Oregon Rules for Reinforced Plastics Manufacturing
(1)Applicability. If a specific type of equipment, process or practice is not limited to the reinforced plastics industry, the provisions contained in other Divisions of OAR 437, Oregon Occupational Safety and Health Code, shall apply.
(a)These rules shall apply to reinforced plastics manufacturing operations, in their shop buildings (not field work) involving the use of polyester, vinylester, and other similar products in which styrene monomer is a reactive monomer for the resin. This division applies to chopper gun, gel coating, hand laminating and casting operations utilizing resin and organic peroxide catalyst.
(b)This division does not apply to:
(A)Application of flammable organic materials such as acetone, methyl ethyl ketone (MEK), either alone or mixed as flammable paints or diluents;
(B)Operations, involving polyurethane finishes or foams utilizing isocyanate catalysts;
(C)Operations involving epoxy resin compounds utilizing amine hardeners; or
(D)Cleaning of chopper guns, lines, and associated equipment in which acetone, MEK, or other flammable organic solvents are sprayed into the open air as part of the cleaning process.
(3)Definitions. The following definitions shall apply to OAR 437-002-0118 (Oregon Rules for Reinforced Plastics Manufacturing):
(a)Chopper Gun — A device that feeds fiber glass rovings through a chopper and ejects them into a stream of resin and organic peroxide catalyst onto a mold surface. The resin and organic peroxide catalyst are combined and ejected from the chopper gun by either one of two systems:
(A)One nozzle ejects resin while another nozzle ejects organic peroxide catalyst towards the mold surface; or
(B)The resin and organic peroxide catalyst are fed into a single chopper gun mixing chamber ahead of the nozzle.
(b)Flammable liquid means any liquid having a flashpoint at or below 199.4 degrees F (93 degrees C). Flammable liquids are divided into four categories as follows:
(A)Category 1 shall include liquids having flashpoints below 73.4 degrees F (23 degrees C) and having a boiling point at or below 95 degrees F (35 degrees C).
(B)Category 2 shall include liquids having flashpoints below 73.4 degrees F (23 degrees C) and having a boiling point above 95 degrees F (35 degrees C).
(C)Category 3 shall include liquids having flashpoints at or above 73.4 degrees F (23 degrees C) and at or below 140 degrees F (60 degrees C). When a Category 3 liquid with a flashpoint at or above 100 degrees F (37.8 degrees C) is heated for use to within 30 degrees F (16.7 degrees C) of its flashpoint, it shall be handled in accordance with the requirements for a Category 3 liquid with a flashpoint below 100 degrees F (37.8 degrees C).
(D)Category 4 shall include liquids having flashpoints above 140 degrees F (60 degrees C) and at or below 199.4 degrees F (93 degrees C). When a Category 4 flammable liquid is heated for use to within 30 degrees F (16.7 degrees C) of its flashpoint, it shall be handled in accordance with the requirements for a Category 3 liquid with a flashpoint at or above 100 degrees F (37.8 degrees C).
(c)Flashpoint – The minimum temperature at which a liquid gives off vapor within a test vessel in sufficient concentration to form an ignitable mixture shall be determined as follows:
(A)For a liquid which has a viscosity of less than 45 SUS at 100 degrees F (37.8 degrees C), does not contain suspended solids, and does not have a tendency to form a surface film while under test, the procedure specified in the Standard Method of Test for Flashpoint by Tag Closed Tester (ASTM D-56-70), which is incorporated by reference as specified in 1910.6, or an equivalent test method as defined in Appendix B to OAR 437-002-1910.1200 – Physical Hazard Criteria, shall be used.
(B)For a liquid which has a viscosity of 45 SUS or more at 100 degrees F (37.8 degrees C), or contains suspended solids, or has a tendency to form a surface film while under test, the Standard Method of Test for Flashpoint by Pensky-Martens Closed Tester (ASTM D-93-71) or an equivalent method as defined by Appendix B to OAR 437-002-1910.1200 – Physical Hazard Criteria, shall be used except that the methods specified in Note 1 to section 1.1 of ASTM D-93-71 may be used for the respective materials specified in the Note. The preceding ASTM standard is incorporated by reference as specified in OAR 437-002-1910.6.
(C)For a liquid that is a mixture of compounds that have different volatilites and flashpoints, its flashpoint shall be determined by using the procdures in subsection (3)(c)(A) or (3)(c)(B) of this definition on the liquid in the form it is shipped.
(D)Organic peroxide catalysts are excluded from any of the flashpoint determination methods specified in this section.
(d)Gelcoating – A chopper gun pressure pot or similar device is used to apply the resin and organic peroxide catalyst mixture to a mold surface without glass fibers;
(f)Hazard – A substance, process, practice or condition which could result in an injury or illness to an employee.
