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Pollution Prevention for Auto Body and Auto Repair Vocational Programs

Prepared bv

Northeast Waste Management Officials Association Androscoggin Valley Council of Governments

Oxford Hills Comprehensive High School

Funded by United States Environmental Protection Agency

December 1998

Resource Guide Pollution Prevention for Auto Body and Auto Repair Vocational Programs - A Curriculum

T- ! Prepared by . !

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. Northeast Waste Management Officials Association Androscoggin Valley Council of Governments


Funded bv United States Environmental Protection Age,ncy

i December 1998 I

Resource Guide Pollution Prevention for Auto Body and Auto Repair Vocational Programs - A Curriculum

Prepared by




December 1998

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Resource Guide - Pollution Prevention for Auto Body and Auto Repair Vocational Programs = A Curriculum

Introduction

The environmental, health and safety curriculum is for high school students in auto repair and auto body vocational programs. It focuses on preventing pollution, reducing waste at auto shops and “ k i n g health and safety hazards.

The curriculum is based on the idea that students prefer learning by doing or hands on instruction. By preparing the cuniculum in small modules, the curriculum was designed to integrate easily into existing lessons or to supplement course work. This Resource Guide is an introduction to the subject which should be covered and provides ideas for integrating the idiomation into classroom instruction.

Each module includes the following infomation:

e Pre and/or Post Test - Teacher Version Pre and/or Post Test - Student Version Description of the issue including information on environmental regulations, health and safety concerns, pollution prevention measures and best management practices

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e Class exercises Handouts

The pre andor post tests can be used in their entirety or questions can be excerpted for use in regular curriculum tests. The text describes the issues, applicable regulations and specific pollution prevention practices. It is designed for the teacher to read to prepare lessons and not for direct student use. The class exercises are suggested, hands-on activities to engage the students in pollution prevention activities and other skills necessary for the work force. Finally, we have made a list of pages in the curriculum which could be photocopied as handouts and used to facilitate in-class discussions.

A Note on the Curriculum Design

Often environmental curricula are developed as an add-on to the “regular” curriculum. And, too often, this is a reflection of how environmental requirements and preventing pollution are viewed in the working world. People view their “real” job as “auto repair” and then on top of that, they “have” to comply with environmental regulations.

We believe that integrating environmental, health and safety awareness into the everyday

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workings of an auto repair or auto body shop is beneficial in many respects. Careful attention to environmental and safety regulations can actually help a business to run more efficiently. For instance, less waste means higher profits. A clean shop is an appealing shop for customers as well as a safer workplace. Fewer hazardous chemicals translate to lower purchasing costs and less liability.

Hence, whenever possible, we have tried to design this pollution prevention and health and safely curriculum to fit into existing lessons on DOING auto repair. In general, we do not recommend separating pollution prevention/ health and safety from general instruction. However, in some instances, the ‘‘standad’ shop practices which include pollution prevention and safe work practices that students learn at school may not be what they experience in the working world. Because of this concern, we recommend pointing out, in some cases, that you are teaching the newest practices and not all shops are as up to date as the schools. In this way, students will be prepared to encounter different working practices and will understand that there are preferred ways of doing auto repair work. To help reinforce this understanding, we recommend that teachers select one or two modules fkom the curriculum and teach them as designed.

Summary of the Curriculum

The curriculum contains five units.

Unit 1 serves as the introduction to the course and contains information on hazardous waste, pollution prevention and health and safety. It lays the groundwork for the remainder of the curriculum.

Unit 2 is specific to auto body programs. It discusses the environmental, health and safety concerns in surface preparation, the spray application process and the spray equipment cleaning.

Unit 3 applies both to auto repair and auto body programs. It discusses all the various fluids and wastes that go into and come out of a vehicle and how to piopeily manage them. In each module, pollution prevention is a major focus.

Unit 4 contains personal protection and health and safety information and is applicable to both programs. However, module 3 discusses isocyaates, which we of particulw concern in auto body programs.

Unit 5 serves as a summary for the entire course. It includes a review of all of the information from the entire curriculum and applies it in a hands-on fashion. It prepares students for a compliance inspection by doing an audit of their own shop and/or an audit of the other program’s shop.

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) Module by Module Summary of the Curriculum

The following sections describe the contents of each module and provide suggestions for student handouts to introduce materials from the modules. Also included are resources for additional idomation.

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UNIT 1 - COURSE INTRODUCTION

Module I -Hazardous Wastes (pages 1 - 11)

e The “cradle to grave” system of regulations for the proper management of hazardous wastes includes regulations for generators of hazardous waste, transporters, and facilities for recycling, treatment and disposal. ’ Auto shops may be hazardous waste generators.

e A waste is hazardous if it: a) is specilidy listed by the Maine DEP as a hazardous waste, or b) exhibits one of characteristics of hazardous waste - ipitability, corrosivity, reactivity or toxicity or c) is a mixture of a hazardous waste listed by the Maine DEP and other non-hazardous materials.

An example of a listed hazardous waste is spent solvent used in parts cleaning. Characteristic wastes are discarded gasoline, battery acid or certain paint wastes.

Pollution is released to the air, surface water, soil and groundwater. When wastes are poured on the ground or down a drain, pollutants can contaminate water supplies or harm fish and wildlife.

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People can be exposed to hazardous substances through ingestion, skin absorption, inhalation and injection.

Suggested Student Handouts: How Pollution Gets Into the Environment - page 7 Exposure to Hazardous Substances - page 8 Video: “The Tuned Up Shop: Best Management Tips for a Smooth Running,

Environmentaiiy Friendly Auto Repair Operation - Contact New England Interstate Water Pollution Control Commission 978-323-7929

Additional Resources wwwxcar-rreenhk.org - federal government web site with state regulatory information www.asashop.org - Automotive Service Association web site includes regulatory

ME Small Business Assistance Center - 207-287-6188 information

http://wwwxcar-rreenhk.org

http://www.asashop.org

j Module 2 - Hazard Communication Standard @ages 12 - 27)

0 The Hazard Communication Standard, which is fiequently called the Employee Right to Know law, is a law that requires employers to explain the hazards of chemicals they produce or use. The technical information the manufacturers prepare are called Material Data Safety Sheets (MSDSs).

0 The MSDS sheets must be kept on file by the employer and be made available to people using the chemicals. Auto shops in schools must also keep a set of MSDS sheets for hazardous materials used.

0 Employers must also: a) develop a written hazard communication program to inform employees of hazardous materials and how they are to be handled, b) conduct employee training on hazardous materials and c) ensure all containers are properly labeled.

