Abrasive Blasting Code of Practice 2004
Abrasive Blasting Code of Practice 2004
2004
The Workplace Health and Safety Act 1995 places obligations on a person who
conducts a business or undertaking. The Act refers to a person who conducts a
business or undertaking as a ‘relevant person’. The obligations apply whether or not:
• the relevant person conducts the business or undertaking as an employer, self-
employed person or otherwise
• the business or undertaking is conducted for gain or reward, and
• a person works on a voluntary basis.
The term ‘relevant person’ is also used in the Workplace Health and Safety
Regulation 2008.
Where this code of practice provides advice to employers and self-employed persons
on managing exposure to risks, other persons who conduct a business or undertaking
may also find this advice applicable depending on their circumstances.
How can I meet my obligations?
Under the Act, there are three types of instruments to help you meet workplace health
and safety obligations – regulations, ministerial notices and codes of practice.
If there is a regulation or ministerial notice about a risk, you MUST do what the
regulation or notice says.
If there is no regulation, ministerial notice or code of practice about a risk, you must
choose an appropriate way to manage exposure to the risk and take reasonable
precautions and exercise proper diligence to ensure that your obligations are met.
Note
There may be additional risks at your workplace which have not been specifically
addressed in this code of practice. You are still required under the Act to identify and
assess these risks and ensure that control measures are implemented and reviewed to
eliminate or minimise exposure to these risks. The risk management process section
contains information on how to carry out a risk management process for risks which
have not been specifically covered by this code of practice.
Contents
Introduction....................................................................................................................1
The control measures in this code of practice are presented by a hierarchy of control.
This is an order which tells you which of the control measures provides a better level
of risk control. You should use control measures which are presented first, wherever
possible.
Below is a table which lists out the various levels of the hierarchy.
In practice, several control options are often used in combination. This is particularly
true in abrasive blasting, with personal protective equipment usually used in
conjunction with other control measures.
Abrasive blasting
Abrasive blasting is used in a wide range of industries for many different purposes
including the removal of rust, scale, paint, graffiti, mildew, and various forms of
surface preparation. Abrasive material is propelled on to the surface at high speed,
using air pressure, water pressure, or centrifugal force.
1
The most common method of abrasive blasting uses compressed air to propel abrasive
material from a blast pot, through a blasting hose to a nozzle that is manually
controlled by the operator. Blasting is done in commercially built blast rooms,
blasting yards, or inside temporary enclosures erected on-site.
Other methods use wet abrasive blasting or water jetting with or without an abrasive.
Automated abrasive blasting machines such as centrifugal wheel systems and
tumblers are also occasionally used.
Protective coating
The application of a protective coating goes hand in hand with abrasive blasting, and
is done mainly to protect metal surfaces from corrosion, or to improve the appearance
of a product. There are many types of finishing methods, usually dependent upon the
type of paint selected and the manufacturer's recommendations for application.
There are a number of factors that affect the degree of risk associated with dust
produced in abrasive blasting work. These factors include:
• the abrasive medium used
• the surface being treated
• the concentration of airborne dust in the breathing zone of the worker
• the size of the dust particles generated
• whether dust particles are inspirable or respirable
• whether blasting is carried out in a confined space
• how easily the abrasive material breaks down
• the duration of exposure, and
• the individual responses to exposure - some individuals may be more affected
than others due to differences in their biology or lifestyle.
2
Inspirable dust is any dust which can be inhaled.
Respirable dust is only that dust which is small enough to be inhaled into the lungs.
This sort of dust can result in permanent scarring of the lung tissue. Abrasive blasting
results in high concentrations of respirable dust.
Toxic dusts
Many types of abrasive materials produce toxic dust and you must assess the degree
of risk associated with each material.
Silica dust
Silica dust can be generated by:
• using abrasive materials that contain silica, e.g. river sand, beach sand or quartz
rock, and
• abrasive blasting surfaces that contain silica – e.g. concrete, sandstone masonry,
calcium silicate bricks.
Exposure to silica dust can result in silicosis, a stiffening and scarring of the lungs. It
results in shortness of breath, coughing, and chest pain. The effects are irreversible
and lead to a degeneration in the person's health, invariably resulting in death.
Silicosis can result from either a single exposure (acute silicosis) or it can develop
over a number of years. Inhalation of silica dust may also lead to the development of
some forms of cancer.
Lead dust
Lead dust can be generated by:
• using an abrasive material that contains lead
• the abrasive blasting of surfaces containing lead, and
• abrasive blasting surfaces covered by paint that contains lead.
Lead is a hazardous substance that is easily taken into the body by:
• inhaling dust or fumes
• eating contaminated food, and
• smoking with contaminated fingers.
The rate of absorption depends on the size of the particles. Abrasive blasting produces
particles small enough to be absorbed rapidly, leading to more acute and severe toxic
effects.
The major risk associated with lead is lead poisoning (plumbism). This effects the
blood system and can cause anaemia. Other symptoms include abdominal pain,
convulsions, hallucinations, coma, weakness, tremors, and reduced fertility.
3
Managing risks from dusts
The first thing you should do when managing the risk from dusts at your workplace, is
to conduct a risk management process. This means:
• identify sources of dusts
• assess dusts levels
• evaluate the risk to exposed workers and other persons, and
• decide what control measures, health surveillance and monitoring is required.
Air monitoring is a relatively simple and inexpensive method of assessing the risks
from dust. You should conduct air monitoring when you start a job to ensure that you
are aware of the risks of that particular situation. This information is important for
helping you to decide which control measures are most appropriate for that particular
job.
Air monitoring should also be conducted at regular intervals over the job to ensure the
control measures you have chosen are still effective. More information on how to
conduct air monitoring is covered under review of control measures later in this
section.
Control measures
Some control measures that you can introduce to reduce the exposure of workers to
risk from dust include:
• substituting a less hazardous abrasive material
• substituting a less hazardous surface preparation method
• isolation / engineering controls
• administrative controls, and
• personal protective equipment.
Any abrasive material you choose to use will fall into one of 3 categories that have
specific requirements under workplace health and safety legislation. These are:
• a ‘hazardous substance’ as defined under Part 16 of the Workplace Health and
Safety Regulation 2008
• a ’lead hazardous substance’ as defined under Part 17 of the Workplace Health
and Safety Regulation 2008, and
• or if it isn't either of these, it will still be a ’substance’ under section 34 of the
Workplace Health and Safety Act 1995.
Depending on the category under which the abrasive medium falls, there are certain
things that the manufacturer / importer, your supplier and you MUST do in relation to
information about the abrasive material.
4
• prepare the Material Safety Data Sheet (MSDS) before first manufacturing or
importing the substance (or if this is not practicable, as soon as practicable after
first manufacturing or importing the substance)
• amend the MSDS when necessary to keep it current
• review the MSDS every five years, and
• provide a copy of the MSDS when first supplying the product or on request.
Suppliers must:
• provide you with a copy of the current MSDS when first supplying the substance
or on request, and
• label containers appropriately.
You will need to consult Part 16 – Hazardous Substances, of the Workplace Health
and Safety Regulation 2008 for more detail on the legislative requirements for
hazardous substances.
You will need to consult Part 17 – Lead, of the Workplace Health and Safety
Regulation 2008 for more detail on the legislative requirements for lead hazardous
substances.
