Code of Practice for Health and Safety in

The Manufacture of
Composites Based on
Synthetic Resins
(Fibreglass)
Published by
Composites Association of New Zealand Inc.
May 1998
ISBN 0-473-05151-6
$30 + GST
CONTENTS

Foreword 5
Preface 6
Summary of the Health and Safety in Employment Act 1992 7
1. Introduction 11
1.1 Parties involved in production of this code 11
1.2 The purpose of this code 11
1.3 The objectives of this code 11
1.4 Processes discussed in this code 11
1.5 Definitions 12
2. The Raw Materials, Manufacturing Processes and their Hazards 13
2.1 The raw materials and their hazards 13
2.2 The manufacturing processes for composites and their hazards 16
3. Health and Safety Requirements for Composites Process
Workplaces 18
3.1 General health and safety 18
3.2 Information to be provided to employees 18
3.3 Training and supervision of employees 19
3.4 Building construction 19
3.5 Controlling exposure—ventilation and extraction of vapours 20
3.6 Controlling exposure—health 22
3.7 Personal protection and facilities 22
3.8 Housekeeping, cleaning and removal of waste 25
3.9 Dust 26
3.10 General storage 27
3.11 Installation and use of spray booths 27
4. Dangerous Goods Requirements 28
4.1 Areas where resins of Class 3(b) are used 28
4.2 Relevant legislation and standards 29
4.3 Transportation of dangerous goods 30
4.4 Storage of flammable liquids and isolation distances 31
MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

5. Electrical Requirements 32
5.1 General electrical information 32
5.2 Protection against static electricity 32
5.3 Pouring flammable liquids 32
5.4 Personal electrical equipment 33
5.5 Portable electrical equipment 33
6. New Developments 34
6.1 Updating systems 34
Appendices
Appendix A: Workplace Exposure Standards 35
Appendix B: Properties and Health Effects of Substances Used in
Composite Manufacture 38
Appendix C: Excerpts from the Dangerous Goods Act 1974 and
Associated Dangerous Goods Regulations 1985 48
Appendix D: Manufacturing Processes for Composites 58
Appendix E: Reference Material 59

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FOREWORD

I commend the Composites Association of New Zealand Incorporated for their

initiative in producing this code of practice. It is a comprehensive document
that provides practical guidance on managing health and safety in the
manufacture of composites based on synthetic resins (fibreglass). Adopting the
safe work practices in this code will assist employers to meet their obligations
under the Health and Safety in Employment Act 1992. The code will also
assist employees to be aware of the health and safety hazards they may
encounter at work and how to take the necessary precautions.
The Occupational Safety and Health Service of the Department of Labour
encourages the adoption of this code of practice by all those working in the
composites industries.

R.J.M. Hill
General Manager
Occupational Safety and Health Service

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PREFACE

The Composites Association of New Zealand is concerned about the potential

hazards involved in the manufacture of composites based on synthetic resins
and the possible injuries and health problems directly attributable to work
practices in this industry.
This industry code of practice has been written by the Composites Association
of New Zealand Incorporated as a guide to the New Zealand composites
industry and offers practical information and advice on managing health and
safety in composites workshops.
The Health and Safety in Employment Act 1992 places the responsibility for
providing safe and healthy workplaces firmly on the shoulders of employers,
and the code has been written with this in mind. The code has been prepared
with the best intention to promote safe working practices within the composites
industry and makes no attempt to relieve employers or employees from their
responsibilities under this Act. It is also intended as a source of information for
employees on the hazards they may face in their daily work and to offer
assistance in avoiding work-related injury and health problems.
The Composites Association recommends this code for all composites-related
industries. The intention is to trial the code in the workplace for a period of
one year. After this period the code will be revised, if necessary, with a view to
becoming an approved code of practice under the Health and Safety in
Employment Act 1992.
We welcome any comments on this code and any suggestions for improving its
content.

Glenn Campbell
President
Composites Association of New Zealand Incorporated

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SUMMARY OF THE HEALTH AND SAFETY IN

EMPLOYMENT ACT 1992
The principal object of the Health and Safety in Employment Act 1992
(hereinafter referred to as the HSE Act) is to prevent harm to employees at
work. To do this it imposes duties on, and promotes excellent health and safety
management by, employers. It also provides for the making of regulations and
codes of practice.

APPROVED CODES OF PRACTICE

“Approved codes of practice” are provided for in section 20 of the HSE Act.
They are statements of preferred work practice or arrangements, and may
include procedures which could be taken into account when deciding on the
practicable steps to be taken. Compliance with codes of practice is not
mandatory. However, they may be used as evidence of good practice in court.

EMPLOYER’S DUTIES
Employers have the most duties to perform to ensure the health and safety of
employees.
Employers have a general duty to take all practicable steps to ensure the safety
of employees at work. (This is set out in section 6 of the HSE Act). In
particular, they are required to take all practicable steps to:
• Provide and maintain a safe working environment;
• Provide and maintain facilities for the safety and health of employees at
work;
• Ensure that machinery and equipment in the place of work is safe for
employees;
• Ensure that working arrangements are not hazardous to employees; and
• Provide procedures to deal with emergencies that may arise while
employees are at work.
Taking all “practicable steps” means doing what is reasonably able to be done
in the circumstances, taking into account:
• The severity of the injury or harm to health that may occur;
• The degree of risk or probability of that injury or harm occurring;

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• How much is known about the hazard and the ways of eliminating,
reducing or controlling it; and
• The availability, effectiveness and cost of the possible safeguards.

HAZARD MANAGEMENT
Employers shall identify and regularly review hazards in the place of work
(existing, new and potential) to determine whether they are significant hazards
and require further action. If an accident or harm occurs that requires
particulars to be recorded, section 7(2) of the HSE Act requires employers to
investigate it to determine if it was caused by or arose from a significant
hazard.
“Significant hazard” means a hazard that is an actual or potential cause or
source of:
• Serious harm; or
• Harm (being more than trivial) where the severity of effects on any
person depends (entirely or among other things) on the extent or
frequency of the person’s exposure to the hazard; or
• Harm that does not usually occur, or usually is not easily detectable until
a significant time after exposure to the hazard.
Where the hazard is significant, the HSE Act (section 10) sets out the steps
employers shall take:
• Where practicable, the hazard shall be eliminated;
• If elimination is not practicable, the hazard shall be isolated;
• If it is impracticable to eliminate or isolate the hazard, the employer shall
minimise the likelihood that employees will be harmed by the hazard.
Where the hazard has not been eliminated or isolated, employers shall, where
appropriate:
• Ensure that protective clothing and equipment is provided, accessible
and used;
• Monitor employees’ exposure to the hazard;
• Seek the consent of employees to monitor their health; and
• With informed consent, monitor employees’ health.

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INFORMATION FOR EMPLOYEES

Before an employee begins work, they shall be informed by their employer of:
• Hazards employees may be exposed to while at work;
• Hazards employees may create which could harm people;
• How to minimise the likelihood of these hazards becoming a source of
harm to themselves and others;
• The location of safety equipment; and
• Emergency procedures.
Employers are also required to inform employees of the results of any health
and safety monitoring. In doing so, the privacy of individual employees shall
be protected.

EMPLOYERS TO INVOLVE EMPLOYEES IN THE DEVELOPMENT

OF HEALTH AND SAFETY PROCEDURES
Employers need to ensure that all employees have the opportunity to be fully
involved in the development of procedures for the purpose of identifying
hazards and dealing with significant hazards or dealing with or reacting to
emergencies and imminent dangers (section 14 of the HSE Act).

TRAINING OF EMPLOYEES
Employers shall ensure employees are either sufficiently experienced to do
their work safely or are supervised by an experienced person. In addition,
employees shall be adequately trained in the safe use of equipment in the place
of work, including protective clothing and equipment (section 13 of the HSE
Act).

SAFETY OF PEOPLE WHO ARE NOT EMPLOYEES

Employers are also responsible for the health and safety of people who are not
employees. Employers shall take all practicable steps to ensure that employees
do not harm any other person while at work, including members of the public
or visitors to the place of work (section 15 of the HSE Act).

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EMPLOYEES’ AND SELF-EMPLOYED PERSONS’ DUTIES

Employees and self-employed persons have a responsibility for their own
health and safety while at work. They shall also ensure that their own actions
do not harm anyone else. However, these responsibilities do not detract from
the employer’s responsibilities.

ACCIDENTS AND SERIOUS HARM (RECORDS AND

NOTIFICATION)
The HSE Act requires employers to keep a register of work-related accidents
and serious harm. This includes every accident that harmed (or might have
harmed):
• Any employee at work;
• Any person in a place of work under the employer’s control.
Employers are also required to investigate all accidents and near-misses to
determine whether they were caused by or arose from a significant hazard.
Employers are required to notify serious harm that occurs to employees while
at work to the Secretary of Labour (in practice, the nearest OSH office), as
soon as possible. In addition, the circumstances of the accident shall also be
notified in the form prescribed within 7 days. (Suitable forms for notification
are available from OSH offices and selected stationers.)
If a person suffers serious harm, the scene of the accident shall not be disturbed
unless to:
• Save life or prevent suffering;
• Maintain public access for essential services, e.g., electricity, gas; or
• Prevent serious damage or loss of property.
The OSH office will advise whether it will wish to investigate the accident and
what action may be taken in the meantime.

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1. INTRODUCTION

1.1 PARTIES INVOLVED IN PRODUCTION OF THIS CODE

This code of practice was produced by the Composites Association of New
Zealand Incorporated (CANZ) with the assistance of, and in consultation with,
the Occupational Safety and Health Service (OSH), a Service of the
Department of Labour. In the process of developing this code, contributions
were solicited from the Chief Electrical Inspector of the Ministry of
Commerce; the Chief Explosives and Dangerous Goods Inspector of OSH;
members of the various representatives from composites manufacturing
companies throughout New Zealand; supply houses to the industry; the
executive members of CANZ, and various other organisations.

1.2 THE PURPOSE OF THIS CODE

The purpose of this code of practice is to provide practical guidance for the
protection of the health and safety of all personnel involved in industrial
processes which use synthetic resins for the manufacture of composites.

1.3 THE OBJECTIVES OF THIS CODE

The objectives of this code are:
• To eliminate the long- and short-term health risks to employers and
employees in the industry, and to prevent accidents;
• To ensure that workplaces are safe and healthy to benefit not only those
in the workplace, but also the wider community and the environment;
• To promote training in safe procedures, work methods and work
practices, thereby minimising the risk of injury and accidents, and
reducing financial losses to employers caused by fire and damage to
stock or equipment.

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1.4 PROCESSES DISCUSSED IN THIS CODE

The code discusses the processes and describes the hazards involved in
manufacturing composites based on synthetic resins. It provides information
on workroom safety requirements, including classification of hazardous areas,
cleaning, and dealing with spillages. It also covers work in hazardous areas
and the training and supervision of employees. Practicable methods of
compliance with the Health and Safety in Employment Act 1992 and the
Health and Safety in Employment Regulations 1995 are provided.