0 While there is no required format €or an MSDS, the h e r i c a n National Standards Institute recommends the following format: Section I: Chemical product and Company I n f o d o n , Section 2: Composition, Information or Ingredients, Section 3: Hazard Identification, Section 4: First Aid Measures, Section 5: Fire-Fighting Measures, Section 6: Accidental Release Measures, Section 7: Handling and Storage, Section 8: Exposure Controls and Personal Protection, Section 9: Physical and Chemical Properties, Section 10: Stability and Reactivity, Section 1 1 : Toxicological Information, Section 12: Ecological Information, Section 13: Disposal Considerations, Section 14: Transport Infomation, Section 15: Regulatory Information, and Section 16: Other Information.

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Suggested Student Handout A Quick Guide to Reading An MSDS Sheet - page 17

Additional Resources ME OS€?? Ccmltation - 207-624-6460 NOSH - National Institute for Occupational Safety and Health - 1-800-35-NOSH www.labsafety.com - Includes information on OSHA regulations as well as other health

and safety information. www.cac.eov/~iabshQ~~~b~e~h~! - curricula for promoting health and safety in

vocational programs including automotive programs. httI,://www3.uchc.edu/-safety/- web site for MSDS sheets

Module 3 -Pollution Prevention @ages 28 - 44)

0 Pollution prevention encourages more efficient use of hazardous materials, energy, water

hazardous ones, or changing shop practices to create smaller amounts of hazardous waste. and other natural resources. It includes using non-hazardous materials as a substitute for

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http://www.labsafety.com

Pollution control involves treating and managing pollution once it is created while pollution prevention includes reducing the pollution created in the first place. For parts cleaning solvents, pollution control is shipping solvents off-site for recycling or burning while pollution prevention is replacing a hazardous solvent with a non-hazardous cleaner.

Pollution prevention can save money by: a) reducing health costs fiom employee exposure to hazardous materials, b) decreasing wasted raw materials, c) reducing costs for hazardous waste disposal, d) decreasing costs for managing wastes, and e) limiting environmental liability.

Pollution prevention includes: a) reducing; chemical usage and waste generation, b) reusing materials before recycling or disposing and c) recvcling hazardous materials.

The steps for instituting pollution prevention programs are: Step 1 - Look at all the chemicals and oils you handle. Which chemicals come in with the car and which ones end up as waste? Then look at shop purchasing records and ask why is this chemical ~ecesszry? Step 2 - Decide wh& poflction prevention techniques yoy want to do, Evaluate all the chemicals and waste streams to determine which ones you want to tackle first. Step 3 - Put the new pollution prevention technique into place.

Suggested Student Handouts: 1 Pollution Prevention vs. Pollution Control - page 3 1

Pollution Prevention Can Save Money - page 32 Steps for Doing Pollution Prevention - page 35 Pollution Prevention Tip Sheet for Auto Repair Shops - Unit 5 , page 8 Video: Lany’s Auto Works -Contact Mission College Television (408) 988-2200, Ext.

3217.

Additional Resources ME Small Business Assistance Center - 207-287-6188 US. EPA Region I, New England Environmental Assistance Team - 800-90-NEEAT www.iwrc.org - Iowa Waste Reduction Center has a curriculum for auto repair and auto

body vocational programs and numerous publications on pollution prevention. www.dnrec.state.de.us/delauto.htm - Succinct pollution

prevention guide for auto repair shops. www.eDa.state.oh.us/oDD/facf35.html- Fact sheet on pollution prevention processes for

auto repair shops.

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http://www.iwrc.org

UNIT 2 - AUTO BODY - POLLUTION PREVENTION

Module 1 - Surface Preparation (pages 1 - 8)

0 To reduce solvent usage during surface preparation, shops can use: a) prewashing with soap and water, b) water-based cleaners or c) solvent-based cleaners as a last resort.

0 Wastewater generated h m vehicle cleaning may contain oil, dirt, soaps and solvents. Avoid outside vehicle washing. Consult with your city or town Code Enforcement Officer (CEO) to determine the acceptable options for vehicle washing.

0 Sludges and rags contaminated with solvents may be hazardous wastes. Ifrags are cleaned at licensed laundries, they are exempt h m hazardous waste regulations.

0 Dust from sanding operations may contain heavy metals such as lead and chromium. Breathing this dust is harmful to the lungs and nervous system. Use ventilated mech~cal sanders to avoid breathing contaminated dust.

Suggested Student Handout Hazard Controls - Control of Dusts fiom Sanding in Auto Body Repair Shops - page 6

Additional Resources www.autobodvDro.com - source of auto body information including regulations www.autobodvonline.com - source of auto body information including regulations www.abm.com - Auto Body Repair News online ME OSHA Consultation - 207-624-6460 NOSH - National Institute for Occupational Safety and Health - 1-800-35-NOSH

Module 2 - Spray Application Process (pages 9 - 24)

0 There are two major types of wastes associated with automotive painting: a) air emissions in the form of volatile organic compounds (VOCs) and particulates, and b) solid and hazardous wastes including waste paints and solvents. VOCs form smog which can interfere with proper lung functioning causing chest pain, shortness of breath and aggravation of asthma.

0 55% of the VOCs come fiom topcoats. 20% come fiom equipment cleaning, 17% result from undercoats and 8% come fiom surface preparation.

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0 In each phase of the painting of a vehicle, there are ways to " i z e the amount of VOCs emitted. For example, when using primer-surfacer, ensure first, that all major body imperfections are removed prior to priming to avoid using extra primer as a body filler.

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http://www.autobodvDro.com

http://www.autobodvonline.com

http://www.abm.com

VOC emissions can also be reduced by improving transfer efficiency. Factors affecting transfer efficiency include: spray equipment type, gun set up, spray angle, spray distance, spray techniques and equipment maintenance and practices.

0 Much of the paint waste results fiom too much paint being mixed for the job. Using an in-house paint mixing system reduces the material costs of paints.

Suggested Student Handouts Comparison of Low VOC Content Paint Formulations - page 9 Reducing VOC Emissions in Each Phase of Auto Body Surface Coating -page 10 Fact Sheet - Tips h m King County Auto Body Shops - page 19 Control of Paint Overspray in Auto Body Repair Shops - page 21 Fact Sheet - HELP Paint Guns - page 23 Case Study - Auto Body Repair Shop Waste Reduction Measures - page 3 1

Additional Resources mw=iwrcory/STAlLhtml- Iowa Waste Reduction Center’s Spray Technique Analysis

and Research (STAR) Program focuses on improving the efficiency of manual spray painting operations. Instead of focusing on the spray guns or coatings used, the STAR Program analyzes a painter’s spray techniques.

Module 3 - Spray Equipment Cleaning (pages 25 - 33)

a Approximately 20% of VOCs released fiom auto refinishing occurs during equipment cleaning operations. In manual gun cleaning, the solvent is exposed to the air during most of the cleaning operations and therefore much of it evaporates.

a Manual gun cleaning can use up to 3 times the amount of solvent as an enclosed gun washing system. There are measures to reduce solvent usage in manual gun cleaning including: a) spraying into an enclosed backdrop to catch the solvent for reuse or recycling and b) storing the dirty solvent in a closed container to let the solids settle to the bottom then pouring off the clear solvent for reuse.

a Mechanical gun cleaners can reduce the amount of thinner used during the cleaning process by more than 50% and reduce labor for equipment cleaning by 60%.

a Paint sludge will collect in the gun washer and must be removed on a regular basis to keep the gun washer in working order. The paint sludge is a hazardous waste.