(g)Resin – A mixture of true esters dissolved in a polymerizable monomer (styrene).
(h)Threshold-Limit Value – Short Term Exposure Limit (TLV-STEL) – The maximum concentration to which workers can be exposed for a period of up to 15 minutes continuously without suffering from (a) irritation, (b) chronic or irreversible tissue change, or (c) narcosis of sufficient degree to increase accident proneness, impair self-rescue, or materially reduce work efficiency, provided that no more than four excursions per day are permitted, with at least 60 minutes between exposure periods, and provided that the daily TLV-TWA also is not exceeded. The STEL should be considered a maximum allowable concentration, or ceiling, not to be exceeded at any time during the 15-minute excursion period.
(4)Permissible Exposure Limits.
(a)An employee’s exposure to any material listed in Table 1, in any 8-hour workshift of a 40-hour work week, shall not exceed the 8-hour time-weighted average limit for that material in the table.
(b)An employee’s exposure to a material listed in Table 1 shall not exceed, at any time during an 8-hour shift, the TLV-STEL level given for the material in the table, except for a time period, and up to a concentration not exceeding the maximum duration and concentration allowed in the column under “Acceptable Maximum Peak.”
(c)Employee exposure to other airborne contaminants shall be in accordance with OAR 437, Division 2, Subdivision Z, 1910.1000, Air Contaminants, and other applicable regulations.
(5)Methods of Compliance.
(a)To achieve compliance with OAR 437-002-0118 (Oregon Rules for Reinforced Plastics Manufacturing)(4), Permissible Exposure Limits, administrative or engineering controls must first be determined and implemented whenever feasible.
(b)When such controls are not feasible to achieve full compliance, protective measures as prescribed in OAR 437, Division 2/I, Personal Protective Equipment, shall be used to keep the exposure of employees to airborne contaminants within the limits prescribed in OAR 437-002-0118 (Oregon Rules for Reinforced Plastics Manufacturing).
(6)Employee Information and Training. A training program shall be established and all affected employees shall be trained regarding the safe handling of materials used in the industry which shall include instruction in storage, handling large and small quantities, cleanup and disposal of spills, first aid for spills, equipment training, potential health and safety hazards, personal hygiene, personal protective measures, and the labeling system.
(7)Personal Protective Equipment.
(a)Safety glasses shall be worn at all times by personnel working in the manufacturing area of reinforced plastics plants.
(b)Face shields and safety glasses shall be worn when opening and filling pressurized catalyst injection equipment.
(c)An eyewash fountain shall be provided no more than 25 feet or 15 seconds of actual travel from a work area where MEK peroxide is being mixed or transferred.
(A)The criteria of 25 feet shall apply if the employee is working alone.
(B)The criteria of 15 seconds shall apply if other employees are close enough under normal working conditions to provide assistance and a formal training program which includes emergency first aid procedures for eye protection has been implemented.
(d)Clothing saturated or impregnated with flammable liquids, corrosive or toxic substances, irritants, or oxidizing agents, that present a health hazard to employees shall be removed and disposed of, or properly cleaned before reuse; however, clothing coated with cured resin may be worn.
(8)Warning Signs and Labels.
(a)Label chemical containers in accordance with OAR 437-002-1910.1200, Hazard Communication.
(b)Where extreme occupational health hazards are known to exist in the workplace, the employer shall provide warning signs or other equally effective means of calling attention to such hazards at the location where the hazards exist.
(a)Housekeeping shall be sufficient to keep accumulations of combustible residues to a minimum as practical.
(b)All combustible and flammable residues shall be placed in covered noncombustible containers.
(c)To prevent excessive permanent buildup of overspray and overchop, the use of paper, polyethylene film, building or roofing paper or other similar sheet material shall be permitted on side walls and floors of chopper gun and gelcoat areas.
(A)When the accumulated depth of overchop and/or gelcoat has reached an average thickness of 2 inches in the overspray area, it shall be disposed of after at least 4 hours curing.
(B)A single day’s accumulation of more than an average of 2 inches shall be permitted provided it is disposed of before operations are resumed the next day.
(d)Excess catalyzed resin inside a building shall be disposed of in open-topped containers provided with bar screens, large mesh wire screens, or other means, to support individual containers across its top through which surplus catalyzed resin can be poured and upon which empty containers that once held catalyzed resin can be placed to cure. The open-topped containers shall contain water at least 2 inches deep in which the resin shall be poured and permitted to cure in a safe fashion. Containers can be used until filled with setup resin and disposed of along with other nontoxic waste.
(10)Hygiene Facilities and Practices. If acetone is used directly on the skin to clean hands, barrier or a therapeutic cream must be made available to the employee. Gloves shall be provided should any employee wish additional protection.