3. For a ‘substance’
If the abrasive material is not a ‘hazardous substance’ or a ‘lead hazardous substance’,
it will still be a ‘substance’ under section 34 and 34A of the Workplace Health and
Safety Act 1995. These sections apply to manufacturers, importers and suppliers.
5
Substituting a less hazardous abrasive material
Table 1 lists abrasive blasting materials which you should avoid because their use is
likely to result in exposures which exceed national exposure limits. The table also
gives some examples of blasting media which will in most cases be acceptable for
use. This table is not exhaustive, and you should check with your supplier about the
content of any abrasive material that you are planning to use.
Blast media which should not be used Blast media which could be substituted
In dry abrasive blasting: The following materials will not usually result in
• Materials containing more than 2% exposures greater than national exposure limits when
crystalline silicon dioxide using a blast helmet with supplied air.
• Recycled materials which have not been • ilmenite
treated to remove respirable dust • aluminium oxide
• Materials likely to harm the upper • garnet
respiratory tract • other rocks and mineral sands containing less
In general abrasive blasting: than 2% silica
• Materials containing a radioactive • metal shot
substance as stated in the ‘Radiation • steel grit
Safety (Radiation Safety Standards) • crushed glass
Notice 1999 or the Radiation Safety • sodium bicarbonate
Regulation 1999’ • some metal slags (check content analysis before
• Materials containing more than: purchase)
- 0.1% antimony
- 0.1% arsenic Note 1: There are environmental requirements in
- 0.1% beryllium relation to abrasive blasting materials. If in doubt,
- 0.1% cadmium seek advice from your local council.
- 0.5% chromium
- 0.5% cobalt Note 2: There are also health requirements in
- 0.1% lead relation to the use of radioactive substances. For
- 0.5% nickel more information, contact Radiation Health Unit
• River sand Queensland Health.
• Beached sand
• other white sand Website:
• quartz rock dust www.health.qld.gov.au/phs/ehu/radiation.htm
• Diatomaceous earth (pool filter material)
• Some metal slags (check the content
analysis before purchase)
It is important to select an abrasive blasting media with qualities that will generate
minimum dust levels. Metallic and garnet abrasives have proven characteristics that
resist shattering on impact, which is the major cause of the dust produced during
blasting. Environmentally clean and recyclable abrasives such as garnet, chilled iron
grit or cast steel grit should be used where feasible.
These include:
6
to minimise flash rusting. For effective dust suppression the water should be added
before the abrasive leaves the nozzle. Inhibitors must not contain chromate, nitrate or
nitrite.
It does not create a profile on its own, but if the original surface was blast cleaned, the
old paint can be removed to expose the original profile.
Water jetting (high and ultra high pressure) with abrasive injection
The ability of water jetting to remove tight paint, rust and mill scale can be much
improved if an abrasive is injected into the water stream at the nozzle. The quality of
preparation can be improved and profile is imparted to the surface.
The disadvantage of any wet blasting process is that the wet abrasive and paint
residue may be difficult to clean from the surface and recover. If inhibitors are used to
minimise flash rusting, take care, some may be toxic or interfere with subsequent
coatings. Inhibitors containing chromate, nitrate or nitrite must not be used in wet
abrasive blasting.
Abrasive is propelled outwards from the spinning wheel by centrifugal force, striking
the surface to be cleaned and removing rust, paint and mill scale.
Abrasives used include steel shot, steel grit, cut wire and chilled iron grit. They are
recyclable and are continuously recovered, cleaned and returned for re-use.
Centrifugal wheel blasting is normally used where the work is of a consistent size, e.g.
pipes, valves, or steel sections. Normally, the rotating wheel assembly remains fixed
and the surface to be cleaned is passed through the enclosure, but centrifugal wheel
blasting can also be used on-site, e.g. on a tank, with special adaptors where the wheel
assembly moves across a stationary work surface.
Because all blasting takes place within an enclosure, there is no contact with airborne
dust or high velocity particles. This minimises the risk to operators.
Vacuum blasting
7
Vacuum blast cleaning uses a standard abrasive blast nozzle, operating inside a shroud
which is in close contact with the work surface, forming a tight seal. As the abrasive
impinges on the surface, a vacuum is applied inside the shroud, removing the debris.
The abrasive material, which typically can be steel shot, steel grit, chilled iron grit,
aluminium oxide or garnet, is separated, and returned for re-use.
A variety of heads may be used to achieve a tight seal for inside corners, outside
corners, and flat surfaces. In practice, however, operators tend not to change heads,
lifting the assembly from the surface to clean odd shapes and inaccessible surfaces.
While this may save time, it breaks the seal, defeating the purpose of the vacuum, and
creating health and environmental hazards.
When used properly, vacuum blast cleaning can clean effectively with minimal dust
generation.
These include:
• sodium bicarbonate blasting
• blast cleaning with reusable sponge abrasives, and
• carbon dioxide (dry ice) blast cleaning.
You should consider cleaning techniques that do not involve blasting, particularly for
smaller jobs.
These include:
• stripping with non-toxic chemical strippers
• heat guns
• power tools with dust collection systems
• manual sanding, and
• scraping.
These techniques may produce little or no dust and present a relatively low level of
risk in regard to other hazards (e.g. chemicals, fumes).
Isolation/engineering controls
Blasting cabinets
These are suitable for blasting small objects. The cabinet is fully sealed and the
operator manipulates the work piece and the blasting hose from outside, viewing the
object through a sealed window.
When using a properly designed and maintained cabinet, there is no need to wear a
respiratory device. However, a low toxicity abrasive should still be used as poor
maintenance may expose workers to dust. Further information on blast cabinets can be
found in the section on abrasive blasting plant and equipment.
8
Blasting chambers
Blasting chambers (also known as blast rooms) should be used for cleaning
transportable objects that are too large to be treated inside a blasting cabinet.
Objects can be transported to the blasting position by a fork-lift truck or a flat-bed rail
car. Blasting is done manually by an operator (or operators) working inside the
chamber.
Operators working inside blasting chambers must wear a hood or helmet type airline
respirator complying with AS/NZS 1716 Respiratory protective devices fitted with an
inner bib and a shoulder cape, jacket or protective suit.
Temporary enclosures
Temporary enclosures should be used when the object or structure is unable to be
transported. Any object measuring greater than 2.5m X 2.5m X 3.0m can be
considered large. Temporary enclosures are also used for fixed structures, e.g. bridges
or water tanks.
9
Where monitoring indicates that persons in surrounding areas may be exposed to dust
levels in excess of the national exposure standards, they should be excluded from the
area, where possible, by warning signs and barricading, or provided with personal
protective equipment (PPE).
Exclusion zones
Although open air blasting activities are not recommended, there may sometimes be
no alternative. In these circumstances, exclusion zones (also known as buffer zones)
may be used to protect workers and other people in the vicinity from exposure to
hazardous dust levels that are above national exposure limits.
Exclusion zones may also be used in conjunction with blasting chambers and
temporary enclosures.
The extent of the zone should be determined after assessing the risk to all unprotected
people. The prevailing conditions at the time of blasting should be taken into account,
for example, the exclusion zone may need to be extended down-wind.
Where an exclusion zone interferes with other activities at a workplace, other workers
should only work within the exclusion zone after being provided with respiratory
protection equipment as outlined in AS/NZS 1716 Respiratory protective devices.