Suggested Student Handout Case Study - Auto Body Repair Shop Waste Reduction Measures - page 3 1

Additional Resources

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See Modules 1 and 2 above

UNIT 3 - FLUIDS AND WASTE MANAGEMENT - POLLUTION PREVENTION

Module 1 - Used Oil and Filters, Shop Wipers and Absorbents (pages 1 - 12) 0 Motor oil becomes contaminated through normal use by the breakdown of additives in

the oil and gasoline. Contaminants found in oil include: zinc, chlorinated solvents, lead, benzene, toluene, xylene and napthalene. The toxic effects of contaminan ts can cause difficulty in breathing, skin irritation and headaches. It is recommended that technicians use gloves when performing oil changes.

0 Used oil must be managed according to the ME DEP’s regulations. Used oil must be stored in proper containers, labeled, not mixed with other materials and placed on nonporous &xes for storage.

There are ways to catch oil leaks and spills and reduce potential contamination including using: a) drip pans to catch leaking oil, b) dry cleanup methods such as reusable absorbent pads, a bristle broom and brush or mops that absorb only oily liquids, c) rags that can be laundered, and d) dry clean-up compound.

0 Waste oil filters are not regulated as hazardous wastes in Maine as long as the oil is removed h m the filters before disposal by puncturing and hot-draining, or hotdraining and crushing, or dismantling and hot-draining for at least 12 hours.

e Waste oil soaked absorbents may be placed in the trash in small quantities. Larger quantities must be managed as “special waste.” Absorbents should be used as a last resort because once the waste oil is absorbed into the absorbent, it can not be recovered for recycling. Use dry-cleanup methods first. See above.

a The best method for handling waste oil soaked rags is to send them to a laundry licensed to wash rags. Alternatively, those rags that are not saturated or dripping may be thrown in the trash as solid waste.

Suggested Student Handouts Case Study - Oily soil - Issues of Waste Oil Management and Storage at Service Stations

Handling Waste Oil- A Quick Guide for Auto Repair Shops - page 11 and Repairs Shops - page 10

Additional Resources To purchase absorbent pads, contact Lab Safety 800-356-0783; CCP Industries 800-321-

http://enviro.nfesc.navy.miVD2library/6-14 896.html- Lubricant analysis programs 2840; Chem Oil Away 800-625-3268.

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http://enviro.nfesc.navy.miVD2library/6-14

for fleet maintenance used to test how long a lubricant remains effective. A lubricant analysis program may allow longer intervals between changing lubricants.

The Filters Manufacturers Council - 1-800-99-FILTER (993-4383) ME Small Business Assistance Center - 207-287-61 88 - Call for verification of a

laundry's compliance status or for other waste oil questions

Module 2 -Spill Prevention and Control Procedures @ages 13 - 19) a Some of the common operations that result in spills and leaks are oil changes, radiator

flush and fill, radiator repair, parts washing and carrying dripping parts across the room.

0 Preventing spills can be accomplished through good housekeeping, managing and controlling hazardous liquids, catching dripping hazardous liquids and maintaining a controlled storage area

0 Using disposable oil absorbents such as kitty litter, creates additional waste to be disposed. Instead of using disposable absorbents for spills, use a spill kit that includes: one mop and bucket dedicated to cleaning oil and another for antif?eeze, launderable cloth rags, squeegee, storage containers, drain covers, absorbent socks or pads. Clean oil collected using these methods can go into the waste oil tank.

0 AU shops must have an emergency response plan and equipment for handling emergencies such as a spill kit and fire extinguishers.

Suggested Student Handouts Preventing Spills - page 16 Cleaning Up Spills - pages 17 and 18

Additional Reso-mces To purchase absorbent pads, contact Lab Safety 800-356-0783; CCP Industries 800-321-

2840; Chem Oil Away 800-625-3268.

Module 3 - Engine Coolant (Antifreeze) (pages 20 - 27)

0 The active ingredient in antifreeze is ethyleneglycol. It is considered to be moderately toxic. Animals are attracted to the antifreeze's sweet odor; they may drink it, suffer adverse effects and possibly death.

0 Antifreeze drained from cars is likely to contain lead, benzene and other contaminants which, if present at elevated levels, may cause it to be classified as a hazardous waste by failing the toxicity characteristic leaching procedure (TCLP). See page 6, Unit 1, Module 1 on hazardous waste.

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a Maine DEP does not allow the dumping of antifieeze to a sewer, septic system or the environment.

a Management options for spent antifieeze include on-site recycling in equipment owned and operated by a shop or recycling by a service company.

a Antifreeze can be recycled through a distillation or atration process. Still bottoms from the recycling process are potentially hazardous wastes.

0 A less toxic substitute for ethylene glycol is propylene glycol which is available in retail stores. Note that some automotive manufacturers may not approve of propylene glycol for use in their engines.

Suggested Student Handouts Exercise: Calculate the Cost Savings fiom Antif?eeze Recycling - page 26

Additimd Rescmces www.recvcle.net/recvcle/liauids/coovindex.htd - Listing of coolant and refrigerant

recycling categories and compdes.

Module 4 - NCReflgerants (pages 28 - 33)

Freon R-12 was used in air conditioners manufactured before 1994. chloroflurocarbon (CFC) which accounts for 20% of all CFCs then in use in the country.

This refiigerant is a

CFCs are a problem because they release chlorine in the atmosphere which destroys stratospheric ozone. 85% of the atmospheric chlorine came fiom CFCs and other chemicals. Only 15% of the chlorine was natural. The Montreal Protocol, signed by 75 countries, was designed to protect stratospheric ozone and phase out the production of CFCs. CFCs were phased out by 1996.

As ozone is destroyed, higher amounts of ultra violet radiation (WB) reaches the earths surface. This UVB has been linked to skin cancer, cataracts and harm to crops, anhals and marine life. It could also weaken the human immune system.

Automobile air conditioners manufactured after 1994 use R-134a. Regulations were written to prevent the release of previously manufactured CFCs during servicing and to require that technicians be certified. Also, the repair facility must have approved refr-igerant recycling equipment.

Refrigerant should not be vented to the atmosphere. To prevent refr-igerant loss during servicing, evacuate all reiligerant prior to maintenance or repair of air conditioning systems.

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) Additional Resources 1 www.recvcle.net/recvcle/Liauids/cool/index.html - Listing of coolant and refiigerant

www.ari.orF/intro.html- Air-conditioning and Refiigeration Institute web site. U.S. EPA Region I, New England Environmental Assistance Team - 800-90-NEEAT

recycling categories and companies.