1.5 DEFINITIONS
CANZ means the Composites Association of New Zealand Incorporated.
Hazard means an activity, arrangement, circumstance, event, occurrence,
phenomenon, process, situation or substance (whether arising or caused within
or outside a place of work) that is an actual or potential cause or source of
harm; and “hazardous” has a corresponding meaning.
HSE Act means the Health and Safety in Employment Act 1992.
Inspector unless specified means an inspector appointed under section 29(1) of
the HSE Act.
LEL means Lower Explosive Limit and this is the level of concentration in
percentage by volume in air above which explosion can occur upon ignition in
a confined area.
MSDS means Material Safety Data Sheet.
OSH means the Occupational Safety and Health Service of the Department of
Labour.
Regulations, unless specified, means the Health and Safety in Employment
Regulations 1995.
Shall is used in places where there is a technical requirement to achieve the
desired result. It is used to alert the reader to the need for that element to be
included.
Should is used as a way of indicating a preference. It does not indicate a
mandatory requirement as other alternatives could achieve an equivalent result.
Toxic means injurious to human health when swallowed, inhaled or otherwise
absorbed into the body (poisonous).
Workplace Exposure Standard (WES) means any exposure standard listed in
the Workplace Exposure Standards publication currently applicable in New
Zealand. Workplace exposure standards are defined for both short-term effects
(WES ceiling and WES short-term exposure limits) and long-term effects
(WES time-weighted average exposure limits).

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2. THE RAW MATERIALS, MANUFACTURING

PROCESSES AND THEIR HAZARDS

2.1 THE RAW MATERIALS AND THEIR HAZARDS

Resins
The most commonly used resins are unsaturated polyester resins, epoxy and
vinyl ester resins. Less frequently used resins include phenolic and furane
resins.

Hazards

The resins used in the manufacturing process may give off vapours which may
be both harmful to health and flammable over a given range of concentrations.
Unsaturated polyester resins before and during initial curing evolve styrene
monomer vapour. Some epoxy resin hardeners can cause dermatitis and/or
asthma, and may cause sensitisation in susceptible individuals.

Fibres and reinforcements

The resin is normally reinforced by the addition of a fibre, commonly glass
fibre, hence the general term “fibre glassing”. Types of glass reinforcements
include chopped strand mat, woven mats and cloths, continuous filament mats,
rovings and surfacing tissues. Other materials which may be used for
reinforcing include carbon fibres, synthetic fibres such as acrylic and polyester,
metallic and non-metallic, and polyamide fibres.

Hazards

Inhalation of glass and other reinforcing fibres is to be avoided to prevent

possible health problems. Inhalation of glass fibres may exacerbate pre-
existing conditions such as asthma and bronchitis, but does not cause them.
Skin contact can cause a temporary dermatitis and precautions should be taken.
There is no evidence that the glass fibres used in the composite industry are
carcinogenic in humans.

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Fillers and pigments

In some applications, fillers such as calcium carbonate, talc, aluminium
trihydrate, fumed silica and speciality light weight fillers may be used.
Pigments may be added for colour.

Hazards

Commonly, fillers are dusty powders which pose a nuisance risk. The product
data supplied by the manufacturer should always be consulted with regard to
toxic hazards and safe methods of use.

Catalysts/initiators
Unsaturated polyester resins and vinyl ester resins are cured by the action of
catalysts/initiators which are normally organic peroxides, the most common
one being methyl ethyl ketone peroxide (MEKP). Organic peroxides are
classified by the Dangerous Goods Act 1974 as a class 5.2 oxidising substance.
Epoxy resins are cured by mixing with hardeners, which are usually amines or
anhydrides. Some of these may be classified as class 8 corrosive.

Hazards

These chemicals are extremely hazardous and contact between them and an
organic combustible material may cause a spontaneous or delayed fire, or in
some cases, an explosion. All organic peroxides decompose on heating,
releasing oxygen and thereby increasing the risk of fire. Peroxides are severe
irritants and corrosive to moist tissue (eyes, nose, throat, and airways to the
lungs). Skin contact with peroxides can cause burns that do not heal readily.
Eye contact is particularly dangerous as severe damage can occur very rapidly.

Promoters/accelerators
There are two major types of promoters/accelerators used to speed up the
action of the catalyst/initiator:
• Cobalt-based accelerators (cobalt octoate or cobalt naphthenate); and
• Amine-based accelerators (primarily dimethylaniline).

Hazards

The cobalt-based accelerators are commonly dissolved in mineral turpentine or

white spirits. These solutions are all flammable and contact will irritate the
skin and eyes. Breathing high concentrations of the vapours will cause
irritation of the respiratory system. Cobalt-based accelerators react violently
with peroxide catalysts/initiators and this may cause fire as well as releasing
toxic fumes.

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Dimethylaniline should be regarded as a dangerous material as it is toxic by

inhalation and ingestion as well as being readily absorbed through the skin. It
will also react violently with peroxide catalysts/initiators and this may cause
fire as well as releasing toxic fumes.

Inhibitors
Inhibitors such as hydroquinone or tertiary butyl catechol are used to increase
the shelf-life of resins and can be used to slow down the effect of the catalyst/
initiator.

Hazards

These are mostly phenolic materials normally dissolved in styrene or glycol.

Flammability characteristics will be dependent on the dissolving medium. The
inhibitors themselves will cause burns to the skin and are harmful by skin
absorption.

Mould-release agents
A number of different mould-release agents are used to facilitate the removal of
the cured composite product from its mould. These include waxes, silicones,
polyvinyl alcohol, and polymeric films.

Hazards

Some wax type mould-release agents contain flammable solvents. Solutions of

polyvinyl alcohol are normally supplied in a mixture of water and methylated
spirits and are flammable and toxic by ingestion.

Solvents
A number of solvents may be used in the manufacture of composite products,
mainly for cleaning purposes. Examples are acetone and methyl ethyl ketone
(MEK).

Hazards

Acetone, or methyl ethyl ketone are Class 3(a) dangerous goods and are highly
flammable at low concentration levels. The vapours are heavier than air and
can travel considerable distances from the liquid to an ignition source. The
vapours are irritant to the respiratory tract and can depress the central nervous
system at higher concentrations. Contamination of skin with solvents can
cause irritant contact dermatitis.

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2.2 THE MANUFACTURING PROCESSES FOR COMPOSITES

AND THEIR HAZARDS

The manufacture of composite materials from synthetic resins normally

involves placement of resins and reinforcements into moulds or onto or through
formers which provide the shape of the article to be produced. This process
can consist of hand lay-up, spray lay-up, press moulding, automated moulding,
and continuous moulding. Examples of specific moulding processes used in
the production of composites are listed in Appendix D: Manufacturing
Processes for Composites.
The synthetic resins change from liquids to solids during the manufacture of
the composite products. This change is produced by the action of catalysts/
initiators or hardeners which are normally introduced into the resins before or
during the moulding or other processing operation. In some types of
processing, heat is required to speed up the process. Some resins may require
the addition of promoters which further increase the rate of action of the
catalysts/initiators which are added subsequently.
Often the resins will be used in conjunction with reinforcing fibres (most
commonly glass fibres) and in some cases fillers and pigments may be
included. These are normally introduced before or during the moulding
process.
As the materials used are insoluble in water, organic solvents are normally used
to clean equipment used in the moulding process.

Hazards of the Processes

There are five main hazards in the manufacturing process:

1. Fire or explosion risk from the various substances used;
2. Fire or explosion risk from dusts produced during finishing operations.
The dust produced from finishing the cured composite articles by
processes such as sanding and grinding is combustible and at certain
concentrations in air can be explosive. Polyester resin dust has a strong
explosibility rating under test conditions. Concentrations of the dust in
the air should not exceed allowable limits for inert particulate matter.
3. Health risks to persons from inhalation of dusts and chemicals, and
absorption of chemicals through the skin. Repeated skin contact could
cause dermatitis in some individuals. For health effects of individual
substances see Appendix B: Properties and Health Effects of Substances
Used in Composite Manufacture.
4. Fire risk from spontaneous combustion of waste material.

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5. There is an explosion risk from mixing different types of catalysts/

initiators together, and this must be done only by trained people
following suppliers’ specific instructions. Any pre-mixing of these
materials shall be done to manufacturer’s specific instructions.
NOTE: For storage and mixing areas requirements, see section 4, Dangerous
Goods Requirements, and Appendix C.

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3. HEALTH AND SAFETY REQUIREMENTS FOR

COMPOSITES PROCESS WORKPLACES

3.1 GENERAL HEALTH AND SAFETY

Any production in a place of work should be conducted in a manner which
satisfies the requirements of the Health and Safety in Employment Act 1992
and the Health and Safety in Employment Regulations 1995.
Substances used in the manufacture of composites can give rise to chemical
dermatitis and some are absorbed through the skin. Suitable protective
clothing should be provided and worn for protection.
Exposure to high levels of solvent vapours can cause intoxication. The effects
of solvent vapours are generally additive in their health effects, i.e. a mixture of
several solvent vapours in the air is a greater hazard to health than each
individual solvent vapour (this is discussed further in the Workplace Exposure
Standards booklet).
NOTE: See also Appendix A: Workplace Exposure Standards, for further
information.

3.2 INFORMATION TO BE PROVIDED TO EMPLOYEES

The employer shall ensure that all employees are provided with information on
the hazards posed by substances or products used. Material Safety Data Sheets
obtained from the supplier of the products may form the basis of this
information, but it is the employer’s responsibility to ensure that the
information is provided in a form that is likely to be understood by the
employee. It is noted that as well as making the information available, the
employer shall ensure that training is provided on how to access and interpret
the data (see 3.3 below).
All containers used to store products containing solvents or other hazardous
substances must be suitable for the purpose and should be clearly labelled to
identify the contents and to allow the substances to be used safely.

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3.3 TRAINING AND SUPERVISION OF EMPLOYEES

The employer shall ensure that all persons in the place of work are instructed in
the hazards likely to arise, and the precautions to be taken in regard to those
hazards in accordance with the Health and Safety in Employment Act 1992.
Employees are to be advised, trained or supervised as necessary, and provided
with information to ensure a safe and healthy environment is maintained.
Employees should be given instruction and training in the provisions of this
code, and in particular employees shall be advised of the following:
1. The Health and Safety in Employment Act 1992, and the Health and
Safety in Employment Regulations 1995;
2. Storage and use of Dangerous Goods of Class 3(a) and Class 3(b) as
detailed in the Dangerous Goods (Class 3 - Flammable Liquids)
Regulations 1985;
3. All identified hazards to which they will be exposed or may create in the
course of their employment, and the steps that should be taken to
minimise the likelihood of harm to either themselves or other people;
4. The circumstances requiring the use of protective clothing and safety
equipment and the correct use and maintenance of that clothing and
equipment;
5. Any procedure to be followed in case of an emergency, including the
use of all emergency equipment and any special decontamination
procedures to be followed;
6. Disposal of unused catalysed resin in wet bins;
7. Cleaning up procedures for spills of catalysts/initiators;
8. The importance of good housekeeping;
9. When and where mechanical ventilation shall be used;
10. Keeping sources of ignition (e.g. smoking, welding and electrical hand
tools) out of hazardous areas; and
11. Material Safety Data Sheets (MSDS).