Recycling
The recycling of blast media involves three stages - collection, cleaning and reuse of
spent material that contains some useable abrasive grains. During abrasive blasting,
the spent material has endured high velocity impact with the surface being cleaned,
producing shattered abrasive and dust, combined with particles of the material being
removed. The recycling process separates these and allows the recovered abrasive to
be reused efficiently and safely without increase in dust levels. Abrasive that has
become wet cannot be recycled as dust separation is not possible.
10
1. Collection
Collection of the spent media from the blasting site is best done with a method that
least disturbs the spent material. Vacuum recovery equipment offers the best
protection for the operators. Using methods that generate dust (e.g. sweeping or
compressed air blowdown) should be avoided.
2. Cleaning
The following contaminants should be extracted before the blast media is reused:
• oversized trash - all particles (e.g. rust, paint flakes and other foreign matter) that
are of sufficient size to clog the blast machine metering valve or nozzle
• toxic dust - any toxic contaminants that have been introduced or released into the
media e.g. lead from lead paint material
• nuisance dust - fine shattered abrasive grains, and
• respirable dust - powdered material that is respirable and will penetrate the lower
respiratory system.
3. Reuse
The collected material will contain various contaminants (see above) as well as the
reusable abrasive grains. The contaminants must be separated from the media by
passing though engineered equipment including airwashes, cyclones and screens as
required, before it can be returned to the blast machine for reuse.
Administrative controls
Housekeeping
Drift from abrasive blasting can be harmful not only to workers but also to members
of the public. Good housekeeping can minimise the risk of exposure.
While other control measures should prevent dust escaping from the area where
blasting is being done, any dust or residue that does make its way into the workplace
should be cleaned as soon as practical after blasting has finished. Where practical,
accumulated dust should be removed using wet cleaning methods, or High Efficiency
Particulate Air (HEPA) filter vacuum methods (see AS 3544 Industrial vacuum
cleaners for particulates hazardous to health).
Because workers undertaking cleaning work may be exposed to dust levels in excess
of the exposure standard, they should wear personal protective equipment.
Training
11
Proper training in selection of appropriate equipment and safe working methods can
reduce risk. Induction and ongoing training must be given to any worker exposed to
risks from dust.
Amenities
Many types of dust (particularly lead dust), may enter the body by ingestion, so risk
will be minimised by taking care with personal hygiene.
Respiratory protection
Workers engaged in abrasive blasting must be supplied with and must wear an airline
positive pressure hood or helmet complying with AS/NZS 1716 Respiratory protective
devices, fitted with an inner bib and a shoulder cape, jacket or protective suit. To keep
out dust and abrasive grit, protective suits or clothing should also have leather or
elastic straps at the wrist and ankles, and overlapping flaps at all suit closures.
Respirators will only provide a satisfactory level of protection when they are selected,
fitted, used and maintained according to the manufacturer's written instructions and
other regulatory and advisory guidelines. PPE should be individually fitted and if it is
to be shared, it should be disinfected and refitted before use.
12
Review of control measures
After selecting and implementing the control options, the effectiveness of the controls
used for managing exposure to toxic dusts should be checked by:
• atmospheric testing, and
• health surveillance.
Atmospheric testing
Although it is not practical to measure exposure in the breathing zone of an operator
wearing respiratory protection, it is relatively simple and inexpensive to test in the
atmosphere surrounding the abrasive blasting site, to ensure that others working close
to the abrasive blasting area are not adversely exposed to dust generated by the
process.
Atmospheric testing can be used to check the effectiveness of the control measures
being used to prevent or minimise exposure to dust and may also be used at the
commencement of the job to select appropriate control measures. Atmospheric testing
is particularly important in measuring exposure when a toxic material is introduced
into the blasting process.
The sample should be handled carefully after collection so the test results will be
accurate. Ideally, the sample should be hand-delivered to the laboratory.
2. Laboratory analysis
If you employ an occupational hygienist, they will probably arrange for testing of the
sample as part of their service. If you are conducting the testing yourself, you will
need to select a competent laboratory. You should consider the following when
choosing a laboratory.
• Is the laboratory accredited with the National Association of Testing Authorities?
• Is the laboratory quality assured?
• Does the laboratory report the results in a format that is understandable and
provides all of the information required to perform the exposure calculations?
• Does the laboratory staff appear knowledgeable about your workplace operations,
including other substances you use that could interfere with monitoring results?
13
If you are doing the calculations and interpretations yourself, you will need to consult
the Adopted National Exposure Standards for Atmospheric Contaminants in the
Occupational Environment [NOHSC:1003(1995)]. It may also be a useful to follow
an example to help you make your calculations. Don't forget to take into account
whether the sample is collected as a total dust sample or as a respirable dust sample.
4. Take action
When monitoring identifies that the control measures are not adequate to prevent
people being exposed to levels of dust above the exposure standard, abrasive blasting
should cease.
Health surveillance
In certain situations, a relevant person must supply and pay for health surveillance
required under the Workplace Health and Safety Regulation 2008 Part 16 – Hazardous
Substances and Part 17 - Lead. This health surveillance must be done by or under the
direction of a designated doctor. Health surveillance, which includes biological
monitoring, can assist in minimising the risk to health by:
• confirming that the absorbed dose of a substance is below the acceptable level, or
• providing biological results (such as an elevated blood lead level) requiring
cessation of exposure.
The Workplace Health and Safety Regulation 2008 identifies specific substances as
requiring health surveillance. These include cadmium, crystalline silica and lead,
commonly used in abrasive blasting. The primary technique for monitoring the
working environment is usually to assess the concentrations of airborne dust and then
to compare this with the safe exposure standard.
However, if dust may have been ingested or inhaled, biological monitoring techniques
should also be used. For example, in a lead risk job, biological monitoring would
measure the blood lead level of individual workers. Biological monitoring has the
specific advantage that it can take account of issues that dictate an individual's
response to particular hazardous substances. Some of these factors include size,
fitness, personal hygiene, work practices, smoking and nutritional status.
Noise
14
Noise is unwanted sound that may damage a person's hearing. The amount of damage
caused by noise depends on the total amount received over time. The degree of risk is
affected by the intensity (loudness) and the frequency (pitch) of the noise, as well as
the duration and pattern of exposure and the individual's susceptibility to hearing
impairment.
Employers must prevent risks to their workers from exposure to excessive noise.
These are above the prescribed level and control measures are necessary!
Maximum noise levels up to 137 dB(A) and peak levels up to 145 dB(A) have been
measured during blasting activities at the operator position when the abrasive runs
out.
Operators of small abrasive blasting cabinets are particularly at risk. They may not
perceive the noise to be damaging because of the relatively short periods of use.
However, average noise levels at the operator's ears have been measured between 90 -
101 dB(A). This means that at 101 dB(A), for instance, an exposure of unprotected
ears of only 12 minutes is allowed in any 8 hour shift so as not to exceed the exposure
limit of 85 dB(A). In addition, other work activities must not contribute to further
noise exposure.
Unprotected workers and others close to the blasting process may also be exposed to
excessive noise.
Health effects
Noise exposure exceeding LAeq, 8h of 85 dB(A) presents a high risk to a person's
health and safety at the workplace. A person working with or near noisy equipment or
15
processes may be affected by high direct or ambient noise and may develop noise-
induced hearing loss in situations where no control measures have been put in place.