Module 5 -Parts Cceaners (pages 34 - 40)

0 Parts washers often contain solvents made up of chlorinated chemicals which can cause cancer. Materials Data Safety Sheets are a good source of idormation on solvents.

0 Spent solvents are generally considered to be hazardous wastes because they are either ignitable or toxic. Petroleum naphtha or mineral spirits may be ignitable while immersion cleaner, cold parts cleaner and carburetor cleaner are typically hazardous based on the toxicity of the solvent.

0 Alternatives to solvent cleaners are aqueous or alkaline cleaners. High pressure washing and microbial cleaners are particular types of aqueous cleaning.

0 One pollution prevention opportunity for parts washers is to use a two-step precle&g/fhal cleaning system. This allows the use of more contaminated solvent in the precleaning tank while reserving the newer solvent for the final cleaning. The two- step process extends the usable life of the solvents. i

Suggested Student Handouts Best Management Practices for Handling Parts Cleaners - page 38 Exercise: Cost Savings Estimate for Hot Soap Degreaser - page 40

Additional Resources www.dnr.state.~a.us/dnr/D2ad/pblcations/auto2.html- Pollution prevention information

“Reducing Waste From Solvent Sink Parts Washers” 800-685-2443 for parts cleaning.

Module 6 -Asbestos @ages 41 - 45)

Brake linings and clutch facings sometimes contain asbestos. Millions of asbestos fibers may be released into the air during servicing. These fibers may linger for a long time after the work was done and may result in asbestos exposure through eating or smoking.

0 Exposure to asbestos can result in scar tissue in the lungs which eventually may lead to a very serious condition called Asbestosis. A large majority of the deaths from exposure to asbestos result from lung cancer. The lung cancer risk for smokers exposed to asbestos

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is greater than for non-smokers.

0 Asbestos must be disposed in a special landfill that has a permit to receive asbestos. It must be wetted down and double bagged prior to transport.

0 The best measure to reduce asbestos exposure is to do bralce cleaning work in an enclosure which slips easily over the brake assembly and forms a tight seal against the backing plate. The brake dust is sucked into the vacuum cleaner equipped with a special HEPA (High Efficiency Particulate Air) filter, which can remove the tiny asbestos fibers..

Suggested Student Handouts Best Management Practices for Avoiding Exposure to Asbestos during Brake Work -

Video on Handling Asbestos - “Don’t Blow It” - Contact TCSA Assistance, EPA, page 45

401 M St, Wasb@on, DC 20460

Additional Rso-mes ME OSHA Consultation - 207-624-6460 ME Small Business Assistance Center - 207-287-6188

Module 7 - Scrap Tires (page 46 - 50)

0 Tires represent a sigdicant volume of waste. Ifwhole tires are stockpiled in large quantities, they become a serious fire, health and environmental hazard. Tires which were buried whole in landfills years ago may rise to the surface due to natural vibration. Tires collect water when left outside in the rain creating a breeding place for mosquitos.

0 There are no landfills in Maine accepting tires. Generally, tires are transported by a nonhazardous waste transporter licensed by the state of Maine and are brought to a licensed processing facility for shredding or chipping. The chipped tires are used for fuel in industrial boilers and in civil engineering projects.

0 A number of new technologies for reuse and recycling of used tires have been tried. Engineers have been able to separate the scrap steel and produce a mealy rubber that can be added to asphalt for use on roads. Another technology, a catalytic reduction process, bakes chipped tires bleeding away the carbon black and recovers the hydrocarbons as methane gas and as fuel oil.

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a Every automotive service facility should be prepared to accept old tires from customers and have arrangements with a removal contractor.

Additional Resources ME Small Business Assistance Center - 207-287-61 88

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Module 8 - Used Batterks (pages 51 - 55)

.. Automotive batteries are of the lead-acid type and contain a sulfuric acid solution, often called electrolyte or battery acid. This solution is highly corrosive to many materials and can cause serious burns to skin, and permanent eye damage if splashed in the eyes.

0 People handling battery acid should wear protective clothing and eye protection.

0 Store all spent batteries on pallets or shelving; use strapping to prevent spilling. The storage area should have secondary containment made h m acid-resistant material such as plastic or concrete and be indoors. Do not stack batteries since they may crack and fall. Store batteries away h m flammable liquids, ignition sources and drains. Ifthe battery is open or leaking, the acid must be collected and managed as a hazardous waste.

. The battery housing is not regulated ifit is sent for recycling. Battery distributors collect spent batteries for reclamation. Many local scrap metal recyclers also collect batteries and ship them to battery reclaimen. Batteries that are to be disposed, rathei &an reclaimed, are fully regulated as hazardous waste. Accordingly, lead-acid batteries are banned fiom landfilling or incineration in Maine.

Additional Resources ME Small Business Assistance Center - 207-287-61 88

Module 9 - Floor Drains (pages 56 - 61)

0 Fluids entering the drains fiom the bay area of a vehicle maintenance operation may eventually travel into the soil, to local drinking water supplies and to streams. Floor drain wastewater also should not be discharged to a septic system or directly to a ditch, stream, river or any other body of water.

0 There are three options for dealing with floor drains in areas where regulated contaminants are used or stored: a) permanently seal the floor drain, b) install a holding tank or water recycling system, or c) hook into the municipal sanitary sewer system after obtaining permission of the system.

0 If shops have floor drains, minimize pollutants entering them. Use dry clean-up techniques whenever possible. If the drain leads to a tank, keeping hazardous waste out of the tank reduces the amount of hazardous waste produced, and therefore saves on disposal costs. For example, it costs much more to dispose of 20 gallons of snow melt once a pint of gasoline has been mixed into it, than to dispose ,of each of those items separately.

0 Oillwater separators should be checked on a regular schedule and cleaned when needed. 1

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The removed oily solids must be managed as waste oil or hazardous waste.

Suggested Student Handouts Contamination fiom Floor Drains - graphic - page 59

Additional Resources www.smbav.owJbmD/22l.htm - Best management practices for preventing pollutants

fiom going into the storm drain.

Module 10 - Storage Tanks @ages 62 -67)

Waste oil tanks are generally situated above the ground. These tanks must be fiee of rust, dents, bulges, leaks or other kinds of damage. Each tank has to be labeled in large letters with the words ‘Waste Oil.”

Auto repair shops should check with the DEP and the local fire department to determine ifthey need a permit for any tanks, including tanks for virgin oil, at their shops.

Only oil (such as crankcase, heating, hydraulic fluid and transmission fluid) can go into a waste oil tank. Fluids such as gasoline, anti.f?eeze, brake cleaners and solvents are specifically prohibited.