3.4 BUILDING CONSTRUCTION

New buildings or building alterations shall be constructed to the relevant
performance levels set by the Building Code. Acceptable solution documents
published by the Building Code provide means of doing this.
Dangerous goods workrooms and storage depots are to comply with the
requirements of the Dangerous Goods Regulations. Refer to 4.4.

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3.5 CONTROLLING EXPOSURE—VENTILATION AND

EXTRACTION OF VAPOURS
There are several approaches that can be taken to control exposure to styrene
and other vapours or dusts. While there is currently no substitute for styrene in
the resins that are available for composite manufacture, the design and
placement of equipment and the use of low styrene emission resins can
significantly reduce exposure. Work methods and equipment can be adapted to
minimise exposure. For example; the use of long-handled rollers and rollers
designed to minimise mist production during hand lay-up can reduce the
styrene level in the workers breathing zone.
Good housekeeping practices should be employed to minimise unnecessary
evaporation of solvents. When not in use all containers of resin and solvents
should be sealed to prevent open containers contributing to background vapour
levels.
Even where attention has been given to the design of equipment and sound
work practices are used, ventilation will usually still be required to ensure that
styrene and other vapour concentrations within the breathing zone of the
operator are kept as low as practicable. The prevention of pockets of heavier
than air vapour, elimination of dead spots, and a high standard of house
keeping throughout the area of operation is essential.
To find out whether exhaust ventilation is needed the employer is to make an
assessment of the risk to health to which employees may be exposed and the
nature and extent of exposure during their work. In many cases workplace
exposure monitoring will be the only effective way of assessing exposure.
Where workplace exposure monitoring shows that exhaust ventilation is
necessary the detailed knowledge of the exposure levels will help in the design
of an effective system.
Where workplace exposure monitoring has established that the ventilation
system is effectively controlling exposure, then checks on the performance of
the system may be used as the primary means of monitoring.
The atmospheric concentrations shall be kept as low as practicable at all times.
In general it can be assumed that concentrations of contaminant in air that are
regularly below 10% of the WES will not present a significant risk to health.
Natural or mechanical air movement through the hazardous areas shall be as
uniform as practicable, to ensure adequate cross ventilation. If natural
ventilation is provided in any area, all practicable steps shall be taken to ensure
that it is effective at all times.
It is essential that any extraction ventilation system used be properly located
and installed. The predominant requirement is ventilating the operator’s
breathing zone by achieving sufficient air movement to carry fumes off, while
not causing processing difficulties. To be effective, mechanical exhaust

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ventilation in the workplace needs to be installed as near as possible to the

point of origin of the fumes given off.
Extraction shall be kept in use at all times hazardous vapours are present in
hazardous concentrations and shall in any case be capable of ensuring that
under normal working conditions the concentrations of any flammable vapours
will not exceed 25% of the lower explosive limit of the respective vapours.
Air extracted from the workroom shall be exhausted to the open air (away from
air inlets). All discharges to the outside atmosphere shall comply with any
discharge approvals given under section 15 of the Resource Management Act
1992 and not be harmful to the health of persons living or working in the
vicinity of the premises or to their workplace operations.
Ventilation should be in operation while depositing equipment is being cleaned
with solvents.
The concentration of styrene or other vapours should be kept below 25% of the
lower explosive limit (LEL) (see note below) when composites are cured in a
curing room. If the articles are placed in or removed manually from the curing
room, then the styrene or other vapour levels in the curing room should not
exceed the criteria contained in WES booklet.
NOTES: 1. Solvent should be not sprayed in large quantities to flush
depositing guns, one short brief burst is sufficient.
2. It is recognised that if concentrations of contaminants are kept
below the relevant Workplace Exposure Standards (WESs), the
LEL will not be exceeded.
Where it is necessary for personnel to work inside a mould, tank, enclosed
structure, or other enclosed space, portable exhaust or plenum ventilation shall
be provided to remove vapours from inside that space. Vapour concentrations
shall be maintained as low as is practicable below the WES Standard (see
Appendix A). A venturi ventilation system is an economical method for deep
mould ventilation.
When work is carried out in enclosed spaces, and it is not practicable to
provide sufficient mechanical extraction and ventilation to stay below WES
levels, then suitable air-fed respirators shall be provided and worn. (See
Appendix E: Reference Material, for further information on the OSH resource
Safe Working in a Confined Space).
All permanent ducts, trunks and casing used in connection with the ventilation
system require earthing.
NOTE: This provision does not apply to non-metallic temporary flexible
ducting.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

3.6 CONTROLLING EXPOSURE—HEALTH

It is recommended that where the atmospheric concentrations exceed 50% of
the WES for any contaminant, employers should take all practicable steps to
obtain the employee’s consent to the monitoring of their health and arrange for
this to carried out. This may include a physical examination and a urine or
blood test.
Where solvents are easily absorbed through the skin, or where the workers
respiration rate is high, biological monitoring (not available for all solvents)
may be required because air monitoring alone may understate the exposure.
Biological monitoring can also be used to determine the effectiveness of
respirators worn by workers. In the case of styrene, urine or breath levels
correlate with exposure to the solvent. Measurement of metabolites in urine
such as mandelic acid, which results from styrene exposure, is a useful addition
to workplace exposure monitoring. Biological monitoring needs to be closely
supervised by a medical practitioner, occupational health nurse or an
occupational hygienist so that the results can be correctly interpreted.
Solvents can remove the natural protective barrier from the skin, promoting the
penetration and absorption of solvents and other chemicals which may be
present. This can cause skin rashes, and repeated or prolonged exposure may
result in chronic irritant dermatitis. Cleaning your hands in a solvent can also
cause dermatitis, and should be avoided where possible.

3.7 PERSONAL PROTECTION AND FACILITIES

All practicable steps including administrative and engineering controls shall be
taken to reduce the concentration of fume, vapour, fibre and dust to the lowest
practicable level below the appropriate Workplace Exposure Standard (WES).
Where it is not practicable to control the contaminant at source, or when
attending to a spillage, personal protection for employees is to be provided on
an individual basis. Refer to Dangerous Goods Regulation 192 - Protective
Clothing and Equipment which details requirements where dangerous goods of
Class 3 are handled, stored or used. When the use of protective clothing or
equipment is necessary, employers shall ensure that it is used. Training in the
use and care of protective equipment is essential.
Protective equipment is to be provided where it is necessary to protect
employees’ health and safety and where appropriate the safety equipment
should be stored in a sealed container when not in use. For composites
manufacture, employee health and safety protection may be required from the
following hazards:

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

1. Dusts
Eye protection and dust respirators suitable for grinding and trimming
operations.
2. Vapours
Solvent filter respirators or air fed helmets to provide protection against
airborne vapour:
(a) Respiratory protection (complying with AS/NZS 1715: 1994
Selection, Use and Maintenance of Respiratory Protective
devices and AS/NZS 1716: 1994 Respiratory Protective
Devices) is to be issued on a personal basis and chosen to fit
each individual.
(b) Training at no more than 12-monthly intervals on maintenance,
fit testing, storage, and replacement of defective parts is to be
provided.
(c) A filter replacement policy which assures protection is to be
adopted for all negative pressure respirators. It should be noted
that the replacement of filters is dependent on the concentration
and characteristics of the solvents used and the exposure time.
To prevent confusion of wearing the wrong respirator for dust
and solvents, filters should be capable of removing both dust and
solvent vapours.
Alternatively, disposable dust respirators (to the above standard)
are acceptable for tasks generating dust, but these offer no
protection against solvent vapours.
(d) Solvent respirators should be stored in air tight containers
between uses to extend filter life. Filter life is dependent on the
concentration of the vapour during exposure and the total
exposure time. Vapour filters on respirators can lose
effectiveness suddenly when the charcoal filter is exhausted. It
is important to replace the filters immediately when the smell of
vapours is detectable. It is recommended that the filters be
checked after approximately each 30 minutes of use (practical
advice on filter replacement can be obtained from NZS
8409:1995 Agrichemical Users’ Code of Practice).
(e) In high vapour concentrations such as in deep moulds where
heavy vapours displace atmospheric oxygen, air fed helmets
shall be used. The compressed air supply for the respirators
shall be taken from an uncontaminated source and be
substantially free from carbon monoxide. The supplied air shall
also be free from odour and filtered to remove water, dust and
oil mist. Filters should be stored in a vapour proof container.

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3. Handling Chemicals
Full face visors should be used while repairing pressure lines carrying
chemicals and when decanting and mixing chemicals.
Appropriate gloves and aprons, and full face visor should be worn
where necessary. Viton is the preferred glove material for styrene,
aromatic and aliphatic hydrocarbons, but is not suitable for acetone,
methyl ethyl ketone (MEK) or methyl isobutyl ketone (MIBK). Other
materials for gloves are cheaper but offer protection for shorter periods
of time before styrene permeates through. PVC gloves should be
changed at the first sign of cracking or hardening.
To prevent dermatitis, use suitable barrier cream where necessary for
extra protection but not as a substitute for protective clothing.
(NOTE: For some small jobs splash protection goggles may be suitable,
but the use of full face shields is recommended).
4. Noise
Where noise levels exceed 85 dB(A) (LAeq,8h) suitable hearing protective
devices shall be provided and worn. Hearing protection is to be
provided during the period where all practicable steps are being taken to
eliminate noise, or until the noise has been isolated and is no longer a
source or cause of harm to employees. Where elimination or isolation is
not practicable, hearing protection is to be provided to minimise the
likelihood that the noise will be a source or cause of harm to employees
(See Health and Safety in Employment Regulations 1995).
All protective clothing and equipment should be designed and manufactured to
the appropriate New Zealand Standard. The guidance on selection of
appropriate protective equipment should be sought from a reputable supplier
using the product Material Safety Data Sheets as the source of hazard data.
Facilities meeting the requirements of the Health and Safety in Employment
Regulations 1995 are to be provided. Eye washing facilities should be located
as close as practicable to where chemicals are handled and used. It is
recommended that an automatic “head-operated” eye and face shower be
provided. In the event of chemicals entering the eye, the eye should be gently
and immediately flushed thoroughly for 15 minutes. In the case of peroxide
contact, flush continuously until receiving accident and emergency treatment.