Regular exposure to high noise levels causes, in time, hearing loss through the
destruction of the delicate hair cells in the inner ear's cochlea. This is often
accompanied by tinnitus, or ringing in the ears. Damage to your ears can be compared
to damage to your skin from sun exposure. In both cases, the damage is cumulative
depending on the degree and length of exposure.
Other effects from exposure to noise include increased heart rate and blood pressure,
headache, irritability, nausea, insomnia, reduced concentration and depression.
Vibration effects from exposure to excessive noise can also affect a person's sight, for
example, loss of clarity, colour perception and night vision.
In addition to the risk of temporary or permanent hearing loss, high noise levels may
cause difficulties in verbal communication and in hearing warning signals or
emergency commands.
Control measures
Isolation
Methods which can be used to isolate workers and other persons from noise include:
Exclusion zones
Areas where noise levels are in excess of the exposure standard should be identified
and entry restricted to persons with adequate hearing protection. Exclusion zones
should be identified by appropriate signs in accordance with AS 1319 Safety signs for
the occupational environment which warn workers and others that high noise levels
exist and that hearing protection is to be worn.
16
In the open air, mobile enclosures, lined internally with sound absorbent material
could be used at locations where noisy work has to be carried out and other people
may be affected. Such enclosures could reduce operator exposure by about 5 to 20
dB(A) depending on construction. They could also reduce the exposures of people
nearby.
Blast chambers
Shifting the site of the blasting away from other workers
Engineering controls
Administrative controls
Some administrative control measures which can be used to reduce excessive noise
include:
• undertaking abrasive blasting out of normal working hours
• stopping other work and clearing people from a site while blasting is taking place
• ‘buy quiet’ policies, whereby quieter machines and equipment are purchased,
where possible, when replacement is necessary
• adequate training
• reducing the amount of pressure needed to abrade the substrate
• limiting the amount of air required in air-fed helmets to a minimum
• maintenance of plant and equipment, including personal protective equipment
• job rotation, and
• regular noise exposure surveys.
Personal hearing protectors should have passed the physical tests specified in AS 1270
Acoustics – Hearing protectors.
When selecting suitable hearing protectors, you should consider the following:
• type of working environment
• comfort, weight and clamping force
• combination with other items of personal protective equipment
17
• safety of the wearer
• opportunity for personal choice, and
• hygiene aspects.
Monitoring
Monitoring should be undertaken to ensure workers are not exposed to levels in
excess of the exposure standard of 85 dB(A).
All monitoring should be conducted by a competent person, i.e. a person who, through
training, education and experience in acoustics and the principles of noise control, has
the necessary expertise to conduct sound level measurements, and to interpret them.
Where it is identified that unprotected persons are exposed to noise levels in excess of
the exposure standard, abrasive blasting should cease. Work should not be
recommenced until different work methods or equipment modifications have been
developed to reduce workers' exposure to below 85 dB(A), or where this is not
practical workers have been provided with personal protective equipment that will
reduce their exposure to below 85 dB(A).
Particulate matter
Particulate matter includes small particles of the object being blasted, or of the
abrasive material. Particulate matter can also include water. Workers carrying out
abrasive blasting can be struck by particulate matter.
Health effects
Serious injuries or death can result from being struck by particulate matter discharged
under high pressure. Common injuries include:
• eye damage
• severe lacerations burns, and
• skin penetration.
Control measures
Isolation
Abrasive blasting activities should be isolated from other workplace activities to
reduce the possibility of workers being struck by particulate matter. This can be done
by using blasting chambers, blasting cabinets, temporary enclosures and exclusion
zones.
Abrasive blasting plant can also incorporate guards to reduce the possibility of
particulate matter striking the operator.
18
Engineering controls
The risk of sustaining a serious injury from particulate matter is increased when:
• blasting in a confined space
• working in an elevated position, and
• the operator is out of the line of sight of a pot tender or there is no dedicated pot
tender who can provide assistance if required.
Using a blast machine without a fast acting self-actuating cut-off device under the
direct control of the operator is a dangerous practice that may result in serious injury
or death.
The device most commonly used is called a remote control or ’dead man control’
which is usually attached to the nozzle. When the nozzle is dropped, the air supply
shuts off and prevents the whipping hose injuring the worker and the abrasive material
firing at the operator or other people nearby. For more information on ’dead man
controls’ refer to the following section on abrasive blasting plant and equipment.
More information on blast hoses, hose whips and couplings can be found in the
following section on abrasive blasting plant and equipment.
Administrative controls
• When blasting, the nozzle should only be pointed at the work. A blast nozzle
should never be pointed at any person.
• Blast hoses should be uncoiled when in use.
• Blasting personnel should be adequately trained in the use and maintenance of
equipment including personal protective equipment.
19
Workers exposed to high velocity particulate matter should wear suitable personal
protective equipment to protect against ricocheting abrasive. This may include:
• eye protection
• protective gloves (canvas or leather)
• protective footwear
• respiratory equipment, and
• protective clothing (overalls, long trousers, blast suits, aprons).
When purchasing plant and equipment you should also ensure that safety features
have been incorporated into the design.
Abrasive blasting plant and equipment should only be operated by trained people.
Nozzle
• Where dry blasting is being conducted, an efficient means for the discharge of
static electrical charge from the blast nozzle and the object being blasted must be
provided.
• Abrasive blasting equipment must be fitted with a self-actuating cut-off device
(deadman control) under the direct control of the nozzle operator which can
quickly stop the flow of abrasive material to the nozzle.
• The nozzle lining and threads should be checked for wear and damage. Use
nozzle washers, and replace them when they show signs of wear.
20
• Deadman controls must be located near the blast nozzle so that they can be
readily accessed by the nozzle operator.
• Deadman controls can be either pneumatic or electric. Pneumatic controls are
only suitable for distances up to 40 metres because the response time increases
with distance.
• Electric controls are recommended for distances over 40 metres as they respond
almost instantly and response times do not increase with distance.
• Deadman controls are subjected to rough treatment because they are located at the
nozzle. This results in damage and rapid wear. Deadman controls (especially the
lever and lever lock) should be inspected and tested several times each working
day. The moving parts should be cleaned regularly to prevent jamming and the
rubber buttons and seals should be replaced frequently to prevent air escaping and
abrasive from entering.
• Never modify, remove or substitute parts. Follow instruction manual
recommendations for inspection, maintenance and cleaning for each component.
• Never tape down or prevent free movement of the control handle. This defeats the
safety purpose of the remote control system and may cause serious injury if an
uncontrolled nozzle is dropped.
• Inspect and clean control hose line fittings before connecting them as dust and dirt
will clog air passageways throughout the system and may damage control valve
cylinder walls.
21
• High pressure hoses should be firmly secured at a distance of no more than 3
meters from the operator.
• All bypass valves should be equipped with pressure safety relief valves.
• Consider fitting a funnel near the end of the nozzle to minimise the risk of the
water stream coming into contact with the operator.
• Wet blasting equipment must have a water flow rate capable of preventing dust
from forming from the blasting operation.
• Inhibitors containing chromate, nitrate and nitrite must not be used.
Blasting cabinets
• Suitable for small objects.
• Cabinets should be constructed from an abrasive resistant material.