(11)Storage and Handling of Flammable Liquids.
(a)The storage and handling of acetone and other Category 1-3 flammable liquids for cleanup and gun flushing shall be subject to the following requirements:
(A)Category 1-3 flammable solvents shall be kept in containers that are covered during storage;
(B)Areas within the shop where acetone or other Category 1-3 flammable solvents are transferred into containers less than 5 gallons each shall be considered Class I, Division 1 areas for a 5-foot radius around the point of transfer, and Class I Division 2, for an additional 5 feet outside of the area; and
(C)“Dirty” acetone in small individual cleanup containers of less than 5 gallons each may be handled by pouring into a larger container suitable for disposal or recycling which shall be kept covered.
(b)The following subsections shall apply to chopper gun or gelcoating areas:
(A)Areas where flammable liquids are used, shall be protected by automatic sprinklers or equivalent extinguishing systems. If a special extinguishing system including, but not limited to, those employing foam, carbon dioxide, or dry chemical is provided, approved equipment shall be used and installed in an approved manner.
(B)Exhaust fans mounted 4 feet or less, as measured from the invert (bottom) of the duct above the floor, shall have nonsparking fan blades, and
(i)A motor mounted external to the air stream in a nonexplosive atmosphere. The fan shall be driven by an interconnecting belt.
(ii)Those fans having air suction ducts 4 feet or less above the floor shall comply with subsection (11)(b)(B).
(C)Exhaust fans mounted more than 4 feet above the floor shall have nonsparking fan blades.
(D)All other electrical equipment in chopper gun or gelcoating operations must conform to the requirements of National Fire Protection Association (NFPA) 33-1989.
(c)Acetone and other Category 1-3 flammable liquids shall be transferred only though a closed piping system from a safety can by means of a device drawing through the top or from a container or portable tank by gravity through an approved self-closing valve. The nozzle and container shall be electrically interconnected.
(d)Acetone shall be kept in covered containers when not in use.
(e)Special input and exhaust ventilation shall be provided where employees must be inside or under the item being fabricated (e.g., inside a pipe or boat hull or under a large fabricated shape) to keep air concentrations of hazardous and/or flammable materials at or below 25 percent of the lower explosive limit and employee exposure at or below the permissible exposure limit.
(f)Areas where flammable materials are handled shall either be posted with “No Smoking” signs, or smoking shall be prohibited throughout plant, manufacturing and storage areas.
(g)Storage and handling of flammable liquids not addressed in these rules shall meet the requirements of 1910.106, Flammable Liquids.
(12)Storage and Handling of Organic Peroxide Catalysts.
(a)Organic peroxide catalysts shall be isolated and stored in their original containers in a cool place under 100 degrees F (37.8 degrees C), away from other flammable materials and ignition sources.
(b)Organic peroxide catalyst containers shall be covered or kept closed at all times.
(c)Organic peroxide catalysts shall be brought into the area of use in no more than two consecutive days’ supply.
(d)Larger than 8-pound containers of organic peroxide catalyst shall not be permitted outside designated catalyst storage areas, except for hand layup operations or for filling the catalyst reservoir of chopper gun and gelcoat equipment.
(e)When organic peroxide catalyst is being poured into the catalyst reservoir of chopper gun and gelcoat equipment, the catalyst container shall be equipped with a special curved pouring spout or other device which directs the catalyst into the reservoir without splashing.
(A)A supply of water of not less than 1-gallon shall be permanently installed on the chopper gun or gelcoat apparatus to wet down any catalyst spills which may occur due to overfilling. Catalyst spills shall be absorbed in accordance with the manufacturer’s recommendations.
(B)Immediately after filling the chopper gun or gelcoat apparatus with catalyst, the empty or partially filled catalyst container shall be removed immediately before commencement of any other operation.
(13)Fire Protection. Areas where flammable materials are handled shall either be posted with “No Smoking” signs, or smoking shall be prohibited throughout plant, manufacturing and storage areas.
(a)Special input and exhaust ventilation shall be provided where employees must be inside or under the item being fabricated (e.g., inside a pipe or boat hull or under a large fabricated shape) to keep air concentrations of hazardous and/or flammable materials at or below 25 percent of the lower explosive limit and employee exposure at or below the permissible exposure limit.
(b)During cleanup and gun flushing with acetone or other Category 1-3 flammable liquids, sufficient ventilation shall be provided to maintain air concentrations below 25 percent of the lower explosive limit (LEL) and employee exposure at or below the permissible exposure limit.
(c)Where acetone and Category 1-3 flammable solvents are used in physical operations (e.g., mixing), there shall be a minimum ventilation rate of 1 cubic foot per minute per square foot of floor area in the immediate work area.
Rule 437-002-0118 — Oregon Rules for Reinforced Plastics Manufacturing,