If waste oil tanks are located outside, the Maine DEP recommends that the tanks be either double-walled or be single-walled and water-tight. The tank should be placed on a surface made of nonporous material such as concrete with no cracks or gaps. The DEP also recommends secondary containment systems for the above ground tanks - these are systems that capture up to 110% of the volume of the largest tank. The system can consist of curbs around the waste oil storage area or it can be a large plastic tub.

If the tanks are underground, additional requirements apply. A tank is considered to be below ground if 10% or more of the tank is below the ground.

There are additional requirements for the installation, monitoring, reporting and leak detection for underground storage tanks. See the phone number below under Additional Resources.

Suggested Student Handouts Case Study - Gasoline Spill Site, Oxford, ME - page 66 Case Study - Leaking Home Heating Oil tanks - page 67

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Additional Resources ’

Maine DEP - storage tank information - 207-287-2651

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UNIT 4 - HEALTH AND SAFETY i Module I - Carbon Monoxide and Exhaust @ages 1 - 5)

0 Exhaust gas contains asphyxiants, gases that can cause suffocation b_r interfering with the body's use of oxygen. Asphyxiants in exhaust deprive the body of oxygen in two ways: a) carbon dioxide (COJ at high levels will "thin out" the available oxygen, reducing the amount getting into the lungs and b) carbon monoxide (CO) will take the place of oxygen in the blood even if there is enough oxygen available. Both of these gasses are colorless and odorless and can concentrate to dangerous levels with no warning.

e Symptoms of overexposure include headache, irritability, weakness, impairment of judgment, and confusion. These symptoms often go unnoticed leading to more severe effects including fainting, unconsciousness, and death due to respiratory failure.

0 Good ventilation is important in areas where asphyxiants, especially carbon monoxide, are aproblem.

e It is illegal under federal law to remove, disconnect, damage or in any way render inoperative any emission control device or element of design installed on a motor vehicle or motor vehicle engine. Contrary to popular belief, removing emission control devices does not increase fuel economy. In fact, removing them may shorten the life and overall perfomance of a vehicle.

e Catalytic converters are installed on the exhaust system to oxidize hydrocarbons and carbon monoxide and to reduce nitrogen oxides. In large part because of catalytic converters (but also because of better inspection and maintenance and phase-out of leaded gas), today's cars emit about 90% less pollution than cars did in the 1960's.

Additiond Resollrces ME OSHA Consultation - 207-624-6460 M E Small Business Assistance Center - 207-287-6188

M d d e 2 - Personal Protection & Health Issues (pages 6 - 15)

e The key types of personal protection equipment needed are safety shoes, gloves, eye and face protection and ear protection.

e In addition, respiratory protection is extremely important especially when sanding, grinding or painting. There are three types of respirators - air line, self-contained and gas mask (with specific filter cartridges).

) e Serious health risks can result from exposures to epoxy plastics, solvents, paints and

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isocyanates in particular.

0 Isocyanates are a part of topcoats. There are many forms of isocyanates but the most common form is toluene diisocyanate or TDI.

Isocyantes have been shown to cause irritation of eyes, gastrointestinal and respiratory tracts, sensitization and asthma, hypersensitiviiy pneumonitis and cancer.

0 The best way to protect people from exposures to isocyanates is to: a) substitute products without this chemical, b) have closed systems and ventilation, c) wear protective clothing and equipment and d) use fresh air respirators.

Suggested Student Handouts Personal protection - page 9 Respiratory Protection - page 10 Worker Factsheet on Preventing Asthma and Death from Diisocyanate Exposure -

Case Study - Death from Prolonged Exposure to Diisocyanates - page 15 page 14

Additional Resources ME OSHA Consultation - 207-624-6460 NOSH - National Institute for Occupational Safety and Health - 1-800-35-NOSH www.cdcpov/niosh - web site for worker fact sheets on occupational exposures

Module 3 - Health and S a f w Checklist (pages 16 - 17)

There are a wide variety of concerns that the Checklist of Occupational Safety and Health Administration (OSHA) evaluates for auto repair and auto body shops. The OSHA checklist includes questions on the building, flammable materials, safety equipment, fire equipment, etc.

Suggested Student Handout Health and Safety Checklist - page 16

Additional Resources ME OSHA Consultation - 207-624-6460

. Module 1 - Compliance Inspecrions @ages 1 - 9)

A number of different agencies conduct compliance inspections at auto repair shops such as Maine DEP, OSHA, local fire departments and code &orcement officers and in some cases, the shop’s insurance agency.

0 hspectors look for a description of shop activities, physical inspection of fkdity, review

fkility.

of parts cleaning equipment, description of sources of hazardous waste and methods of handling, emergency preparedness pn”, and inspection of outdoor areas around the

Suggested Student Handout Checklist for Auto Repair Shops - Complying with hvironmental, Fire, and Health and

Safety Regulations -page 6

Additio~~.alResources State of Maine, Fire Licensing and Tnspections Unit - 207-624-8744

Acknowledgments

The U.S. Environmental Protection Agency, Region I in Boston, MA funded this curriculum under an environmental justice grant to the Androscoggin Valley Council of Governments in Auburn, Maine. Special thanks go to the auto body and repair teachers at oxford Hills Comprehensive High School in Paris, Maine:

1

Stan Bumpus, Auto Body teacher Dan Chaplin, Auto Repair teacher Mitch Green, Auto Repair teacher

Garry Carr, Auto Body teacher Jesse Cook, Auto Repair teacher

Thanks also go to Jim Chandler of the Oxford County Soil and Water Conservation District, Ferg Lea and Carol Fuller of the Androscoggin Valley Council of Governments and Brian Kavanah of the Maine Department of Environmental Protection.

Much of the material is derived fiom a curriculum titled ‘Tollution Prevention for Automotive Service Technicians” prepared by the NH Department of Environmental Services (NH DES) which was drawn fiom a curriculum titled “A Curriculum Guide for Environmentally Responsible Automotive Servicing” by the Massachusetts Bay Community College. We thank Massachusetts and New Hampshire for leading the way to linking pollution prevention and vocational education. Further, the health and safety checklist comes from the “Automotive Repair and Refinishing Environmental Compliance Manual” prepared by the NH DES and the N.H. Small Business Technical Assistance Program. Finally, we thank the Iowa Waste Reduction Center at the University of Northem Iowa. They wrote “Pollution Prevention

.

Curriculum for Vehicle Maintenance” fiom which we have included numerous class exercises, some charts and text as well as most of the material in Unit 2 on pollution prevention at auto bodyshops. - .

