Safety and Health in Composite Industry

301 Pages·2021·7.748 MB·English

by  S.M. Sapuan, R.A. Ilyas, M.R.M. Asyraf

Composites Science and Technology
S. M. Sapuan
R. A. Ilyas
M. R. M. Asyraf
Safety and
Health in
Composite
Industry
Composites Science and Technology
SeriesEditor
MohammadJawaid,LaboratoryofBiocompositeTechnology,UniversitiPutra
Malaysia,INTROP,Serdang,Malaysia
Composites Science and Technology (CST) book series publishes cutting
edge research monographs (both edited and authored volumes) compre-
hensivelycoveringtopicsshownbelow:
(cid:129)
Composites from agricultural biomass/natural fibres include conventional
composites-Plywood/MDF/Fiberboard
(cid:129)
Fabrication of Composites/conventional composites from biomass and natural
fibers
(cid:129)
Wood,andWoodbasedmaterials
(cid:129)
ChemistryandbiologyofCompositesandBiocomposites
(cid:129)
ModellingofdamageofCompositesandBiocomposites
(cid:129)
FailureAnalysisofCompositesandBiocomposites
(cid:129)
StructuralHealthMonitoringofCompositesandBiocomposites
(cid:129)
DurabilityofCompositesandBiocomposites
(cid:129)
ThermalpropertiesofCompositesandBiocomposites
(cid:129)
FlammabilityofCompositesandBiocomposites
(cid:129)
TribologyofCompositesandBiocomposites
(cid:129)
BionanocompositesandNanocomposites
(cid:129)
ApplicationsofComposites,andBiocomposites
To submit a proposal for a research monograph or have further inquries, please
contactspringereditor,RameshPremnath([email protected]).
Moreinformationaboutthisseriesathttps://link.springer.com/bookseries/16333
· ·
S. M. Sapuan R. A. Ilyas M. R. M. Asyraf
Safety and Health
in Composite Industry
S.M.Sapuan R.A.Ilyas
AdvancedEngineeringMaterials SchoolofChemicalandEnergy
andCompositesResearchCentre Engineering,FacultyofEngineering
DepartmentofMechanical UniversitiTeknologiMalaysia
andManufacturingEngineering JohorBahru,Johor,Malaysia
UniversitiPutraMalaysia
Serdang,Selangor,Malaysia
M.R.M.Asyraf
DepartmentofAerospaceEngineering
UniversitiPutraMalaysia
Serdang,Selangor,Malaysia
ISSN2662-1819 ISSN2662-1827 (electronic)
CompositesScienceandTechnology
ISBN978-981-16-6135-8 ISBN978-981-16-6136-5 (eBook)
https://doi.org/10.1007/978-981-16-6136-5
©TheEditor(s)(ifapplicable)andTheAuthor(s),underexclusivelicensetoSpringerNature
SingaporePteLtd.2022
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Preface
SafetyandHealthinCompositeIndustryprovidesthelatestdevelopmentsandbest
possiblesafetypracticesutilizedincompositemanufacturingfacilitiesforstudents,
workers, engineers, and other participants. Composite products range from skate-
boardstocomponentsofthespaceshuttle.Materialswithinthecompositesindustry
areoftencalled“advanced”iftheycombinethepropertiesofhighstrengthandhigh
stiffness,lowweight,corrosionresistance,andinsomecasesspecialelectricalprop-
erties. Several of the manufacturing processes and potential hazards are common
to advanced matrix composites. The materials most frequently used in composite
manufacturing,suchasmatrix(polyester,vinylester,phenolic,epoxies,methylethyl
ketoneperoxide,benzoylperoxide,hardeners,andsolvents)andreinforcementmate-
rials (carbon, glass and Kevlar fibers, honeycomb, and foams) can be highly toxic
to human body. These materials can also be very toxic to the environment when
dumpedoutuncontrollably,creatingmajorfuturehealthandenvironmentalconcerns.