• They should have a sealed window so that the operator can view the object being
cleaned. They should be fitted with a dust extraction / collection system which
has a sufficient air change rate to increase visibility and keep dust exposures less
than national exposure limits when the cabinet is opened.
• In conjunction with the air change rate, a suitable clearing time should also be
allowed before opening the cabinet.
• Cabinets should have a dust tight light fixture.
• Doors should be interlocked to eliminate the possibility of the machine being
operated while the door is open.
• Cabinets should be regularly inspected and maintained especially in relation to
gloves, gasket, door seals and structural integrity.
Blasting chambers
• Blasting chambers must be constructed from an abrasive resistant, non-
combustible material, designed to prevent the escape of dust and minimise
internal projections on which dust may settle.
• They must have windows or inspection ports which are fixed in a metal sash and
constructed of toughened safety glass, laminated safety glass or safety wired glass
complying with AS/NZS 2208 Safety glazing materials in buildings. Windows or
inspection ports must be maintained so as to allow effective visibility.
• They must have an emergency exit located at the further most position from the
main entrance.
• They must be fitted with a mechanical dust extractor/ collection system which
provides an air velocity which ensures: good visibility, prevents dust settling and
accumulating in the chamber, and reduces dust concentrations so PPE can provide
adequate protection. This system should also have ducting fitted with inspection
and cleaning ports where dust can accumulate.
• They must have an apparatus to separate the abrasive from the dust and to prevent
the abrasive from being reintroduced into the blasting apparatus until it has been
separated. They must have an illumination of at least 200 lux measured on a
horizontal plane 1 metre above the floor of the blasting chamber or enclosure.
• They must have an electrical supply which complies with the Australian and New
Zealand Standard series AS/NZS 2381 Electrical equipment for explosive gas
atmospheres and AS/NZS 3000 Electrical installations (known as the Australian
/New Zealand Wiring Rules).
• They should be equipped with easily accessible operating controls.
22
• Blasting chambers must be maintained so as to prevent dust from escaping. Doors
must be kept closed during blasting.
• Doors should be interlocked to eliminate the possibility of the machinery being
operated while the door is open.
• Only abrasive blasting work, work incidental to abrasive blasting, or maintenance
or repairs to the blast room or its equipment are to be conducted in the blasting
room. Ventilation systems must be operated continuously while blasting is being
done, for at least 5 minutes after blasting has finished and during blowdown
subsequent to the blasting process.
• Manufacturers of blasting chambers should conduct testing to ascertain the level
of ventilation required under normal operating conditions. This should assist you
to select a chamber appropriate to your needs.
• Monitoring should be conducted on-site when the chamber is installed to ensure
that its operating performance under normal operating conditions is sufficient to
prevent exposure above national exposure limits.
• Monitoring should also be conducted where there has been a change in blasting
procedures (e.g. use of a different abrasive material) after damage or repairs and
on a regular basis (e.g. every 12 months). This monitoring can be conducted by an
occupational hygiene consultant.
Temporary enclosures
• Where possible the object should be fully enclosed.
• Where full enclosure is not possible, screening should extend 2 metres above the
structure and blasting should be conducted downwards. Stringent monitoring
should be used to ensure that people outside the structure are not exposed to dust
levels greater than national exposure standards. Where monitoring shows levels
are high, exclusion zones and PPE should be used.
• Containment screens should be made of puncture and tear resistant materials such
as woven polypropylene fabric or rubber for high abrasion areas inside the
enclosure. Selection should also consider fire retardancy, burst strength, and UV
resistance.
• Shade cloth will not prevent the escape of fine dust, and should not be used for
temporary enclosures if the work generates silica, lead, or other toxic dusts.
• Temporary enclosures should be fitted with a dust extraction/ collection system.
• Where monitoring indicates that persons in surrounding areas may be exposed to
dust levels in excess of the national exposure standards, they should be excluded
from the area, where possible, by warning signs and barricading, and/ or provided
with personal protective equipment (PPE).
23
• All users of respirators must be adequately trained in their safe use and
maintenance.
• Respiratory equipment must be fitted for each person individually and if it is to be
used by another operator, it must be disinfected and refitted before use.
• The tightness of all connections and the condition of the face piece, headbands
and valves should be checked before each use.
• Never drop a helmet or leave it in areas where it might be exposed to dust and
dirt.
• After removing the helmet, vacuum dust from the helmet and cape. Place the
cleaned helmet in a plastic bag and store it in a dust-free area.
• The helmet cape requires periodic cleaning, frequent inspection and immediate
replacement if damaged. NEVER use tape to repair holes or worn areas. Replace
the inner collar when the elastic becomes stretched out of shape.
• At least once a week, wash the inside of the helmet with warm water and mild
detergent. Detach the cape and inner collar from the helmet and wash in warm
water and mild detergent.
• Replace window frames and window seals immediately if there is any leakage.
The outer lens of the helmet should be replaced when it starts to frost over.
• In most cases, additional hearing protection will be required.
24
• Skin and foot protection must be worn by people engaged in abrasive blasting
activities.
• Protective eye equipment should meet AS/NZS 1336 Recommended practices for
occupational eye protection and AS/NZS 1337 Eye protectors for industrial
applications.
• Protective gloves should meet the Australian and New Zealand standard series
AS/NZS 2161 Occupational protective gloves.
• Protective footwear should meet the Australian and New Zealand standard series
AS/NZS 2210 Occupational protective footwear.
• Protective clothing such as overalls, long trousers or blast suits should also be
worn.
Other hazards are similar to those encountered in abrasive blasting, and may include:
• manual handling slips, trips and falls
• working in confined spaces
• working on elevated work platforms, and
• heat.
Each application method presents different levels of risk. For example, when applying
coatings by brush or roller, the risks are usually limited to the inhalation of toxic
vapours given off by the coating or from splashes of paint which may land on the skin
or in the eyes.
When applying coatings by spray painting methods, a higher degree of risk exists for
applicators as these methods emit more paint fumes, mists and aerosols into the
working environment.
The priority health and safety issues for protective coating applicators include:
• occupational lung disease (including occupational asthma)
• occupational cancer
25
• painters' syndrome (resulting from long term exposure to organic solvents)
• reproductive hazards
• occupational skin diseases (including allergic contact dermatitis)
• consequences of paint injection into the skin, and
• consequences of fire and explosion.
Control measures
Elimination / substitution
There are three ways of looking at substitution for controlling the risks from
protective coatings and solvents:
1. Substitute a safer alternative, for example, use water based paints instead of
solvent based paints.
2. Substitute another method of application, for example, brush or roller application
for spray painting.
3. Substitute the spray painting process, e.g., use airless instead of conventional air
spraying to reduce the amount of overspray and toxic substances in the air.
Isolation
A practical way of isolating unprotected workers and other people from exposure to
toxic substances is by exclusion or hazard zones: an area created around a work
activity where access is denied to people not wearing the required protective
equipment. The size of the exclusion zone should be determined as part of the risk
assessment process.
Engineering controls
Where this is not possible because of the size of the object, or where the work consists
of minor spotting or touching up operations, or where the work is not carried out in
the open air, local exhaust systems which draw the fumes away from the source
should be used.
These exhaust systems should be carefully placed so that the drift of contaminated air
being drawn into the extractor does not go through the breathing zone of the
applicator or other workers. Fresh air should also be directed into the work area to
replace the contaminated air being removed.