PAGE 18

Curriculum Po I I uti o n P reve n t i o n for Auto Body and Auto Repair Vocational Programs

Prepared by




December 1998

Pollution Prevention for Auto Body and Auto Repair Vocational Programs

Introduction

Unit 1 - Course Introduction

Module 1 - Hazardous Wastes Module 2 - Hazard Communication Standard (MSDS sheets) Module 3 - Pollution Prevention

Unit 2 - Auto Body - Pollution Prevention

Module 1 - Surface Preparation Module 2 - Spray Application Process Module 3 - Spray Equipment Cleaning

Unit 3 - Fluids and Waste Management - Pollution Prevention

Module 1 - Waste Oil, Waste Oil Filters and Oil Contaminated Wastes Module 2 - Spill Procedures - Routine and Emergency Module 3 - Engine Coolant (Antifreeze) Module 4 - A/C Refiigerants Module 5 - Parts Cleaners Module 6 - Asbestos Module 7 - Used Tires Module 8 - Used Batteries Module 9 - Floor Drains Module 10 - Storage tanks

Unit 4 - Health and Safety

Module 1 - Carbon Monoxide and Exhaust Module 2 - Personal Protection and Health Effects Module 3 - Health and Safety checklist

Payes 1 - 2

1 -11 12 - 27 28-44

1 - 8 9 -24 25 - 33

1 -12 13 - 19 20 - 27 28 - 33 34 - 40 41 -45 46 - 50 51 -55 56 - 61 62 - 67

1 - 5 ' 6 -15 16 - 17

Unit 5 - Summary

Module 1 - Compliance Inspections 1 - 9

t Introduction

This environmental, health and safety curriculum is for students in auto repair and auto body vocational progrqns. It focuses on prevention - the prevention of pollution and prevention of health and safety hazards through improved workplace practices.

Designed by auto repair and auto body teachers with the idea that students prefer “learning by doing,” the curriculum includes many hands-on exercises, charts, graphics and minimal reading. It includes a short test which can be used as either a pre or post test, or both. Further, in many of the modules, we have included charts in the text, and brochures in the back of the chapters that teachers can photocopy for handouts.

By preparing the curriculum in small modules, the curriculum was designed to integrate easily into existing lessons or to supplement course work.

Each module includes the following information:

0 Pre and/or Post Test - Teacher Version Pre and/or Post Test - Student Version

health and safety concerns, pollution prevention measures and best management practices Class exercises

0 Handouts

a Description of the issue including information on environmental regulations,

The curriculum contains five units. Unit 1 serves as the introduction to the course and contains information on hazardous waste, pollution prevention and health and safety. It lays the groundwork for the remainder of the curriculum.

Unit 2 is specific to auto body programs. It discusses the environmental, health and safety concerns in surface preparation, the spray application process and the spray equipment cleaning.

Unit 3 applies both to auto repair and auto body programs. It discusses all the various fluids and wastes that go into and come out of a vehicle and how to properly manage them. In each module, pollution preventim is a major focus.

Unit 4 contains health and safety information and is applicable to both programs. However, module 3 discusses isocyanates, which are of particular concem in auto body programs. Finally, Unit 5 serves as a summary for the entire course. It includes a review of all of the information from the entire curriculum and applies it in a hands-on fashion. It prepares students for a compliance inspection by doing an audit of their own shop and an audit of the other program’s shop. (if applicable.)

INTRODUCTION PAGE 1

Introduction

A Note on the Curriculum Design

Often environmental curricula are developed as an add-on to the ‘4regular” curriculum. And, too often, this is a reflection of how environmental requirements are viewed in the working world. People view their “real” job as “auto repair” and then on top of that, they “have” to comply with environmental regulations.

We believe that integrating environmental, health and safety awareness into the everyday workings of an auto repair or auto body shop is beneficial in many respects. Carefid attention to environmental and safety regulations can actually help a business to run more efficiently. For instance, less waste means higher profits. A clean shop is an appealing shop for customers as well as a safer workplace. Fewer hazardous chemicals translate to lower purchasing costs and less liability.

Hence, whenever possible, we have tried to design this curriculum to fit into existing lessons on DOING auto repair. We look forward to your feedback.

Acknowledgements

The U.S. Environmental Protection Agency, Region I in Boston, MA funded this curriculum under an environmental justice grant to the Androscoggin Valley Council of Governments in Auburn, Maine. Special thanks go to the auto body and repair teachers at Oxford Hills Comprehensive High School in Oxford, Maine: Stan Bumpus, Auto Body teacher Dan Chaplin, Auto Repair teacher

Gany Cam, Auto Body teacher Jesse Cook, Auto Repair teacher

Thanks also go to Jim Chandler of the Oxford County Soil and Water Conservation District, Ferg Lea of the Androscoggin Valley Council of Governments and Brian Kavanah of the Maine Department of Environmental Protection.

Much of the material is derived from a curriculum titled “Pollution Prevention for Automotive Service Technicians” prepared by the NH Department of Environmental Services (NH DES) which was drawn from a cumculum titled “A Cumculum Guide for Environmentally Responsible Automotive Servicing” by the Massachusetts Bay Community College. We thank Massachusetts and New Hampshire for leading the way to linking pollution prevention and vocational education. Further, the health and safety checklist comes from the “Automotive Repair and Refinishing Environmental Compliance Manual” prepared by the NH DES and the N.H. Small Business Technical Assistance Program. Finally, we thank the Iowa Waste Reduction Center at the University of Northem Iowa. They wrote “Pollution Prevention Curriculum for Vehicle Maintenance” from which we have included numerous class exercises, some charts and text as well as most of the material in Unit 2 on pollution prevention at auto body shops.

INTRODUCTION PAGE 2

Unit I - Module 1 - Hazardous Wastes ~~~~ ~

Learning Objectives

1. Learn about the system of regulations for the proper management of hazardous wastes.

2. Identify if a waste is hazardous. Be able to describe whether automotive wastes are hazardous because they: a) are specifically listed by the Maine DEP as hazardous waste, b) exhibit one of characteristics of hazardous waste - ignitability, corrosivity, reactivity or toxicity or c) are a mixture of a hazardous waste listed by the Maine DEP and other non-hazardous materials.

3. Become familiar with how pollution moves through the environment and affects it.

4. List how a hazardous substance can get into the body and the potential affects.

UNIT^ PAGEI

Unit 1 - Module 1 - Hazardous Wastes

Pre/Post Test - Teacher Version

1. Why do you think a waste would be considered hazardous? Pick out the reason that would NOT make a waste a hazardous waste:

A) Makes you dizzy B) Smellsawful C) Gives you a headache D) E) May cause cancer F) Fish get sores

Will ignite at 140 degrees or below

2. Hazardous substances can enter the body through any one of these methods, EXCEPT for?

A) Breathing B) Throughtheskin

D) Swallowing C) sweating

3. Match the following wastes with the type of hazard they represent. One of the '

hazards needs to be used more than once.

TyDe of Waste TvDe of Hazard

Paint thinner Corrosive Battery acid Ignitable Antifreeze Toxic Gasoline Reactive Pressurized Aerosol Cans

Paint thinner and gasoline are ignitable, battery acid is corrosive, antifreeze is toxic and aerosol cans are reactive.

