrogen gas can react with

inorganic arsenic to form the highly toxic gas – arsine

Hazardous Decomposition Products:

Electrolyte: Sulfur trioxide, carbon monoxide, sulfuric acid mist, sulfur dioxide, hydrogen

sulfide.

Lead Compounds: Temperatures above the melting point are likely to produce toxic metal

fume, vapor, or dust; contact with strong acid or base or presence of nascent hydrogen may

generate highly toxic arsine gas.

SECTION 11 -- TOXICOLOGICAL INFORMATION

Routes of Entry: Sulfuric Acid: Harmful by all routes of entry.

Lead Compounds: Hazardous exposure can occur only when product is heated, oxidized or

otherwise processed or damaged to create dust, vapor or fume. The presence of nascent

hydrogen may generate highly toxic arsine gas.

Inhalation:

Sulfuric Acid: Breathing of sulfuric acid vapors or mists may cause severe respiratory

irritation.

Lead Compounds: Inhalation of lead dust or fumes may cause irritation of upper respiratory

tract and lungs.

72
Skin Contact:

Sulfuric Acid: Severe irritation, burns and ulceration.

Lead Compounds: Not absorbed through the skin.

Arsenic compounds: Contact may cause dermatitis and skin hyperpigmentation

Eye Contact:

Sulfuric Acid: Severe irritation, burns, cornea damage, and blindness.

Lead Compounds: May cause eye irritation.

Effects of Overexposure - Acute:

Sulfuric Acid: Severe skin irritation, damage to cornea, upper respiratory irritation.

Lead Compounds: Symptoms of toxicity include headache, fatigue, abdominal pain, loss of

appetite, muscular aches and weakness, sleep disturbances and irritability.

Effects of Overexposure - Chronic:

Sulfuric Acid: Possible erosion of tooth enamel, inflammation of nose, throat & bronchial

tubes.

Lead Compounds: Anemia; neuropathy, particularly of the motor nerves, with wrist drop;

kidney damage; reproductive changes in males and females. Repeated exposure to lead and

lead compounds in the workplace may result in nervous system toxicity. Some toxicologists

report abnormal conduction velocities in persons with blood lead levels of 50 μg/100 ml or

higher. Heavy lead exposure may result in central nervous system damage, encephalopathy

and damage to the blood-forming (hematopoietic) tissues.

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SECTION 12 -- ECOLOGICAL INFORMATION

Environmental Fate: Lead is very persistent in soil and sediments. No data on

environmental degradation. Mobility of metallic lead between ecological compartments is

slow. Bioaccumulation of lead occurs in aquatic and terrestrial animals and plants but little

bioaccumulation occurs through the food chain. Most studies include lead compounds and

not elemental lead.

Environmental Toxicity: Aquatic Toxicity:

Sulfuric Acid: 24-hr LC50, freshwater fish (Brachydanio rerio): 82 mg/L

96 hr- LOEC, freshwater fish (Cyprinus carpio): 22 mg/L

Lead: 48 hr LC50 (modeled for aquatic invertebrates): <1 mg/L, based on lead bullion

Arsenic: 24 hr LC50, freshwater fish (Carrassisus auratus) >5000 g/L

SECTION 13 -- DISPOSAL CONSIDERATION

Spent Batteries: Send to secondary lead smelter for recycling. Spent lead-acid batteries are

not regulated as hazardous waste when the requirements of 40 CFR Section 266.80 are met.

Spilled sulfuric acid is a characteristic hazardous waste;

EPA hazardous waste number D002 (corrosivity) and D008 (lead).

Electrolyte: Place neutralized slurry into sealed acid resistant containers and dispose of as

hazardous waste, as applicable. Large water diluted spills, after neutralization and testing,

should be managed in accordance with approved local, state, and federal requirements.

Consult state environmental agency and/or federal EPA. Following local, State/Provincial,

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and Federal/National regulations applicable to end-of-life characteristics will be the

responsibility of the end-user.