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3.8 HOUSEKEEPING, CLEANING AND REMOVAL OF WASTE

All practicable steps shall be taken to ensure that every place of work is kept in
a clean and hygienic state.
Deposits of combustible materials collecting on the floor of the workroom need
to be minimised by regular cleaning.
A covering (lining) for floors and walls of workrooms can be used to facilitate
cleaning of deposits. Any covering (lining) needs changing frequently to
prevent hazardous accumulations.
All wet waste bins which are to be used solely for the disposal of catalyst/
initiator and catalysed resins should be clearly labelled. At least one wet waste
bin is needed for the laminating and/or gel-coating area and the distance
between operations using catalysed resins and a wet waste bin should not
exceed 10 metres.
The water level in each wet bin is to be sufficient to fully submerge all the
volume of waste deposited in that bin.
A period of at least eight hours is required between the time the last amount of
waste is added to a wet bin and when the bin is emptied. This period allows
any resin and catalyst/initiator to react before disposal.
All spillage, including resins, solvents and chemicals, need to be cleaned up in
a safe manner immediately. Cleaning rags or materials are to be disposed of
properly.
NOTE: Suitable cleanup rags or other cleanup materials should be kept
available and properly stored to prevent contamination.
Any spillage of peroxide should be taken up with an inert absorbent such as
sand, vermiculite, diatomaceous earth or perlite. Rags, paper or sawdust are
NOT to be used. Refer to MSDS.
Disposal of resin drums and gel coat containers—refer to MSDS and
Regional Authority requirements.
Disposal of MEKP containers—refer to MSDS and Regional Authority
requirements.
Disposal of composite process waste—for requirements in relation to the
disposal of associated wastes, refer Resource Management Act 1991 and
Regional Authority requirements.

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3.9 DUST
Control of dusts is a general requirement of section 6 of the Health and Safety
in Employment Act 1992.
Where practicable, dusts generated in the process shall be controlled at source.
Such controls can include enclosures provided with extraction ventilation,
removal at source by local exhaust ventilation and exclusion of sources of
ignition. Where practicable, air-driven tools should be used.
Where dust may be generated by sanding or other work, a housekeeping
programme using a suitable vacuum method can be provided. Such machines
or systems are to be designed for the collection of dust. Where fine dust is
formed, the housekeeping programme should include the removal of dust from
ledges as well as from the floor. Sanding operations can be confined to defined
areas to restrict the hazardous area and simplify the housekeeping process.
Portable vacuum cleaners need not be dust ignition proof providing they are
designed for industrial purposes and fitted with a HEPA filter to ensure that the
exhaust air passing through the fan and motor housing is essentially free of all
dust. The collection bag should be less than 200 litres capacity to ensure that
the effects of a possible dust explosion are unlikely to cause harm. Such
cleaners must not be used in the presence of flammable vapours unless the
motor is certified for use in a Zone 1 hazardous area, defined in AS/NZS
2430.3 Parts 1 to 9.
NOTE: The current New Zealand Standard covering combustible dusts is
NZS 6101 Part 2: Classification of hazardous areas: Combustible dusts,
however a new joint AS/NZS/IEC document is likely to be adopted later this
year as an international standard IEC 61241.3.
Explosion venting is required on all fixed explosive dust collection systems.
The National Fire Protection Association (NFPA) Code No. 68: Guide for
venting of deflagrations (1988 edition) should be followed as guidance. Dust
collector vessels constructed from various materials must be able to withstand
different levels of pressure without bursting and guidelines for the relevant
pressures can be found in the appendix of the above NFPA Code.
Where possible, portable tools incorporating dust extraction equipment or other
means of dust extraction at source should be used. The equipment is to be
designed for use in a hazardous area as defined by NZS 6101 Part 2:
Classification of Hazardous Areas: Combustible Dusts.

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3.10 GENERAL STORAGE

All practicable steps are to be taken to ensure that employees at work are not
exposed to hazards arising out of the arrangement, disposal, organisation,
storage or use of things in their place of work or near their place of work. The
storage of equipment, materials and other items should be such as to ensure the
health and safety of employees. Advice on general storage can be obtained
from the OSH publication Safe Stacking and Storage, see Appendix E.

3.11 INSTALLATION AND USE OF SPRAY BOOTHS

(Recommended—to reduce hazardous area/rating and to minimise styrene
vapour concentrations.)
The production of composites differs from normal solvent-based spray coating
operations where 60% to 80% of the deposited material evaporates. Composite
laminating is a spray (or hand) depositing operation where over 95% of the
deposited material forms the item being manufactured and only a small
percentage of styrene (Class 3(b) Dangerous Goods) evaporates. Once the
resin and catalyst/initiator have gelled, styrene emission drops drastically and
very quickly; low styrene emission resins also reduce emissions.
The Spray Coating Regulations 1962 exclude from the definition of spray
coating the processes of chopped strand spraying or gel coating. Hand lay-up,
employing use of rollers and brushes, is not subject to the Spray Coating
Regulations 1962. Spray coating of solvent-based paints is subject to the Spray
Coating Regulations 1962.
For requirements for the installation and use of spray booths, refer to the Spray
Coating Regulations 1962.
The hazardous classification of spray coating booths is to be done in
accordance with AS/NZS 2430.3 Parts 1 to 9.

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4. DANGEROUS GOODS REQUIREMENTS

4.1 AREAS WHERE RESINS OF CLASS 3(b) ARE USED

Where resins classified as dangerous goods of Class 3(b) under the Dangerous
Goods Act 1974 are used, see 4.2 and Appendix C: Excerpts from the
Dangerous Goods Act 1974 and Associated Dangerous Goods Regulations
1985, the following action should be taken:
1. The safety and health provisions contained in this code (see Section 3)
should be observed at all times;
2. The explosive vapour levels in any working area shall be kept below
25% of the Lower Explosive Limit (LEL). (Where people are not
present, the average vapour levels within any space should be kept
below 25% of the LEL);
NOTE: It is recognised that if exposure levels are maintained below the
workplace exposure standards, the LEL will not be exceeded in the
majority of cases.
3. Where products such as acetone, methyl ethyl ketone (MEK), or any
other dangerous goods of Class 3(a), are in use, they shall be kept
separated by at least 6 metres from any source of ignition, unless:
(a) The work area in which they are kept and dispensed, and the
containers in which they are stored, meets the provisions of the
Dangerous Goods Act 1974 and Dangerous Goods Regulations
1985 (see Appendix C);
(b) Depositing guns are flushed into a flash-proof safety container;
and
(c) Sanding operations of composite articles which create
potentially explosive dust concentrations are to be excluded
from the work area by at least a 6 metre separation, see also 3.9.
Where the criteria listed in 4.1 above is met, the area should be classified as
non-hazardous for the purposes of AS/NZS 2430.3 Parts 1 to 9. (This rating is
for fire/explosion only. Toxic fumes at much lower levels can be still
hazardous to health).
Where dangerous goods of Class 3(a) are used other than in accordance with
the conditions set out in 4.1 above, then the hazardous area in relation to those
operations is defined by AS/NZS 2430.3 Parts 1 to 9.
Where the sanding of composite articles creates potentially explosive dust
concentrations, the hazardous area in relation to those operations is defined by

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NZS 6101 Part 2: Classification of Hazardous Areas: Combustible Dusts, see

also, 3.9.
Excluding dangerous goods attached to depositing machines that are normally
in use, the maximum quantity of dangerous goods which may be allowed in the
dangerous goods workroom at any one time is to be specified on the dangerous
goods license issued for the premises. This would normally equate to no more
than one day’s supply of Class 3(b), plus any other stand-by product where
permitted.
There shall be no source of ignition in any defined hazardous area. When
material is brought into or removed from the hazardous area by means such as
a vehicle or crane capable of providing a source of ignition, the vehicle or
crane shall not be activated while in the area unless all operations involving
dangerous goods are stopped and the ventilation system is in operation.
Mixing and finishing rooms are included in these provisions. Refer also to AS/
NZS 2430.3 Parts 1 to 9 for advice and 3.8, 4.2, 5.1, and Appendix C: Excerpts
from the Dangerous Goods Act 1974 and Associated Dangerous Goods
Regulations 1985.
Suitable fire extinguishers and/or water hose must be provided and be easily
accessible in areas where polyester resin is mixed and used.
Smoking shall be prohibited in all workrooms and hazardous areas.
Notices prohibiting smoking shall be prominently displayed in and at the
entrances to hazardous areas or workrooms. All such notices should comply
with NZS/AS 1319: Safety Signs for the Occupational Environment.

4.2 RELEVANT LEGISLATION AND STANDARDS

Acts, Regulations and Standards are constantly under review, it is important to
ensure that you have the relevant legislation and Standards at the date of
consideration. Refer Appendix E: Reference Material, for appropriate
legislation and Standards denoted with *.
NOTE: Provisions in the Hazardous Substances and New Organisms Act 1996
(HASNO Act) will repeal the Dangerous Goods Act and Regulations in the
near future.
Dangerous goods commonly used in the composites industry are classified as
either:
1. Class 3: Flammable liquids, mixtures of liquids, liquids containing
solids in solution or suspension, and nitrocellulose, being:
(a) Class 3(a): Those having a flashpoint lower than 23°C;
(b) Class 3(b): Those having a flash point of 61°C or lower, but not
lower than 23°C.

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2. Class 5: Oxidising substances, and organic peroxides.

3. Class 8: Corrosives.
For characteristics and properties of substances used in the composites
industry, refer to Material Safety Data Sheets provided by the supplier of the
raw materials.

4.3 TRANSPORTATION OF DANGEROUS GOODS

When transporting any dangerous goods, it is essential to ensure compliance
with the Transport Act Amendment 1990. Documentation is to be completed
and supplied to the driver and end-user.
Documentation particular to the substance involved:
1. Proper Shipping Name: taken from the NZS 5433: 1988 Code of
Practice for the Transport of Hazardous Substances on Land as
specified in the Transport requirements; and
2. UN (United Nations) Number related to the Proper Shipping Name; and
3. The Hazard Class for the substance being transported; and
4. The Packaging Group for the substance being transported; and
5. The quantity of substance being transported expressed as the number of
packages by size.
Labelling is to include:
1. Dangerous Goods Diamond appropriate to the substance; and
2. A correct technical name and trade name if appropriate.
NOTE: The Toxic Substances Regulations have additional requirements
regarding wording and letter sizing for some substances.
Placarding of vehicles is to be in accordance with the Transport requirements.
Segregation of dangerous goods is to be in accordance with the Transport
requirements. Separation of incompatible goods, also refer to NZS 5433: 1988
Code of Practice for the Transport of Hazardous Substances on Land.

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4.4 STORAGE OF FLAMMABLE LIQUIDS AND ISOLATION

DISTANCES

Definitions
Storage means to retain the dangerous goods on any premises for a period of
not less than one hour. If it is retained for more than one hour it shall be stored
in a storage depot.
Bulk Storage means containment receptacles of capacity greater than
250 litres. For 250 litres or less capacity it is “otherwise than bulk”.
Storage depots shall be constructed in accordance with the requirements of the
relevant sections of dangerous goods and building legislation. Under certain
circumstances, storage may be provided by the use of metal cabinets in a
suitable area. Advice should be sought from the OSH, Dangerous Goods
Inspector or local authority Dangerous Goods Inspector.
NOTE: For further information see Appendix C: Excerpts from the Dangerous
Goods Act 1974 and Associated Dangerous Goods Regulations 1985.