1. Name three things in an vehicle that would be hazardous wastes when disposed:

1. 2.

0

U N I T I PAGE^

Unit I - Module 1 - Hazardous Wastes

The answers here could be any of the following: gasoline, brake cleaner, carburetor cleaner, solvents for parts cleaning, paint thinners, paint cleaners, battery acid etc. Waste oil is legally not considered to be a hazardous waste though if a student included it, we would suggest marking it correct.

NOTE: In Maine, waste oil is not considered to be a hazardous waste as long as it is picked up by a licensed transporter of hazardous waste. Waste oil filters are generally not considered hazardous wastes either as long as they do not have a high concentration of metals. Certain metals like lead, cadmium or chromium would cause discarded oil filters to fail the hazardous waste characteristic “toxicity characteristic leaching procedure.”

2. How would you find out if a cleaning substance you were using was hazardous?

Look at the MSDS or read the label. Also: call the manufacturer, call the State assistance l i e .

U N I T ~ PAGE^


PrePost Test

1. Why do you think a waste would be considered hazardous? Pick out the reason that would NOT make a waste a hazardous waste:

A) Makesyoudm B) Smellsawful C) Gives you a headache D) E) May cause cancer F) Fish get sores

Will ignite at 140 degrees or below

2. Hazardous substances can enter the body through any one of these methods, EXCEPT for?

A) Breathing B) Throughtheskin

D) Swallowing C) sweating

3. Match the following wastes with the type of hazard they represent. One of the hazards needs to be used more than once.

T p e of Waste

Paint thinner Battery acid Antifreeze Gasoline Aerosol Cans

m e of Hazard

Corrosive Ignitable Toxic Reactive

4. Name three things in an vehicle that would be hazardous w stes when dispo ed

1. 2. 3.

How would you find out if a cleaning substance you were using was hazardous? 5 .

UNIT? PAGE^

Unit I - Module I - Hazardous Wastes

What is a waste? What is a hazardous waste?

A waste-is any solid, liquid or contained gaseous material that you no longer use and either dispose or recycle. Wastes that could cause injury or death, or damage or pollute the land, air, or water are considered hazardous wastes. Because of the potential for harm caused by hazardous wastes, the U S . Environmental Protection Agency and Maine Department of Environmental Protection have set up a system of regulations to provide management of hazardous wastes from the point at which they are first generated to the point when they are finally recycled, treated and disposed.

Regulations for safe management extend from the generators of hazardous waste such as auto repair shops, to transporters which pick up the hazardous waste, to recycling facilities which purify the waste so it can be reused again, to treatment facilities who neutralize, incinerate or otherwise reduce the toxicity or volume of the waste to the final destination, disposal facilities which put the wastes in secure landfills.

Not all wastes go through all these steps. Some wastes like antifreeze or refrigerants are reqckd right at auto repair shops or by outside vendors and returned to be used again. These wastes never go to treatment or disposal facilities.

At each stage in the chain of hazardous waste management, people in charge of the waste must carefully account for the waste they handle by labeling it, segregating it from other wastes or materials with which it may react, keeping accurate records for shipping, and being prepared for emergencies including spills, fire or employee exposure.

There are three ways a waste may be identified as a hazardous waste.

1) 2) 3)

It is specifically listed in the U.S. EPA or Maine regulations; It exhibits a hazardous waste characteristic (as outlined below); or It meets the definition of a hazardous waste mixture in the regulations.

Listed Wastes

Wastes that are specifically listed in the federal and state regulations include certain discarded chemical products, spent solvents, and certain process wastes. Examples of wastes from automotive service facilities which are included in these listings are:

1. 2. 3. spent non-halogenated solvents 4.

spent halogenated solvents (e.g. containing chlorine) used in degreasing parts spent solvents used in paint formulations and as thinners

still bottoms of all these solvents and spills of these solvents

Unit 1 - Module I - Hazardous Wastes

Examples of these solvents are: methylene chloride, 1, 1 , l trichloroethane, chlorinated fluorocarbons (freons), trichloroethylene, xylene, acetone, nitrobenzene, toluene, methyl ethyl ketone and benzene. These wastes are considered one of the following: Fool, F002, F003, FOO4 and F005.

Characteristic Wastes

A waste is classified as hazardous waste if it exhibits any one of the four “hazardous characteristics. They are:

1.

2.

3.

4.

Ignitability: Liquid wastes with a flash point below 140 degrees F., non-liquid wastes which ignite easily and burn to create a hazard, ignitable compressed gases, and wastes identified by the U.S. Department of Transportation as oxidizers are classified as ignitable hazardous wastes. Examples from the automotive service indusv are gasoline, parts cleaning solvents like petroleum naphtha, and paint thinners.

Corrosivity: Aqueous wastes with a pH I 2.0 or 2 12.5 or other wastes which easily corrode materials or human tissue are corrosive hazardous wastes. Examples are battery acid, paint strippers, and some engine degreasing solutions.

Reactivity: Wastes that are unstable, react violently with water or air, give off toxic fumes, or are capable of detonation or explosive reaction are classified as reactive hazardous wastes. This type of waste is not commonly encountered in automotive servicing. An example of th is kind of waste are pressurized aerosol CanS.

Toxic: Wastes which can leach toxic metals or organic compounds as determined by a special laboratory test called the Toxicity Characteristic Leaching Procedure or TCLP are toxic hazardous wastes. The toxic constituents include heavy metals such as lead and chromium, and organic compounds such as benzene and tetrachloroethylene. Common examples are sludge from shop floor drains, some paint wastes, and spent antifreeze.

Waste Mixtures

When a listed hazardous waste (e.g Fool - F005) is mixed with any another material, the entire mixture is classified as a hazardous waste. For these reasons, it is important to carefully store hazardous wastes and segregate them from other materials.

Unit I - Module 1 - Hazardous Wastes

How Pollution Gets Into the Environment

Pollution occurs when wastes are released into the environment. In general, pollution can occur when wastes are dumped, spilled, bumed or evaporated, or when storage tanks leak. When pollution gets into the environment, it goes into the soil, water and air.

In many towns across the United States, the water supply has been shut down because of contamination from hazardous materials or wastes. For instance, in Norway, Maine, the water supply was shut down for more than 3 years because of gasoline contamination. (See unit 3, module 10) Other serious effects of water pollution include harm or death to fish, birds and wildlife. Soil contamination is a problem because harms creatures living in the soil, it is unsightly and provides a source of contamination for ground water or surface water supplies.

One of the less visible forms of pollution is air pollution. Solvents and paints contain volatile organic compounds (VOCs) which evaporate or are vented into the air. They react with other chemicals and sunlight to form smog. Smog causes poor visibility and can interfere with breathing particularly for people with asthma.