Throughoutthemanufacturingprocess,workersinhalevaporsoftheliquidmatrix,
hardeners,andsolvents/thinners,aswellasreinforcementmaterials(choppedfibers
and particles) in airborne. Milling, cutting, and machining of the composites can
further increase the toxic inhalations of airborne composite particles, resulting in
major rashes, irritation, skin disorders, coughing, severe eye and lung injury, and
other serious illnesses. The major portions of these hazardous materials can be
controlled using appropriate personal protective equipment for the chemicals and
materialsusedincompositemanufacturingandmachining.Thisbookcoverstopics
of (1) introduction to safety and health, (2) composites and biocomposites: manu-
facturing and processing, (3) emission of hazardous air pollution in the composite
production,(4)safetyincompositelaboratory,(5)designforsafetyincomposites,
(6) carbon footprint in health care, (7) safety issues in composite materials, (8)
firesafetyinpolymers composites,(9)healthhazard fromcomposites,(10)safety
and health issues associated with fiber-reinforced polymer composites in various
industrial sectors, (11) occupational safety and health administration in composite
industry,(12)theroleofbiocompositesinhealthissuesduringCOVID-19pandemic,
and(13)safetyissuesintransportationdesign.Thisbookincludescommentaryfrom
leadingacademicexpertsinthefieldwhopresentcutting-edgeresearchonadvanced
v
vi Preface
composite materials. Illustrations,figures, and tables willbe included in this book
in order to make it easier for students, workers, engineers, and other participants
tounderstandthecontentsofthisbook.Theenduserwillknowthatthesafetyand
healthshouldbepracticedincompositeindustryandtheirrightincompositeindustry.
Besidesthat,thecompositesindustryplayerscanupgradetheircurrentsafetysystem
totherecommendedpracticedsystem.Alotofproblemswillbesolvedbyintegrating
thecurrentsystemandadvancedtechnologysystemfromextensiveresearch.
Serdang,Malaysia S.M.Sapuan
JohorBahru,Malaysia R.A.Ilyas
Serdang,Malaysia M.R.M.Asyraf
Contents
1 IntroductiontoSafetyandHealth .............................. 1
1.1 Introduction ............................................. 1
1.2 AccidentandItsConsequences ............................. 2
1.3 Losses .................................................. 3
1.4 UnsafeActsandUnsafeConditions ......................... 4
1.5 Engineering Knowledge in Safety and Health
forCompositeFields ...................................... 5
1.5.1 SafetyEngineering ................................ 5
1.5.2 ErgonomicsandHumanFactorEngineering .......... 5
1.5.3 ChemicalEngineering ............................. 6
1.5.4 FireProtectionEngineering ........................ 6
1.5.5 IndustrialEngineering ............................. 6
1.6 PreventiveStrategiesandApproach ......................... 6
1.6.1 FrequencyStrategy ............................... 7
1.6.2 SeverityStrategy ................................. 8
1.6.3 CostStrategy ..................................... 8
1.6.4 CombinedStrategy ................................ 8
1.7 TheThreeEs’ofSafety ................................... 8
1.8 SignificanceforSafetyandHealthMonitoring ................ 9
1.8.1 KeepingPeopleSafe .............................. 9
1.8.2 Injury,Cost,Time,andMoney ...................... 9
1.8.3 FewerInjuriesIncreaseProductivity ................. 10
1.8.4 IncreasePublicPerception ......................... 10
1.8.5 MinimizingLegalLiabilities ....................... 10
1.9 Conclusions ............................................. 11
References .................................................... 11
2 Composites and Biocomposites: Manufacturing
andProcessing ................................................ 15
2.1 Introduction ............................................. 15
2.2 Polymers ................................................ 17
vii
viii Contents
2.2.1 SyntheticPolymers ............................... 17
2.2.2 NaturalPolymers ................................. 18
2.3 Fibres .................................................. 19
2.3.1 SyntheticFibres .................................. 19
2.3.2 NaturalFibres .................................... 21
2.4 ExtractionofFibres ...................................... 21
2.4.1 RettingProcess ................................... 22
2.4.2 MechanicalDecortication .......................... 23
2.4.3 MechanicalDehulling ............................. 24