NOTE: Before spray painting in open air, consult your local government authority for
environmental protection requirements.
Administrative controls
26
the specific needs of the workplace and meet the engineering specifications of the
application method.
Each protective coating and solvent should have its own material safety data sheet
(MSDS) which should be referred to as part of the risk assessment. The MSDS should
detail hazards of the coating or solvent and minimum requirements for its safe use.
This information will assist the identification of required control measures.
Where the protective coating contains a hazardous substance you should refer to Part
16 – Hazardous Substances of the Workplace Health and Safety Regulation 2008 for
specific requirements. In addition, you should also refer to the Hazardous Substances
Code of Practice.
Where the protective coating contains a hazardous substance and you apply it in a
spray painting process, you should refer to Division 5 - Spray painting with hazardous
substances of Part 16 - Hazardous substances for specific requirements.
27
at all times in combination with other controls outlined above. PPE must protect
workers against all routes of exposure (skin, eye and inhalation).
Skin protection
All exposed skin should be covered. Many products are available to achieve this
including overalls, long sleeve shirts and trousers. In addition, barrier cream can be
used for short term protection.
Chemically resistant gloves, safety boots and aprons are made from a range of
synthetic or natural materials with varying permeability to solvents and other
hazardous substances in paints. The MSDS will provide information on the
appropriate type of PPE required.
Respiratory protection
Where monitoring indicates that toxic vapours in the air are at an unacceptable level
and other methods of control are unsuitable, a respirator will be required. The MSDS
will provide information on the appropriate type.
The Plant Code of Practice contains general requirements for the installation,
maintenance and use of all types of workplace plant. You should refer to it when
assessing risks.
Of particular concern is the risk of paint injection into the skin or any part of the body
when using high pressure airless spraying equipment. Paint can be injected into the
bloodstream, resulting in a lack of blood supply to the area, and ultimately to
amputation of fingers or hands.
To avoid the risk of injury from paint injection the following points should be noted.
• The safety catch should always be switched on to avoid the danger of the spray
gun trigger being accidentally pulled during stoppages in work or when the spray
tip is being changed.
28
• Operators should never point the spray gun at themselves or any other person.
• Fingers and hands should be kept well away from the spray jet.
NOTE: If the skin has been penetrated, medical advice should be sought
immediately.
Because of the great number of ways in which these particular risks may arise, it is
only possible to give general advice on control options for each risk group. You
should conduct individual risk assessments for your specific circumstances. See
section ‘Risk management process’ for how to conduct a risk assessment.
Manual tasks
29
Many abrasive blasting and protective coating processes involve manual tasks.
Manual tasks are those workplace activities requiring the use of force exerted by a
person to lift, lower, push, pull, carry or otherwise move or restrain any object.
Manual tasks can range from transfer of heavy loads to tasks involving repetitive or
forceful movement and maintenance of constrained or awkward postures.
Some examples of manual tasks often encountered in abrasive blasting and protective
coating processes are:
• lifting bags of abrasive or tins of protective coating
• lifting, pushing or pulling blast pots
• lifting or moving work pieces to be blasted or coated
• restraining a blast hose, and
• repetitive movements associated with abrasive blasting or protective coating
activities.
The risk associated with manual tasks can be compounded by factors including
workplace environment and layout, working posture and position, types of loads and
equipment used, length of time spent on manual handling tasks, the frequency of
manual handling tasks, distance loads are to be moved and personal characteristics of
the worker.
Health effects
Manual task injuries in the abrasive blasting and protective coating industry are not
confined to the back but also include injury to the neck and upper limbs (shoulders,
forearms, wrists and hands). Injuries may occur as a result of a single event, however
they are more often the result of cumulative strain due to awkward postures,
movements, weights and forces on the body.
Control measures
Elimination / substitution
In many instances it will not be possible to eliminate the need for manual tasks.
However where practical, elimination may be achieved by only purchasing plant and
equipment which has been designed to eliminate the need for manual tasks. In some
cases it may be possible to use bulk storage hoppers from which individual blasting
pots can be refilled as required.
Where it is not possible to totally eliminate manual tasks, substituting smaller bags of
abrasives or purchasing equipment such as blast pots with wheels and handles will
reduce the risks.
30
Engineering controls
Administrative controls
Although the weight of the load is not the sole indicator of the risk of a manual task
injury and there is no legislation stating maximum weight, administrative controls
such as the introduction of in-house rules in regard to maximum weights to be lifted,
can reduce the risk of injury. Guidance may be sought from the Manual Tasks Code of
Practice and the ‘National Code of Practice for Manual Handling
[NOHSC:2005(1990)]’.
The following flag point weights should be considered when introducing these rules.
• Lifting loads above the range of 16-20 kg may increase the risk of back injury.
Loads should be kept below or within this range.
• Mechanical assistance or team lifting arrangements should be implemented for
loads 16-55 kg.
• Loads over 55 kg should not be lifted, lowered or carried by a worker without
mechanical assistance unless team lifting arrangements are used.
• Loads above 4.5 kg ideally should not be lifted during seated work.
• Workers under 18 years of age should generally avoid lifting, lowering or
carrying objects more than 16 kg.
Here are some helpful hints when developing in-house rules regarding manual
handling tasks.
Plan the lift and determine the best technique for the situation.
• Adopt a comfortable posture and try to keep the back straight.
• Lift gradually, smoothly and rhythmically (avoid jerking).
• Get a secure grip on the object.
• Avoid unnecessary bending by placing objects at a level between mid-thigh and
shoulder height.
• Avoid twisting your back.
• Avoid reaching out.
• Handle heavy or awkward objects as close as possible to the body.
• Where possible, break up tasks to avoid repetitive bending - vary heavy handling
tasks with lighter work.
• Alternate repetitive and non-repetitive work (e.g. job rotation).
• Team lifting should be adopted when a load is either too heavy or awkward for a
single person to lift or mechanical devices are not available.
31
You should provide education and training on the correct methods of carrying out
manual tasks and lifting techniques at regular intervals. This should also include
training in the correct use of mechanical devices.
A worker whose upper body or head is within a confined space is considered to have
entered the confined space. Employers must identify any hazards associated with
working in a confined space. The primary hazards commonly found in confined
spaces are:
• lack of oxygen
• toxic gases, vapours or fumes
• flammable gases, vapours or fumes
• engulfment, and
• mechanical equipment.
Employers must also ensure a risk assessment is done by a competent person before
workers enter confined spaces. Any risks identified must be eliminated or minimised.
Health effects
A wide range of injuries can be sustained from working in a confined space including:
• burns
• electrocution
• asphyxiation and suffocation
• poisoning
• brain damage and death, and
• crush injuries.
Control measures
Elimination / substitution
You should assess the need to undertake abrasive blasting in a confined space.
Isolation
The confined space should be isolated to avoid the introduction of harmful substances
or activation of moving parts e.g. isolate the confined space from power sources,
remove valves, lock or tag all moveable components.
32
Engineering controls
Administrative controls
You should develop and document a method for confined space entry.
Before entry
The following issues should be addressed.
• Worker selection (aptitude and fitness for task and confined space entry).
• Worker training in:
− emergency entry and exit procedures
− use of PPE
− first aid including cardiopulmonary resuscitation (CPR)
− lockout procedures
− rescue drills
− fire protection
− communications.