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5. ELECTRICAL REQUIREMENTS

5.1 GENERAL ELECTRICAL INFORMATION

References: See Appendix E: Reference Material, legislation denoted with **.
All electrical work shall be done in line with the requirements of NZECP 24:
1993: Safety of Electricity in a Hazardous Area.
All electrical work shall be done in accordance with the Electricity Regulations
1997.
All electrical equipment should be installed by a registered electrician and
maintained in a safe condition in accordance with the Electricity Regulations
1997.
Electrical installations and electrical appliances associated with delineated
hazardous zones shall be inspected and re-certified at intervals of not less than
four years for safety and continued compliance with the Electricity Regulations
1993 as detailed in NZECP 24:1993.

5.2 PROTECTION AGAINST STATIC ELECTRICITY

Machinery which produces static electricity shall not be used in hazardous
areas unless protected, e.g. belt drives should have antistatic belts.
Refer to AS/NZS 1020: 1995, which deals with control of undesirable static
electricity.

5.3 POURING FLAMMABLE LIQUIDS

When dispensing flammable liquids to or from a conductive container, the
container should be earthed. If the container and the vessel into which
flammable liquids are poured are conductive then a bond wire between
containers would be adequate.

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5.4 PERSONAL ELECTRICAL EQUIPMENT

Items of personal equipment which are battery-operated (e.g. hearing aids,
miniature transistor radios, key ring torches, calculators, cellphones and pagers,
etc.), are not to be used in a hazardous area, unless:
1. They have been approved for use in hazardous areas, and comply with
explosion-protection requirements.
2. A certificate guaranteeing the absence of an explosive atmosphere has
been issued.
NOTE: AS 2380.1: Electrical Equipment for Explosive Atmospheres—
Explosion Protection: General Requirements specifies that devices
whose parameters can never exceed any of the values - 1.2 V, 0.1 A, 20,
uJ and 25 mW and are considered safe for use in an explosive
atmosphere without further protection, unless they are connected to a
device or a storage element of electrical energy which could cause the
circuit to exceed these parameters.

5.5 PORTABLE ELECTRICAL EQUIPMENT

All electrical equipment used in hazardous areas should be of approved type in
accordance with standards listed in NZECP 24.

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6. NEW DEVELOPMENTS

6.1 UPDATING SYSTEMS

The industry is constantly developing, new applications are being evolved with
alternative techniques of application, and new products being introduced.
While an employer needs to keep up to date with new technology and
developments, it is also their responsibility to take all practicable steps to
ensure the health and safety of their employees. Employers can obtain
assistance and advice prior to introducing new systems or plant from:
1. Local offices of the Department of Labour Occupational Safety and
Health Service (Health and Safety Inspectors, Dangerous Goods
Inspectors, Occupational Health Nurses and Occupational Hygienists),
Ministry of Commerce (Electrical Group), Electrical Supply Authority,
Building Industry Authority, Regional Authority (Building Inspector and
the local authority Dangerous Goods Inspector) and the NZ Fire Service
(Fire Safety Officer).
2. In addition to advice from Departmental officers, further advice is
available from Composites Association of New Zealand (Inc.).

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APPENDIX A: WORKPLACE EXPOSURE

STANDARDS

INTRODUCTION TO THE CONCEPT OF WES

In order to have a basis for making decisions on whether or not the
concentration of a contaminant in the workroom air is at, or above a level likely
to adversely affect the health of persons employed, the concept of a WES value
has gained acceptance. WES values have been assigned for a number of
common workplace contaminants. The basis for setting the standards varies
between substances—some standards are designed to prevent the ill-health
after long-term exposure while others are aimed at preventing short-term
effects.
It must be stressed that compliance with any particular standard does not
guarantee protection from discomfort or possible ill-health for all employees.
The aim should always be to reduce exposure to the lowest practicable level
below the WES.
Four terms are used in defining the exposure standards:
• Workplace Exposure Standard-Time Weighted Average (WES-TWA):
refers to the concentration in the air averaged over an 8-hour day or 40-
hour week.
• Workplace Exposure Standard-Short-Term Exposure Limit (WES-
STEL): refers to the average concentration in air over a fifteen-minute
period.
• WES-Ceiling: refers to a concentration that should not be exceeded
during any part of the day
• Biological Exposure Index (BEI): refers to the concentration of a
contaminant, or a marker, in a biological fluid that results from exposure
equal to the WES level.
All of the above terms are discussed in more detail in the Workplace Exposure
Standard booklet.

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APPLYING THE WES VALUES

Where workplace exposure monitoring is required to determine the level of
airborne substances, it is important to ensure that the correct testing procedures
are employed. The aim is to estimate as accurately as possible the actual
exposure and this is normally achieved by sampling the air from the worker’s
breathing zone (personal sampling). Monitoring should be carried out and
interpreted by a person with adequate training in occupational health or
hygiene.
For most substances the method used will be designed to estimate the total
exposure received over a working day in order to be able to compare the result
with the WES-TWA standard. While a comparison with the current WES value
as a measure of the health risk is one aspect, monitoring is also used to
determine what control measures are required, the effectiveness of the controls
currently in place and the effect that any changes made in the workplace have
on exposure. That is, workplace exposure monitoring is to be used as a guide
to contaminant control, with the overruling object always being to reduce air
contaminant concentrations to the lowest practicable level below the
appropriate WES.
The following example illustrates how monitoring results would be compared
against the WES-TWA and WES-STEL standards. Note that while a single
sample could be taken over the full working day, to get information on the
levels associated with different parts of the process, often more than one
sample would be taken. In this example results are given for styrene in air
monitoring.

Exposure Time
104 ppm 1 hour
15 ppm 4 hours
5 ppm 4 hours

The 8-hour TWA level would be given by:

104 ppm x 1 hour + 15 ppm x 4 hours + 5 ppm x 4 hours
8 hours
= 104 + 60 + 20 ppm
8
= 23 ppm
The current exposure standards for styrene are:
WES-TWA 50 ppm (compared with the result above of 23 ppm)
WES-STEL 100 ppm (compared with the 104 ppm level)

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The 8-hour TWA level of 23 ppm is then below the WES-TWA of 50 ppm but
the WES-STEL of 100 ppm must have been exceeded over the one-hour
sampling period.

WORKPLACE EXPOSURE LEVELS IN RELATION TO THE

MANUFACTURING PROCESSES FOR COMPOSITES
In the manufacturing processes for composites, all practicable steps shall be
taken to maintain the concentration of vapours (and dust) to the lowest
practicable level below the appropriate Workplace Exposure Standard (WES).
The Act requires the employer to take all practicable steps to eliminate air
contaminants. If this is not practicable, the employer is to take all practicable
steps to isolate the contaminant to ensure that it will not be a source or cause of
harm to an employee. Where it is not practicable to either eliminate or isolate
the hazard, the employer is required to take all practicable steps to minimise the
hazard to ensure that it will not become a source or cause of harm.
It is recognised that there may be limited opportunities to eliminate or
effectively isolate substances used in composite manufacturing and that in
many instances the only practicable steps will involve minimising the level of
exposure. For example, styrene is an integral part of the final product and
while it may be possible to limit its release by using low styrene emission
resins, elimination is not possible using current technology. Engineering and
administrative controls are preferred over the use of personal protective
equipment for minimising exposure. (See 3.5 to 3.8).
Exposure standards for a number of substances used in the manufacture of
composites can be found in the Occupational Safety and Health Service
publication Workplace Exposure Standards and Biological Exposure Indices
for New Zealand (see Appendix A). While the WES standards offer guidance
on air concentration levels, it should be noted that they do not guarantee
protection to all people because of the wide range of personal susceptibility.
The WES standards are revised from time-to-time (invariably lower) and
employers should aim to provide controls to reduce atmospheric contaminants
to the lowest practicable level below the WES.
Because the processes involved may vary in terms of the environmental
conditions and equipment design, it follows that it is more appropriate to use
workplace exposure monitoring as an indication of air contamination and
consequently of the need for any remedial action, rather than to set an arbitrary
standard rate of air movement through the workroom.

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APPENDIX B: PROPERTIES AND HEALTH

EFFECTS OF SUBSTANCES USED IN
COMPOSITE MANUFACTURE
RELEVANT DEFINITIONS
Chemical Abstract Service Numbers (CAS NO) means a unique number
given to each definable chemical.
Flash Point of a substance, means the lowest temperature at which the
substance, when tested in a prescribed type of apparatus, liberates vapour at a
rate sufficient to produce an explosive mixture with the air that is in immediate
contact with the substance.
Note: Flash points may be expressed as ‘closed cup’ or ‘open cup’
temperatures. Where available, closed cup temperatures are quoted for
substances used in composite manufacture as listed below.
Explosive Range means the Lower and Upper Explosive Limits (LEL and
UEL) of vapour concentrations in air between which the material will explode
if an ignition source is present.
Vapour Density means the density of the vapour given off by a substance
relative to air which is taken as 1. Most organic vapours are heavier than air.
Methane is the only exception.
Vapour Pressure means the pressure of the vapour in equilibrium with the
liquid at a given temperature, normally 20°C. When the vapour pressure
reaches atmospheric pressure (101.3 kPa) the liquid boils. The vapour pressure
of water is 2.3 kPa at 20°C and 101.3 kPa at 100°C.
Vapour pressure data is sometimes expressed in mm Hg—to convert this to
kilopascals (kPa), multiply mm Hg by 0.1333.
NOTE: For more detailed information obtain copies of Material Safety
Data Sheets (MSDS) from the suppliers.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

ACETONE
SYNONYMS: 2-Propanone, Dimethyl ketone
CAS NO: 67-64-1
WES-TWA: 500 ppm
WES-STEL: 1000 ppm
BOILING POINT: 56°C
FLASH POINT: -17°C
EXPLOSIVE LIMITS: 2.9 - 12.8%
VAPOUR DENSITY: 2.0
VAPOUR PRESSURE: 24.0 kPa @ 200C

Potential Health Effects

Inhalation: At high concentrations (approx. 1000 ppm) slight irritation of the
nose and throat occurs. Unusual exposures to very high concentration (in
excess of 10,000 ppm) may result in headaches, weakness, drowsiness, nausea,
a feeling of drunkenness and vomiting.
Long term exposure to high concentrations (approx. 1000 ppm) has been linked
with the development of nose and throat irritation, dizziness and loss of
strength.
Skin Contact: Direct contact may cause slight irritation—prolonged or
repeated contact may cause defatting of the skin and produce dermatitis. The
risk of absorption through intact skin is considered slight.