2.5 FibreTreatments ......................................... 24
2.6 ManufacturingProcessofCompositesandBiocomposites ...... 25
2.6.1 HandLay-Up .................................... 25
2.6.2 Pultrusion ....................................... 26
2.6.3 CompressionMoulding ............................ 27
2.6.4 InjectionMoulding ................................ 27
2.6.5 VacuumBagging/Moulding ........................ 28
2.6.6 ResinTransferMoulding .......................... 28
2.7 Conclusions ............................................. 29
References .................................................... 30
3 Emission of Hazardous Air Pollution in the Composite
Production ................................................... 35
3.1 Introduction ............................................. 36
3.2 StyreneEmissions ........................................ 37
3.2.1 WhatIsStyrene? ................................. 37
3.2.2 ImportanceandUsesofStyrene ..................... 37
3.3 FormaldehydeEmissions .................................. 38
3.3.1 WoodBasedComposites ........................... 38
3.3.2 BuildingMaterialsandIndoorsProducts ............. 39
3.4 Volatile Organic Compound (VOC)
Emissions—Formaldehyde ................................ 39
3.5 IndoorAirQuality ........................................ 41
3.5.1 SubsequentFormaldehydeReleaseRegulations ....... 42
3.6 EnvironmentalIssuesRelatedtoHealth ...................... 43
3.6.1 EmissionofCompositeProduction .................. 43
3.6.2 StyreneEmissionsEffect .......................... 44
3.6.3 FormaldehydeEmissionsEffect ..................... 46
3.6.4 VOCsEmissionsEffect ............................ 47
3.7 National Standard for Hazardous Air Pollutants
inCompositeProduction .................................. 50
3.7.1 CleanAirAct(CAA)Amendments1990 ............. 50
3.7.2 IndustrialCodeofPractice(ICOP)onIndoorAir
Quality(IAQ) .................................... 52
Contents ix
3.7.3 Occupational and Safety (Use and Standard
of Hazardous Chemical Exposure to Health)
Regulation2000(USECHHRegulation) ............. 54
3.7.4 InternationalRegulationsandGuidelines ............. 54
3.8 ControlofCompositePollution ............................ 56
3.8.1 LawRegardingtheControlofCompositePollution .... 56
3.8.2 UsageofLow-StyreneMaterials .................... 58
3.8.3 VOCAbatementSystem ........................... 59
3.8.4 LoweringtheUrea–FormaldehydemolRation
intheSynthesisofUrea–FormaldehydeResin ........ 59
3.9 Conclusions ............................................. 63
References .................................................... 64
4 SafetyinCompositeLaboratory ................................ 67
4.1 Introduction ............................................. 67
4.2 OccupationalSafetyandHealthAct(OSHA)1994 ............ 69
4.3 Safety .................................................. 69
4.4 LaboratorySafetyKnowledge .............................. 70
4.5 GeneralLaboratorySafetyRulesandGuidelines .............. 70
4.6 Awareness,Attitude,andActionTowardSafety ............... 71
4.7 SafetyPractices .......................................... 72
4.8 General Rules and Policies for General Users
oftheAdvancedCompositesLaboratory ..................... 72
4.9 PreliminaryTrainingCoursesonSafety ..................... 74
4.10 RawMaterialHandlingandPreparation ..................... 74
4.11 PersonalProtectiveEquipment ............................. 75
4.11.1 EyeProtection ................................... 75
4.11.2 LaboratoryCoatsandJackets ....................... 76
4.11.3 FaceProtection ................................... 77
4.11.4 HandProtection .................................. 78
4.11.5 RespiratoryProtection ............................. 79
4.12 WasteDisposalManagement ............................... 79
4.13 EquipmentInspectionandMaintenance ..................... 80
4.13.1 ElectricalPoweredLaboratoryEquipment ............ 81
4.13.2 EquipmentwithCompressedGases ................. 87
4.13.3 WorkingwithExtremePressuresandTemperatures
Equipment ....................................... 87
4.14 EmergencyEquipmentandResponseProcedures ............. 88
4.14.1 FireSafetyEquipment ............................. 89
4.14.2 SafetyShowersandEyewashUnits .................. 89
4.15 Conclusions ............................................. 90
References .................................................... 91