• Define responsibilities of responsible persons to:
− co-ordinate planning and supervision of work
− implement emergency rescue plan
− signpost work area
− isolate confined space
− evaluate confined space environment
− monitor confined space during work
− ensure operative rescue equipment and trained staff are available
− authorise entry by permit
− suspend work / evacuate space if conditions warrant.
The potential hazards in the confined space should be determined before entering.
33
• Comparison of initial test results with existing standards to determine ventilation
and / or personal protective requirements.
• Adequate illumination and visibility to allow safe work to continue.
• Ventilate and provide personal protective equipment.
• Ensure that the breathing air line to the respirator is protected.
• Provide rescue capability (including a person outside suitably equipped) and
escape equipment.
• Issue entry permit.
Personal protective equipment and rescue equipment should be selected and fitted to
suit the individual.
34
Working at heights
Falling is a major risk whenever a worker is required to work above or below ground
level and can result in a multitude of injuries including head injuries, spinal injuries,
internal injuries, fractures and dislocations.
Workers may be exposed to the risk of falling when carrying out blasting or coating
activities:
• on external faces, edges and the perimeter of buildings or structures
• from penetrations in the work environment from holes cut or formed in the
working surface
• on fragile roofs and floors
• when accessing the worksite
• in excavations, and
• during erection and dismantling of plant and framework.
Because of the significant risk of death and serious injury from working at heights
Queensland legislation requires that fall protection be provided for persons working at
2m for construction work (other than when working on housing construction where
the limit is 3 metres). Below these threshold heights, Queensland legislation requires
that a risk assessment must be applied.
Control measures
The aim of the control measures is to prevent the person from falling.
Elimination / substitution
You should examine the need to work at heights. The article to be blasted or coated
may be able to be moved to ground level or a less hazardous place (preferably to a
blast chamber or a spray painting booth).
Engineering controls
Blasting nozzles should be fitted with an earthing device to prevent the build up of
static electricity from the abrasive moving at high velocity through the blasting hose.
Although the mild shocks possible are not sufficient to cause electrocution, they may
cause the operator to lose balance and fall when working at heights.
Administrative controls
If working at heights can not be avoided, physical barriers should be put in place to
stop the person from falling. These include:
• edge protection systems e.g. guard railing with mid rails, containment sheeting,
hoarding
• fall protection covers over holes and openings
• working platforms e.g. elevating work platforms such as scissor lifts, boom type
elevated, and
• platforms or mast climbers.
35
Scissor lifts and cherry pickers should be fitted with operator's controls and hand and
toe rails.
The choice of staging should take account of the operators' needs for freedom of
movement to complete the task safely. Extra precautions should be taken when
blasting from a scaffold because an air-fed helmet does not allow a full field of vision,
so planks should be wide and tightly secured for maximum footing.
Some general rules which should always be applied when blasting at heights are:
• no one should work below blast operators - a nozzle or hose dropped can kill or
cause severe injury
• stop frequently to sweep or clean abrasive media from all horizontal surfaces on
the staging - footing can be treacherous on loose abrasive, and
• use ropes or other strong attachment methods to secure the blast hose to the
staging - this relieves the operator from the weight of the hose and prevents a
dropped hose from falling.
36
• persons should be properly trained and supervised in the use of this equipment. In
addition, it is important when using a fall-arrest system to ensure there are no
obstructions in the potential fall path.
Footwear
Footwear should comply with the requirements of Australian Standards and should be
non-slip.
Catch platforms
A catch platform is a temporary platform located below a work area. The platform
should be of robust construction and designed to sustain the impact of a person falling
onto it. A catch platform should be placed as close as possible to the underside of the
work area to minimise the distance a person can fall from the work platform.
Safety nets
A safety net is an industrial net which is attached to or supported by a scaffold or
attached directly to the framework of a building, bridge or tower to catch a person
who has fallen.
Control measures
Isolation
Exclusion zones
The number of people in the work area should be limited to those actually undertaking
abrasive blasting or applying a protective coating.
37
Signs and barricades which limit entry to the work area will reduce the potential for
persons to suffer injury through:
• slipping on wet surfaces
• tripping on hoses, and
• being struck by objects loosened by abrasive blasting.
Administrative controls
The risk of injury through slips, trips or falls may be reduced by maintaining a clean
and tidy workplace. Attention should be paid to:
• the amount of water or other liquids on the ground in the work area
• regular cleaning of waste material (particularly during wet-blasting)
• keeping hoses straight
• keeping access-ways clear of obstruction
• reducing the number of sharp edges that may catch loose clothing, and
• putting tools and equipment away when finished.
The risk of injury may be further reduced by ensuring that there is adequate visibility
in the workplace.
The type of equipment necessary will be determined as a result of the risk assessment,
and may include:
• non-slip footwear
• protective headwear, and
• eye protectors.
Vibration
Abrasive blasters are subject to hand-arm vibration from the force of the abrasive
moving through the blast hose.
Health effects
Prolonged use of abrasive blasting equipment may lead to a condition known as white
finger (dead finger or Feynaud's phenomenon). It results from persistent microscopic
damage to nerves and blood capillaries.
Symptoms include:
• blanching and numbness in the fingers
• decreased sensitivity to touch, temperature and pain, and
• loss of muscular control.
Chronic exposure may result in gangrenous and necrotic changes in the finger. There
is no effective treatment to reverse the effects of white finger.
Control measures
38
Elimination / substitution
The use of vibration-reduced equipment such as vibration isolating handles
incorporated into blasting nozzles may decrease the incidence of white finger.
Administrative controls
The length of time an operator is required to operate a blast nozzle should be kept to a
minimum. This may be achieved through job rotation or more frequent breaks.
Heat
Heat is a problem due to the type of personal protective equipment (blast helmets,
protective suits or leather coveralls) required to be worn, sometimes for long periods.
Health effects
The major risk associated with heat is heat stress.
Where the body is unable to lose heat fast enough through evaporative cooling to
maintain a steady core temperature, it begins to experience physiological heat strain
with different illnesses depending on the degree of heat stress.
Potential health effects for persons under increasing levels of heat stress include:
• discomfort irritability
• dehydration
• reduced concentration
• heat rash
• reduced tolerance to chemicals and noise
• exposure heat cramps, and
• heat exhaustion heat stroke.
Heat cramps, heat exhaustion and heat stroke are the most serious forms of heat
illness. The effects of heat stress are likely to increase in the summer months.
39
• using medications that impair temperature regulation or perspiration.
Control measures
Administrative controls
The use of personal protective equipment required for abrasive blasting often leads to
a build-up of heat.
Heat build-up may be reduced by ensuring the comfortable fit of the personal
protective equipment. Heat stress may also be reduced by the fitting of air
conditioning units to the air supply of blast helmets.
Heat reflective clothing may also be of assistance where working outdoors in the sun.
40
• reviewing any statistics, hazard alerts or other reports from relevant associations
• reviewing material safety data sheets (MSDS), product labels and manufacturers'
specifications, and
• seeking advice.
Identified hazards are assessed to determine their real potential to cause injury or
disease. The likelihood of the hazard causing an injury (probability) and the severity
of the injury (consequence) are considered when prioritising the hazards.