Fire Risks
Acetone has an extremely low flash point and will give off enough vapour to be
easily ignitable. It shall never be used near sources of ignition, e.g. flames,
grinding sparks or electric motors.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

COBALT OCTOATE (6%) AND COBALT NAPHTHENATE (6%)

SYNONYM: Cobalt 6
USE: Promoter for polyester and vinyl ester
resins.
BOILING POINT: 150°C
FLASH POINT: 36°C
EXPLOSIVE LIMITS: 0.7%-6.5%
VAPOUR DENSITY: 4.8
VAPOUR PRESSURE: Below 25 (mm of mercury at 20°C)

Potential Health Effects

Ingestion: This is a major hazard as absorption of this material into the body is
potentially fatal. Cobalt Octoate (6%) and Cobalt Naphthenate (6%) contain
white spirit and are thus STANDARD POISONS.
Skin Contact: Is to be avoided as skin irritation is likely.
Inhalation: Practically non-toxic. Due to the small quantities of this material in
workshops, inhalation is not expected to be a significant concern.

Precautions
1. Store and use in separate part of the building to that used for MEKP.
2. DO NOT STORE WITH MEKP as it reacts violently and can cause fire.
3. Keep away from heat and sources of ignition.
4. Avoid contact with oxidising chemicals.
5. Avoid contact with the skin. Use suitable gloves and goggles.

Fire
Use foam, CO2, or dry chemical.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

DIMETHYLANILINE
SYNONYMS: Dimethylaminobenzene, N,N-Dimethylaniline
CAS NO: 121-69-7
WES-TWA: 5 ppm
WES-STEL: 10 ppm
BOILING POINT: 193°C
FLASH POINT: 63°C
LOWER EXPLOSIVE LIMIT: 1%
VAPOUR DENSITY: 4.17
VAPOUR PRESSURE: Less than 0.1 kPa @ 200C

Potential Health Effects

Dimethylaniline can cause depression of the central nervous system and when
exposed to high concentrations can cause weakness and possible respiratory
failure. Overexposure may also lead to damage to the liver, kidney and other
organs, as well as affecting the blood supply (methaemoglobinaemia).
It is readily absorbed through the skin.

Precautions
• Prevent eye contact by wearing chemical goggles.
• Prevent inhalation of vapour by wearing an organic vapour canister
respirator.
• Prevent skin contact by wearing protective (impermeable) gloves.
• Remove any contaminated clothing immediately and wash the skin area
thoroughly.
• Use only in a well ventilated area.

Fire Risks
Dimethylaniline is hard to ignite but if it does burn it will give off toxic fumes
of oxides of nitrogen.

Incompatible Materials
Peroxides and other oxidising agents.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

EPOXY RESINS AND HARDENERS

Potential Health Effects

Because there are a wide range of resins and hardeners used in composite
manufacture it is not possible to give all the properties.
MSDS should be obtained for each resin and hardener used.
Generally they are skin irritants and sensitisers.
The amine hardener vapours will irritate the airways causing coughing and
severe discomfort. They are also corrosive to tissue.

Fire Risks
The finished resin product is inert, however if sanding and grinding take place
the dust produced is potentially explosive.
Dust should be collected and disposed of safely.
Vacuuming dust with a household vacuum cleaner could lead to a dust
explosion if there is a leak in the bag and the motor is arcing.
If the resin product should ignite beware of the fumes which could be acrid and
toxic.

FUMED SILICA (AMORPHOUS SILICA)

WES-TWA: 10mg/m3

Potential Health Effects

Respirators should always be worn when handling dry silica.

Fire Risk
Silica is non-flammable and will not cause dust explosions.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

GLASS FIBRE - DUST

WES: 1 respirable fibre per millilitre air, and 5 mg/m3
inspirable dust.

Potential Health Effects

Inhalation: If fibrous glass particles are inhaled it may result in irritation of the
mouth, nose and throat.
Skin Contact: Direct contact with glass particles may cause mechanical
irritation.
Eye Contact: Airborne glass fibres that come in contact with the eye can cause
mechanical irritation.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

METHYL ETHYL KETONE

SYNONYMS: MEK, 2-Butanone, Butan-2-one
CAS NO: 78-93-3
WES-TWA: 150 ppm
WES-STEL: 300 ppm
BOILING POINT: 79.6°C
FLASH POINT: -7°C
EXPLOSIVE LIMITS: 1.8-10%
VAPOUR DENSITY: 2.4
VAPOUR PRESSURE: 10.3 kPa @ 200C

Potential Health Effects

Inhalation: Concentrations of approximately 350 ppm produce irritation of the
nose and throat. Higher exposures may produce central nervous system
depression with symptoms such a headaches, nausea, dizziness, drowsiness and
confusion.
Prolonged exposure to MEK in combination with other solvents may effect the
nervous system.
Skin Contact: Direct contact may cause slight irritation—prolonged or
repeated contact may cause defatting of the skin and produce dermatitis.

Fire Risks
MEK has a very low flash point and will always give off enough vapour to be
easily ignitable.
It shall never be used near sources of ignition, e.g. flames, grinding sparks or
electric motors.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

METHYL ETHYL KETONE PEROXIDE

SYNONYMS: MEKP, 2-Butanone peroxide
CAS NO: 1338-23-4
WES CEILING: 0.2 ppm
SELF-ACCELERATING
DECOMPOSITION
TEMPERATURE: 60°C approximately

Potential Health Effects

Inhalation: Inhalation of mist or vapour can cause irritation of the nose, sore
throat, coughing, shortness of breath and breathing difficulty. In extreme cases,
life threatening accumulation of fluid in the lungs (pulmonary oedema) can
occur.
Skin Contact: Direct contact with the skin will cause irritation, redness, pain
and blistering. Permanent scarring may result.
Eye Contact: Direct contact with eyes will cause irritation, redness, pain and
blurred vision. Blindness or other permanent damage may result.
It is essential that suitable eye protection be provided and worn. Care should
be taken with contact lenses as even the vapours can get behind the lens and
react with moisture and corrode tissues, but the risk is minimal provided eye
protection is worn.

Fire Risks
MEKP has a high flash point, and is not readily ignited, but it is unstable and
could decompose and burn explosively if exposed to heat, shock or
contamination. Fight fire with water fog from a safe distance.
It should be kept cool (<30°C) and clean, and handled with care.

Incompatible Materials
Reducing agents, metals and metal salts, amines and other promoters used in
unsaturated polyester resins. Spillage may cause delayed ignition of organic
materials such as paper or rags.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

METHYL METHACRYLATE
Note: Methyl methacrylate is sometimes used as a partial replacement for
styrene in some unsaturated polyester resins.
SYNONYMS: MMA, Methacrylic acid methyl ester
CAS NO: 80-62-6
WES-TWA (skin, sens): 100 ppm
BOILING POINT: 101°C
FLASH POINT: 10°C (open cup)
EXPLOSIVE LIMITS: 2.1 - 12.5%
VAPOUR DENSITY: 3.5
VAPOUR PRESSURE: 3.9 kPa @ 20°C

Potential Health Effects

Inhalation: Methyl methacrylate is a strong smelling (low odour threshold)
moderately toxic substance. Low concentrations are irritating to the nose and
throat. Higher concentrations may cause symptoms of central nervous system
(CNS) depression, such as headache, nausea, dizziness, drowsiness and
confusion. Repeated or prolonged inhalation may cause respiratory
sensitisation and mild CNS disturbances.
Skin Contact: Direct contact with the skin may result in irritation or redness.
Repeated or prolonged skin contact can cause allergic skin sensitisation.

Fire Risks
Methyl methacrylate has a low flash point and will give off enough vapour to
be easily ignitable. It should never be used near sources of ignition, e.g.
flames, grinding sparks or electric motors.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

STYRENE
Styrene is the volatile component of unsaturated polyester and vinyl ester
resins.
SYNONYMS: Cinnamene, Ethenylbenzene, Phenylethylene,
Vinylbenzene
CAS NO: 100-42-5
WES-TWA: 50 ppm
WES-STEL: 100 ppm
BOILING POINT: 145.2°C
FLASH POINT: 31°C
EXPLOSIVE LIMITS: 1.1-6.1%
VAPOUR DENSITY: 3.6
VAPOUR PRESSURE: 0.7 kPa @ 20°C

Potential Health Effects

Inhalation: Relatively low levels of exposure may result in respiratory
irritation. Higher concentrations (above 100 ppm) can cause depression of the
central nervous system (CNS) with symptoms such as drowsiness, headache,
confusion, incoordination and in extreme cases, unconsciousness.
Long term exposure to levels in the order of 100 ppm have been shown to
effect the nervous system and produce subtle changes in hearing, balance,
colour vision and psychological performance. The significance of these
finding and the exposure levels they occur at has been the subject of debate.
Skin Contact: Styrene will defat the skin and repeated or prolonged contact
can cause dermatitis (red, itchy dry skin). Styrene can be absorbed through the
skin but this will not usually be the major route of exposure.
Eye Contact: Splashes to the eye will cause severe irritation. Exposure to
vapour at moderate concentrations (approximately 50 ppm) can also result in
irritation.
All practicable steps are to be taken to reduce the vapour concentrations to the
lowest practical level by engineering controls (ventilation) or by isolating the
process.

Fire Risks
The flash point of styrene is greater than the normal ambient temperature (in
New Zealand), therefore it will not normally give off enough vapour to be
ignitable despite the strong smells associated with it.
If it does ignite it will burn with a thick black smoke. Fire fighting should be
with dry powder, CO2 or water fog.

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APPENDIX C: EXCERPTS FROM THE DANGEROUS

GOODS ACT 1974 AND ASSOCIATED
DANGEROUS GOODS REGULATIONS 1985
1. “Protected work” means:
(a) Any dwelling house, or any place of worship, public building,
university, college, school, hospital, public institution, court, theatre, or
other building in which persons are accustomed to assemble; and
(b) Any factory, workshop, office, store, warehouse, shop or other building
where persons are regularly employed for the purpose of any trade or
business, and any other building which a licensing authority may
consider is of sufficient importance or value to warrant protection; and
(c) Any wooden-decked wharf (not being a wharf specifically designed for
the transfer of dangerous goods) public railway (not being a siding), or
timber yard, and any place where it is customary for ships to berth
moor, or lie;
but does not include a small office or other building connected with the
storage or use of dangerous goods on premises in which such storage or use
is a major function.

2. “Public place” means:

A place (other than a protected work) which is freely open to and frequented
by the public; including a place where a section of the public may be
permitted to assemble; but does not include any public place (being private
property) where access to dangerous goods is, in effect, controlled by the
licensee.