SECTION 14 -- TRANSPORT INFORMATION

United States: The U.S. Department of Transportation (DOT) hazardous materials regulations

(49 CFR) applicable tolead acid batteries are specified in 49 CFR 173.159.

Proper Shipping Name: Batteries, wet, filled with acid

Hazard Class: 8
ID Number: UN2794
Packing Group: III
Labels: Corrosive

49 CFR 173.159(e) Specifies that when transported by highway or rail, electric storage

batteries containing electrolyte or corrosive battery fluid are not subject to any other

requirements of this subchapter, if all of the following are met:

(1) No other hazardous materials may be transported in the same vehicle;

(2) The batteries must be loaded or braced so as to prevent damage and short circuits in

transit;

(3) Any other material loaded in the same vehicle must be blocked, braced, or otherwise

secured to prevent

contact with or damage to the batteries; and

(4) The transport vehicle may not carry material shipped by any person other than the shipper

of the batteries.

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SECTION 15 -- REGULATORY INFORMATION

UNITED STATES FEDERAL REGULATIONS:

EPCRA Sections 302, 304, 311 & 312

Industrial lead-acid batteries, such as those used in forklifts, do NOT meet the OSHA definition of an

"article" (US EPA, Oct. 1998). Therefore, the lead and acid that compose these batteries must be

included when determining the various thresholds for these EPCRA section regulations. The acid in

lead-acid batteries is Sulfuric Acid, which is an Extremely Hazardous Substance (EHS). The

following table outlines the applicable EPCRA Sections and their respective thresholds for

Sulfuric Acid:

*The reporting threshold for Sulfuric Acid is ≥ the designated TPQ or 500 lbs, whichever is less.

The lead used in lead-acid batteries does not qualify for any OSHA or EPCRA exemptions. Lead is

not an EHS, and the following table outlines the applicable EPCRA Sections and their respective

thresholds for Lead:

EPCRA Section 313

The reporting of lead and sulfuric acid (and their releases) in lead-acid batteries used in cars, trucks,

most cranes, forklifts, locomotive engines, and aircraft for the purposes of EPCRA Section 313 is not

required. Lead-acid batteries used for these purposes are exempt for Section 313 reporting per the

"Motor Vehicle Exemption." See page B-22 of the

U.S. EPA Guidance Document for Lead and Lead Compound Reporting under EPCRA Section 313

for additional information of this exemption.

Supplier Notification: This product contains toxic chemicals that may be reportable under EPCRA

Section 313 Toxic Chemical Release Inventory (Form R) requirements. For a manufacturing facility

under SIC codes 20 through 39, the following information is provided to enable you to complete the

required reports:

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Toxic Chemical CAS Number Approximate % by Weight

Lead 7439-92-1 73

Sulfuric Acid/Water Solution 7664-93-9 25

EPCRA Sections – Sulfuric Acid Thresholds

302 - Emergency Planning Notification *TPQ ≥ 1,000 lbs.
304 - Emergency Release Notification *RQ ≥ 1,000 lbs.
311 - MSDS Reporting *TPQ ≥ 500 lbs.
312 - Chemical Inventory Reporting (i.e. Tier II) *TPQ ≥ 500 lbs.

EPCRA Sections - Lead Thresholds

311 - MSDS Reporting ≥ 10,000 lbs.
312 - Chemical Inventory Reporting (i.e. Tier II) ≥ 10,000 lbs

SECTION 16 -- OTHER INFORMATION

NFPA Hazard Rating for sulfuric acid:

Flammability (Red) = 0
Health (Blue) = 3
Reactivity (Yellow) = 2
Sulfuric acid is water-reactive if concentrated.

Distribution into Quebec to follow Canadian Controlled Product Regulations (CPR) 24(1)

and 24(2). Distribution into the EU to follow applicable Directives to the Use, Import/Export

of the product as-sold.

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Appendix B: Posters

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Appendix C: OSHA Forms

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