41
Risk priority chart
Probability Consequence
How likely could it How severely could it hurt someone?
happen? Catastrophic Major Minor
Kills, disables Significant injury First aid only
Permanent injury Not permanent No lost time
Very likely 1 2 2
Could happen
frequently
Likely 2 3 4
Could happen
occasionally
Unlikely 3 4 5
Could happen rarely
Very unlikely 4 5 6
Could happen,
probably never will
From this chart you can give a specific hazard a risk priority. If you score a:
• 1 or 2, do something now
• 3 or 4, do something soon
• 5 or 6, do something to address the risk.
For example, operators undertaking dry blasting activities are constantly exposed to
respirable dust. If the dust contained free crystalline silica, the consequences are
catastrophic.
With a probability very likely, this gets a rating of 1 which means it needs to be fixed
immediately - before work continues.
A person may be walking through an area and slip on loose abrasive, suffering an
abrasion to the hand. The probability is likely and the consequence minor, so this gets
a rating of 4 which means it needs to be controlled as soon as possible but after more
immediate risks have been attended to.
A blank risk assessment form is included at the end of this section to help you to
assess the risks in your workplace. You should conduct a separate risk assessment for
each hazard identified.
42
If that cannot be done, use isolation/engineering controls.
This could involve some structural change to the work environment or work process
to place a barrier to, or interrupt the transmission path between the worker and the
risk. For example conducting work in a blasting chamber.
You should attempt to select control measures from the top of this hierarchy where
possible, but it is often necessary to use a combination of measures.
Record keeping
For the best results from the risk management process, the results of these steps
should be recorded and kept for future reference. Records will also help to show that
you have been actively working to ensure workplace health and safety at your
workplace, should you need to prove this.
43
Risk assessment form
Please photocopy a separate sheet for each hazard
_____________________________________________________________________
_____________________________________________________________________
On the following chart, circle the most likely harm to a person if the risk happens
(along the top). Next circle how often in could happen (down the right hand side).
The risk priority (score) is the number where the two intersect.
What is the risk priority? (score from 1-6 from the above chart). If you score a:
Choose control measures from the highest possible level in the following list:
1. elimination,
2. substitution,
3. isolation or engineering,
4. administrative, or
5. personal protective equipment.
44
Control measures
Action to take:
Now: _______________________________________________________________
____________________________________________________________________
____________________________________________________________________
_____________________________________________________________________
In many cases, the best method of control for health and safety risks in abrasive
blasting and protective coating work will be a combination of methods (i.e. other
methods of control in conjunction with PPE).
45
Additional references
General
1. Workplace Health and Safety Act 1995
2. Workplace Health and Safety Regulation 2008
3. Workplace Health and Safety Queensland
a. ‘A Quick Start to the Workplace Health & Safety Act 1995’ (guide –
www.worksafe.qld.gov.au)
Dusts
1. Workplace Health and Safety Regulation 2008
2. Part 16 - Hazardous Substances, Part 17 - Lead
3. Hazardous Substances Code of Practice
4. ‘Adopted National Exposure Standards for Atmospheric Contaminants in the
Occupational Environment [NOHSC:1003(1995)]’
5. List of Designated Hazardous Substances [NOHSC:10005(1999)]
6. Approved Criteria for Classifying Hazardous Substances [NOHSC:1008(2004)]
7. Australian Standard AS1319 Safety signs for the occupational environment
8. Australian and New Zealand Standard AS/NZS 1715 Selection, use and
maintenance of respiratory protective devices
9. Australian and New Zealand Standard AS/NZS 1716 Respiratory protective
devices
10. Australian Standard AS 2985 Workplace atmospheres – Methods for sampling
and gravimetric determination of respirable dust
11. Australian Standard AS 3544 Industrial vacuum cleaners for particulates
hazardous to health
12. Australian Standard AS 3640 Workplace atmospheres – Methods for sampling
and gravimetric determination of inspirable dust
13. Australian Standard AS 4361.1 Guide to lead paint management – Industrial
applications
Noise
1. Workplace Health and Safety Regulation 2008, Part 12 - Noise
2. Noise Code of Practice
Particulate matter
1. Australian and New Zealand Standard AS/NZS 1336 Recommended practices for
occupational eye protection
2. Australian and New Zealand Standard AS/NZS 1337 Eye protectors for industrial
applications
3. Australian and New Zealand Standard AS/NZS 1715 Selection, use and
maintenance of respiratory protective devices
4. Australian and New Zealand Standard AS/NZS 1716 Respiratory protective
devices
5. Australian and New Zealand Standard AS/NZS 1269 Occupational noise
management
6. Australian and New Zealand Standard AS/NZS 1270 Acoustics – Hearing
protectors
46
7. Australian and New Zealand Standard Series AS/NZS 2161 Occupational
protective gloves
8. Australian and New Zealand Standard AS/NZS 2210 Occupational protective
footwear
47
11. Australian and New Zealand Standard AS/NZS 1716 Respiratory protective
devices
12. Australian Standard AS 1940 The storage and handling of flammable and
combustible liquids
13. Australian and New Zealand Standard AS/NZS 2210 Occupational protective
footwear
14. Australian Standard AS 2268 Electrostatic paint and powder spray guns for
explosive atmospheres
Manual tasks
1. Manual Tasks Code of Practice
2. National Code of Practice for Manual Handling [NOHSC:2005(1990)]
Confined spaces
1. Workplace Health and Safety Regulation 2008
2. Part 18 - Confined Spaces
3. Workplace Health and Safety Queensland
a. ‘A guide to working safely in confined spaces’ (guide –
www.worksafe.qld.gov.au)
4. Australian New Zealand Standard AS/NZS 2865 Safe working in a confined
space
Working at heights
1. Australian Standard AS 1418.10 Cranes, hoists and winches - Elevating work
platforms
2. Australian and New Zealand Standard AS/NZS 2210 Occupational protective
footwear
Vibration
1. Plant Code of Practice
2. Australian Standard AS 2670.1 Evaluation of human exposure to whole-body
vibration – General requirements
3. Australian Standard AS 2763 Vibration and Shock – Hand-transmitted vibration –
Guidelines for measurement and assessment of human exposure
Heat
1. Workplace Health and Safety Queensland. ‘ Heat Stress’
http://www.worksafe.qld.gov.au
48
Risk management
1. Australian and New Zealand Standard AS/NZS 4360 Risk management
Work activities
• The Environmental Protection Act 1994 – Schedule 2 (Notifiable activities)
• The Environmental Protection Act 1994 – Chapter 7, Part 8 (Contaminated land)
You should contact your local authority for environmental guidelines. (In many cases
local authorities have adopted the Operators Compliance Guidelines for Abrasive
Blasting and the Operator Compliance Guidelines for Metal Surface Coating.)
Waste management
• The Environmental Protection (Waste Management) Regulation 2000
• The Environmental Protection (Waste Management) Policy 2000
• The Environmental Protection Regulation 1998 Schedule 1 (Level 1, Item 23
Abrasive Blasting and Item 25 Metal Surface Coating) and Schedule 7 (Regulated
Wastes)
• The Australian Code for the Transportation of Dangerous Goods by Road and
Rail (ADG Code) and associated state legislation.
Abrasive materials
• Radiation Safety Act 1999
• Radiation Safety Regulation 1999
• Radiation Safety (Radiation Safety Standards) Notice 1999
49