3. Storage depots:
Depots for the storage of dangerous goods of Class 3 otherwise than in bulk
shall be divided into 5 types as follows:
Type A: Depots consisting of a compound of clay or clean binding earth
or brick or concrete erected in the open. Such depots may be provided
with an approved hardwood or incombustible platform on which to stand
containers of dangerous goods and may be protected with a shelter roof
having a metal or wooden frame and covered with iron or other approved
materials. They may be protected against unauthorised access by means
of a barbed wire fence, cyclone mesh fence, or other approved method.
Type B: Depots consisting of a metal or wooden frame building covered
externally with iron or other incombustible material and compounded.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

Type C: Depots having walls of brick, concrete block or reinforced

concrete, with a roof of wood and iron or similar approved construction
and compounded.
Type D: Depots with walls of brick, concrete block or reinforced
concrete and a roof of reinforced concrete or equivalent approved
construction and compounded.
Type E: Such other type of building or storage place as may be approved
by an Inspector as being adequate, having regard to the character and the
quantity of dangerous goods stored therein, the type of container in
which the dangerous goods are packed, the isolation distance from
protected works, and any special provision made for fire protection.
For acceptable construction details refer to NZBC Clause F3 as detailed in
the New Zealand Building Code contained in the First Schedule of the
Building Regulations 1992.

4. Table 1: Isolation distances for depots for Class 3(a) in drums over
60 litres capacity (Ref: Regulation 35 Dangerous Goods (Class 3 -
Flammable Liquids) Regulations 1985.)
Every storage depot for storage of Class 3(a) Dangerous Goods (e.g.,
acetone or MEK) in containers of capacity greater than 60 litres shall be
separated from all protected works by not less than the distance laid down in
the following table.

Quantity stored Minimum distance

between the depot and
Depots Depots Depots the title boundary or
Types A and B Type C Type D protected work.
(litres) (litres) (litres) (metres)

Up to 10,000 Nil
Up to 500 2
Up to 250 2,000 3
20,000 4
1,000 100,000 6
200,000 8
10,000 400,000 10
and over
10,000 25,000 15
40,000 17
20,000 60,000 20
200,000 25
and over
40,000 27
60,000 30
and over

Note: Isolation distances may be interpolated for intermediate quantities.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

5. Table 2: Isolation distances of depots for dangerous goods of Class 3(b)

(all capacities) and Class 3(a) in containers less than 60 litres (Ref:
Regulation 36 Dangerous Goods (Class 3 - Flammable Liquids)
Regulations 1985.)
Storage depots for storage of Class 3 (b) dangerous goods in containers of
all capacities and the storage of Class 3 (a) dangerous goods in containers of
less than 60 litres shall be separated from protected works by not less than
the distance laid down in the following table:

Quantity stored Minimum distance

between the depot and
Depots Depots Depots the title boundary or
Types A and B Type C Type D protected work.
(litres) (litres) (litres) (metres)

Up to 250 Up to 1,000 Up to 20,000 Nil

500 1
750 2,000 2
2,000 30,000 3
100,000 4
10,000 200,000 5
400,000 6
and over
10,000 100,000 10
25,000 400,000 15
and over
40,000 17
60,000 20
and over

Note: Isolation distances may be interpolated for intermediate quantities.

For higher quantities refer to the Dangerous Goods Regulations.

In Tables 1 and 2, for any quantity intermediate between two quantities laid
down in the tables, the required distance will be that which is proportional to
the difference in quantity.
For storage of dangerous goods in containers greater than 250 litres, e.g.
bulk —refer to the relevant Dangerous Goods Regulations.

6. Storage of Organic Peroxides

“Organic peroxide” includes an organic peroxide which has been
phlegmatised or mixed with another substance or substances for safety or for
convenience for transport or use. Refer to Regulations 20 to 28 of the
Dangerous Goods (Class 4 - Flammable Solids or Substances, Class 5 -
Oxidising Substances) Regulations 1985.
Storage requirements are:
(a) Catalyst/initiators (organic peroxides) in quantities exceeding 25 kg
shall be kept in a separate building (depot) having a concrete floor,

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

walls of brick, concrete or other approved materials and roof of

wood and iron or similar light construction; and
(b) The doors shall be of timber sheathed with flat galvanised iron and
of approved construction; and
(c) The building shall be well ventilated by vents protected with
stainless steel wire gauze of not less than 3 meshes to the centimetre
and where liquid organic peroxides are to be stored provisions shall
be made to prevent outflow in the event of spillage; and
(d) Shelves and fittings which should be provided shall be of
incombustible material which is compatible with organic peroxides.
Except with the approval of the Chief Inspector of Explosives, no
electric lighting or fittings shall be installed in the building; and
(e) There shall be displayed in a conspicuous position at the entrance to
the building in letters of such size as should be easily read, the
warning “Organic Peroxides. Flammable. No Smoking”; and
(f) The building shall be kept secured against unauthorised entry.
Reference Regulation 24 of the Dangerous Goods (Class 5 -
Oxidising Substances) Regulations 1985.
Every depot for storing dangerous goods of Class 5(b) shall be isolated from
any protected works in accordance with the following table:

Weight of organic peroxide Minimum distance from Minimum distance from

(kg) public place protected works
(metres) (metres)

25 5 10
50 7 15
100 10 20
200 12 25
500 15 35
1000 20 45
2000 25 55
3000 35 80

For quantities in excess of 3000 kg the depot shall be isolated in accordance

with requirements of the Chief Inspector.
For storage of quantities not exceeding 25 kg:
Dangerous goods of Class 5(b) stored in quantities exceeding 10 kg but
not exceeding 25 kg shall be kept either in a building meeting the
requirements of Regulation 24 of the Dangerous Goods Regulations
1985, or in a cabinet constructed, fitted up and maintained as follows—

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

(i) The bottom, top and sides of the cabinet shall be constructed of
steel sheet not less than 1 mm thick, with double wall
construction throughout having a cavity not less than 40 mm thick
and all joints shall be welded.
(ii) The door of the cabinet shall be of construction equivalent to that
of the walls and shall be fitted with a friction-type lock which
will be effective to permit relief to pressure in the event of
explosion, and a sill not less than 50 mm deep shall be fitted
beneath the door.
(iii) There shall be displayed on the door of the cabinet in letters such
size as should be easily read the warning—“ORGANIC
PEROXIDES, FLAMMABLE, KEEP FIRE AND
COMBUSTIBLES AWAY”.
(iv) Unless it is impractical the cabinet shall be vented to the outside
of the building.

7. Depots or cabinets for storage

A depot or cabinet for the storage of dangerous goods of Class 5(b) shall be
used only for the keeping of such goods and the containers in which they are
packed, and no person shall open any such container or weigh out any such
goods in the storage space.

8. Use of flammable liquids—Class 3(a) and 3(b) dangerous goods, and

dangerous goods workrooms
“Dangerous goods workroom” means a room constructed from approved
fire-resisting materials reserved primarily for such use of dangerous goods
of Class 3(a) or 3(b) and ancillary purposes i.e. construction, ventilation,
compounding, egress (see Regulations 128-190).
The construction of dangerous goods workrooms shall be of three types, as
follows:
(a) Type 1: The walls, floor and (unless otherwise approved under sub-
clause 1 of Regulation 134 of the Dangerous Goods Regulations
1985) the ceiling shall be of construction having a minimum fire-
resistance rating of one hour.
(b) Type 2: The walls, floor and (unless otherwise approved under sub-
clause 1 of Regulation 134 of the Dangerous Goods Regulations
1985) the ceiling shall be of construction having a minimum fire-
resistance rating of 2 hours.
(c) Type 3: The walls, floor and (unless otherwise approved under sub-
clause 1 of Regulation 134 of the Dangerous Goods Regulations
1985) the ceiling shall be of construction having a minimum fire-
resistance rating of 4 hours.

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Isolation distances-dangerous goods workrooms

No person shall, without the approval of the Chief Inspector, bring or permit
to be brought into any dangerous goods workroom any dangerous goods in
excess of the following quantities:
(a) Dangerous goods of Class 3(a): 7,500 litres.
(b) Dangerous goods of Class 3(b): 10,000 litres.
Every dangerous goods workroom shall be isolated from any protected work
by the distance specified in the tables set out below having regard to the
class and quantity of dangerous good permitted in that dangerous goods
workroom at any one time.

Dangerous Goods of Class 3(a)

Distance from nearest protected work
Quantity Type 1 Type 2 Type 3
(litres) (metres) (metres) (metres)
500 Nil Nil Nil
1,750 5 Nil Nil
3,000 8 5 Nil
7,500 15 8 5

Dangerous Goods of Class 3(b)

Distance from nearest protected work
Quantity Type 1 Type 2 Type 3
(litres) (metres) (metres) (metres)
750 Nil Nil Nil
2,500 5 Nil Nil
4,000 8 5 Nil
10,000 15 8 5

Classification and zoning of dangerous goods hazardous areas

Classification is done in accordance with AS/NZS 2430.3 Parts 1 to 9.
This means a dangerous goods inspector will zone the workroom for
purposes of ensuring appropriate electrical equipment is installed.

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9. Use of dangerous goods (flammable liquids) otherwise than in a

workroom regulations 147-151
Regulation 149 permits the use of dangerous goods otherwise than in a
workroom, provided that the maximum quantity in any building at any one
time does not exceed 60 litres of Class 3(a) or 200 litres of Class 3(b) with
the following provisions:
(a) The building is sole occupancy;
(b) The dangerous goods work area is of fire resisting construction for a
distance of 6 metres, in all directions, from the place at which the
dangerous goods are used;
(c) Adequate ventilation is provided;
(d) No smoking or source of ignition within 15 metres, if more than
30 litres of 3(a) is used, unless the area is protected by a screen wall;
(e) Regulations 150 and 151 shall also be considered when assessing use
of flammable liquids otherwise than in a workroom.
Regulation 138 prescribes that workrooms shall be at ground level except:
(a) With the Chief Inspector’s approval.
(b) Where quantities used are less than 60 litres of 3(a) or 100 litres of
3(b).
(c) In a building of fire resisting construction entirely under one
occupancy, and the use is an essential phase of the business
conducted in the building.

10. Handling dangerous goods

Packages shall be opened in a work area constructed of fire resistant
materials.
Only goods necessary for immediate use are permitted in the work area.
Maximum permitted is one day’s supply.
No contaminated goods are permitted to be returned to the original container
of good for storage.
All practicable steps shall be taken to prevent fire or explosion.
Any spillage or contaminated goods shall be immediately removed and
disposed of in an approved manner.
No sources of ignition permitted in the area where goods are being used.
Goods shall be protected from:
(a) Direct sunlight;
(b) Impact;
(c) Friction.

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11. Fire protection

Every licensee shall install or maintain fire extinguishing equipment in
accordance with the Dangerous Goods Regulations.
Where, under the regulations, there is a requirement for the provision of
hand fire extinguishers, any such extinguisher should be one of the
following type:
(a) Type 1: Vaporising-type extinguishers, refer Ozone Layer Protection
Act 1991.
NOTE: A permit is required to use this type of extinguisher.
(b) Type 2: Foam-producing extinguishers, i.e. extinguishers which
generate a foam which can be applied to blanket the surface of
burning liquids and other burning substances and which is suitable
for the kind of dangerous goods at risk.
(c) Type 3: Extinguishers delivering an inert gas, such as carbon dioxide
or other similar approved agent.
(d) Type 4: Dry-powder extinguishers, i.e. extinguishers which expel a
powder such as a specially treated sodium bicarbonate by means of a
stream of nitrogen, carbon dioxide, or other approved inert gas.
(e) Type 5: Fractionising dry-powder extinguishers, i.e. extinguishers
which expel a powder such as specially treated decrepitating
potassium salt by means of a stream of nitrogen carbon dioxide or
other approved inert gas.
11.1 A single unit of capacity of the extinguisher shall be respectively as
follows:
(a) Type 1 Extinguishers: The liquid capacity of the extinguisher shall
be not less than 1.8 kg bromotrifluoromethane,
bromochlorodifluoromethane, or equivalent approved capacity of
other approved fire extinguishing agent.
(b) Type 2 Extinguishers: The liquid capacity of the extinguisher shall
be not less than 9 kg.
(c) Type 3 Extinguishers: The extinguisher shall have a capacity of not
less than 4.5 kg of carbon dioxide or equivalent weight of other
approved inert gas.
(d) Type 4 Extinguishers: The extinguisher shall have a capacity of not
less than 2 kg of dry powder.
(e) Type 5 Extinguisher: The extinguisher shall have a capacity of not
less than 2 kg of fractionising dry powder.
A fire extinguisher shall be located and supported so that it is not unduly
subject to corrosion, is readily accessible and removable and is easily
seen.

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MANUFACTURE OF COMPOSITES BASED ON SYNTHETIC RESINS (FIBREGLASS)

The type, location and unit capacity of hand-fire extinguisher shall be in

accordance with the following:
(a) Protected work in which goods of Class 3 are stored, one of either
type 1, 2, 3, 4 or 5, provided that a licensing authority should require
additional extinguishers or extinguishing capacity if warranted by
circumstances;
(b) Depot for goods of Class 3 which open into a protected work, one of
either type 1, 2, 3, 4, or 5.
11.2 Use of dangerous goods of Class 3 (a) or Class 3 (b):
(a) In workrooms, Types 1, 2, 3, 4 or 5 of total capacity equivalent to one
unit for each 20 square meters of floor area.
(b) In workrooms communicating directly to other portions of the
building, as for (a) above plus one additional extinguisher.
(c) In small dip tanks and machines, one either of type 1, 2, 3, 4 or 5.
(d) In small cabinets, one either type 1, 2, 3, 4 or 5.
(e) In situations otherwise than workrooms one either of type 1, 2, 3, 4
or 5.
(f) In containers not exceeding one litre or more, one either of type 1, 2,
3, 4 or 5. If more than one container is used exceeding this capacity,
extra extinguishers will be required.
(g) In open containers not exceeding one square meter of liquid surface
area, one either of type 1, 2, 3, 4, or 5 being additional to any other
requirement of regulation 153(1).
(h) In open containers exceeding one square meter of liquid surface area,
but not exceeding 2.5 square meters, one either type 1,2,3,4 or 5 of at
least two unit capacity, being additional to any other requirement of
regulation 153(2).
(i) In drying rooms, cabinets, or ovens, one either of type 1, 2, 3, 4 or 5.
The Chief Inspector of Dangerous Goods should approve the use of other
types of extinguishers subject to such conditions and ratings as he
considers appropriate.
Where under the regulations there is any requirement for the provision of
a local application fire extinguishing system the system shall of the type
prescribed in the regulations.
On a premise where there is a requirement for a provision of a fixed fire
extinguishing system the licensing authority may call for a report on the
efficiency of the system installed, including its compliance with any
standards imposed by the regulations from a Fire Safety Officer

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appointed under the Fire Service Act 1975 and the licensing authority
should act as it considers fit on any recommendation or adverse comment
made in that officers report, except in the case where the Chief
Inspector’s approval is required, in which event it shall refer the report to
the Chief Inspector.
The Fire Safety and Evacuation of Buildings Regulations 1992, require
all buildings storing hazardous substances to have a Fire Service-
approved evacuation scheme.
NOTE: The Hazardous Substances and New Organisms Act 1996 will
revoke the Dangerous Goods Act and Regulations in due course. Until
such time, the terms and information given above are still valid.

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APPENDIX D: MANUFACTURING PROCESSES

FOR COMPOSITES

A variety of processes are available to fabricate composite products. The

process may be separated into two basic classes, open and closed moulding.
Open moulding includes hand lay-up, spray up, filament winding, and
centrifugal casting. Closed moulding includes matched die moulding, injection
moulding, continuous laminating and pultrusion.
Gel coats which contain no fibre reinforcing can be pre-applied to the mould by
either spraying or brushing to form a thin outer layer of resin. This provides a
smooth, non-porous surface finish in whatever colour is required.
Hand lay-up moulding is the oldest method of preparing composite products.
Layers of fibreglass reinforcement and resin are laid on the mould until the
desired thickness is reached. Rollers and squeegees are used to consolidate the
laminate.
In spray-up moulding, chopped glass or other reinforcements, resin and
catalyst/initiator are deposited simultaneously on to the mould by the use of
special depositor equipment. The mixture is then rolled as for hand lay-up.
In filament winding, continuous filament roving is fed under tension from a
reel through a resin bath on to a shaped revolving mandrel so that the
reinforcement is applied in the required place and at the correct angle.
Centrifugal casting, used in pipe manufacture, involves depositing catalysed
resin and reinforcement inside rotating cylindrical moulds. Centrifugal force is
used to consolidate the composite.
Matched die moulding is a hot press process in which pre-made compounds
containing resin, catalyst/initiator, reinforcements and fillers are pressed
between matched metal dies.
Resin injection or transfer moulding employs matched male and female moulds
and the reinforcement is laid in the mould cavity, and the resin injected at a
specific point using special dispensing equipment with typical pressures of up
to 2 atmospheres.
In continuous laminating, resin impregnated reinforcement supported by a
carrier film is pulled through formers and cured by passage through an oven.
This process is used to manufacture corrugated roof sheeting.
Pultrusion is the process of pulling resin impregnated fibrous material through
a bath of catalysed resin into mandrels or dies that are heated to initiate setting
into a continuous profile or tube.

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APPENDIX E: REFERENCE MATERIAL

ACTS AND REGULATIONS

* Dangerous Goods (Class 3 - Flammable Liquids) Regulations 1985
* Dangerous Goods (Class 4 - Flammable Solids or Substances and Class 5 -
Oxidising Substances) Regulations 1985
* Dangerous Goods (Labelling) Regulations 1978 and amendments
* Dangerous Goods Act 1974
* Ozone Layer Protection Act 1996
* Resource Management Act 1991 and Resource Management Amendment Act
1994
* Transport Act 1962
** Electricity Act 1992
** Electricity Regulations 1997
Building Act 1991
Fire Safety and Evacuation of Buildings Regulations 1992
Fire Service Act 1975
Hazardous Substances and New Organisms Act 1996
Health and Safety in Employment Act 1992
Health and Safety in Employment Regulations 1995
Spray Coating Regulations 1962
Toxic Substances Act 1979
Toxic Substances Regulations 1983
Transport Amendment Act 1990

STANDARDS
AS 2380: Electrical equipment for explosive atmospheres - Explosion -
protection techniques.
AS 2380.1:1989: General requirements
AS/NZS 1020:1995 The control of undesirable static electricity
AS/NZS 1715:1994 Selection, use and maintenance of respiratory protective
devices
AS/NZS 1716:1994 Respiratory protective devices
AS/NZS 2430.3 Parts 1 to 9
AS/NZS 4114:1995 Spray painting booths Pt. 1 Design, construction and
testing.
NZS 4503:1974 Hand-operated firefighting equipment for use in buildings.

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NZS 5433:1988 Code of practice for transportation of hazardous substances

on land
NZS 6101: Classification of hazardous areas
Part 1:1988: Flammable gas and vapour atmospheres
Part 2:1990: Combustible dusts
NZS 8409:1995 Agrichemical users’ code of practice
NZS/AS 1319 Safety signs for the occupational environment

OSH PUBLICATIONS
A Guide to Occupational Skin Disease (1995)
A Guide to Respirators and Breathing Apparatus (1992)
Approved Code of Practice for the Management of Substances Hazardous to
Health (MOSHH) (1997)
A Practical Guide and Workbook for Completing a MOSHH Assessment in
Your Workplace (1997)
Guidelines for the Provision of Facilities and General Safety in Commercial
and Industrial Premises (1996)
Health and Safety Guidelines for the Selection and Safe Handling of Synthetic
Mineral Fibres (1994)
Practical Guidelines for the Safe Use of Organic Solvents (1992)
Safe Stacking and Storage (1989)
Safe Working in a Confined Space (1997)
Workplace Exposure Standards Effective From 1994

OTHER PUBLICATIONS
** NZECP 24:1993 Safety of electricity in a hazardous area
National Fire Protection Association (NFPA) Code 68: Guide for venting of
deflagrations (1988 edition)

FOR FURTHER ASSISTANCE

The following authorities can provide further information and assistance:
1. Occupational Safety and Health Service (OSH), Department of
Labour, branch offices and General Manager’s office.
For advice on the Health and Safety in Employment Act and
Regulations, Spray Coating Regulations, Dangerous Goods legislation,
classification of hazardous areas (spray coating and dangerous goods),
and safety and health issues relating to hazard identification and control,

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combustible dust, machine guarding, workplace facilities, chemicals,

noise, and manual handling.
2. The office of the Chief Electrical Engineer, Energy Inspection,
Energy and Resources Division of the Ministry of Commerce.
For advice on electrical safety and electrical equipment for use in
hazardous areas.
3. New Zealand Fire Service.
For advice on fire safety and emergency procedures.
4. Building Industry Authority and Regional Authority Building
Inspectors.
For advice on building requirements, new and altered buildings,
classification of hazardous areas (dangerous goods), and environment
protection and waste disposal.
5. Ministry for the Environment.
For advice on environmental protection and waste disposal.
6. Standards Association of New Zealand.
Provide information and advice on industry Standards.

All these authorities can be contacted by reference to the local telephone

directory.
The Composites Association of New Zealand (Inc.) also provide
advice on industry developments and the application of the code.

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COMPOSITES ASSOCIATION OF NEW ZEALAND

INCORPORATED

This code of practice was developed by, and remains the property of, the
Composites Association of New Zealand Incorporated and shall not be
reproduced either entirely or in part without written permission from this
Association.
Copies of this code and further information on the Association may be obtained
from the office of the Association by contacting:

Mr G R Henderson
Executive Director
Composites Association of New Zealand Incorporated
PO Box 54 160
Bucklands Beach
Auckland
New Zealand
Telephone: (09) 535 6494
Fax: (09) 535 6494

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