Where Waste Travels in the Environment

River or Creek

Soil and Groundwater

HOW WASTE GETS INTO THE AIR evaporation, burning, venting, spraying or exhausting into atmosphere. LOOK FOR: smoke from an industrial stack, dust mcles , exhaust, paint particles in the air or settled on the ground outside paint exhausts

HOW WASTE GETS INTO THE WATER spilling during use, spilling while transferring, direct dumping, rainwater picks up conmnjnants LOOK FOR. oil sheen, garbage, dying fish, foul smelling streams

Graphic from Massachusetts Department of Environmental Protection, Toxics Use Reduction Program

HOW WASTE GETS INTO SOIL AND GROUNDWATER direct dumping or spilling when transferring materials or waste, through floor drains, leaking from storage areas, rainwater falling on waste and picking up contaminants dumping onto the soil and soaking through to the groundwater LOOK FOR: discolored soil, dying vegetation

UNITI PAGE^


Exposure to Hazardous Substances

In order for a hazardous substance to exert its toxic effect, it must come in contact with the cells in the body. There are four routes of entry for chemical compounds in the form of liquids, gases, mists, dusts, fumes, and vapors:

1. Ingestion (through the mouth) 2. 3. Inhalation (through the lungs) 4.

Skin absorption (through the skin)

Injection (direct to body tissue as a result of foreign object piercing skin)

Potential Adverse Health Effects of Common Vehicle Maintenance Chemicals

Waste

ieavy Metals found in 3atteries, Paints, Used Oil btifieeze, Solvents

Petroleum based solvents Parts Cleaning Painting

Ethylene Glycol (Antifreeze)

Eazardous Contaminant

Benzene Lead

Lead Other heavy metals

Mineral spirits Methylene chloride Toluene Xylene

~~

Ethylene Glycol Lead Benzene

Health Effect

~

Skin and eye initation Diarrhea ($ingested)

Brain damage (learning disabilities and mental retardation) Kidney disease Reproductive problems Birth defects

Skin rash Central Nervous System depression (symptoms include nausea, vomiting, fatigue) Reproductive problems & birth defects, Cancer Death - concentrated fumes

Central Nervous System disturbance Liver and kidney damage Coma Death

Unit 1 - Module I - Hazardous Wastes ~~

Class Exercise: Let’s Build a Vehicle

1. 2. 3. 4. 5. 6.

7.

Assemble the students into teams of no more than four. Ask the students to name their team with a car name. Write the team names on the board in separate columns. Ask each team to identify the different materials that make up each part of the car. Write on the board each item the students come up with. When the students run out of materials, ask them which materials are hazardous and which ones are not. The team with the most right answers wins.

Concept: Hazardous materials include 1) some of the fluids and chemicals used in servicing vehicles and 2) some of the fluids and chemicals that come out of the vehicle and can no longer be used. Other materials in the automobile are not hazardous. The service technician and service operation are responsible for safe management of fluids and materials removed fiom the car or added to the car during vehicle repair.

Example:

Hazardous

disposed? I

I no

I no

3 points 3 Hazardous Wastes include: waste motor oil* including hydraulic fluid, power steering fluid, transmission fluid, brake fluid, gear oil; waste oil filters**, brake cleaner, carburetor cleaner, cleaning solvents including mineral spirits, solvent or oil contaminated rags or absorbents , refrigerant, gasoline, antifreeze, aerosol cans containing solvents, discarded paints, discarded thinners, masking tape contaminated with paints, battery acid, asbestos filings (must be handled by a licensed hauler but are not considered hazardous wastes by Maine regulations).

UNIT? PAGE^

Unit I - Module I - Hazardous Wastes

*Note: Waste oil would be considered a hazardous waste if it were disposed rather than picked up by a waste oil transporter for blending or recycling.

** If waste oil filters are not probably drained, they are more likely to fail the “toxicity characteristic leaching procedure,” and would therefore be a hazardous waste.

Class Exercise: Video

View a video on Hazardous Waste Management such as “The Tuned-Up Shop: Best Management Tips for a Smooth Running, Environmental-Friendly Auto Repair Operation” (14 minutes).

Class Exercise: Identifying if a Substance is Hazardous

1. 2.

3. 4.

Divide the students into groups of 4 or 5. Ask each group to get one of each of the aerosol cans used to repadpaint vehicles (for instance, get a spray can of carburetor cleaner or paint). Ask each group to write down what the hazard(s) stated on the warning labels. Then, ask each group to sort the cans into different categories of hazards.

Example categories might be: flammable, ignitable, toxic, hazardous, harmful.

At this point, the teacher can introduce the MSDS sheets and discuss how MSDS sheets provide information in addition to the information on the warning label.

Field Trip: Visit to a Local Automotive Recycling Operation

1. 2.

3. 4.

5 . 6.

Ask the students to attend a field trip to the “Auto Salvage Yard”. Document the process the salvager goes through in separating the materials that the vehicle is made of. Determine how the materials will then be used. Document the process the salvager goes through in separating the fluids and gases from the vehicle. Determine what then happens to the fluids and gases. NOTE: When talking with the salvage yard to arrange the field trip, mention that you are there to learn and you will not be talking with or reporting to any government officials about your visit.

UNITI PAGE 10

Unit 1 - Module 1 - Hazardous Wastes 1 Class Exercise: Make a Car Ready to Sit in a Salvage Yard Without Leaking

1. 2.

3.

4.

Ask a local salvage yard if they would donate a wrecked vehicle to your school. Before you take a wrecked vehicle, make certain there are no obvious leaks, ,

otherwise you may contaminate the land or water before it gets to your school. When the vehicle is in your possession, drain all the fluids fiom the vehicle and properly recycle or dispose of them. When the car is completely empty of all the fluids, it is ready for the salvage yard.

UNIT? PAGEI I

Unit 1 - Module 2 - Hazard Communication Standard

Learning Objectives

1. Introduce the Hazard Communication Standard which is frequently called the Employee Right to Know law.

2. Describe the requirements for Automobile Service facilities to comply with the Hazard Communication Standard.

3. Learn what type of information. is found on au MSDS.

4. Explain where you can obtain an MSDS.

UNITI P A G E I ~

Unit I - Module 2 - Hazard Communication Standard 1 PreRost Test - Teacher Version

1. The Hazard Communication Standard is a law that does all of the following except: A)

B) C)

D)

Prepare an inventory of all chemicals and hazardous substances used at the facility which require a Material Safety Data Sheet (MSDS). Requires an employer to properly dispose of hazardous wastes. Conduct employee training so they will know what materials are hazardous. Provide access of MSDS's to every employee.

2. Material Data Safety Sheets (MSDS) are: A) Shipping Information B) Hazardous Materials C) Technical Data Sheets D) General Information Sheets

3. MSDSs are required to tell you whether a hazardous substance would be a hazardous waste when disposed. A) True B) False

4. The MSDS contains the information shown below, except for: A) Explosion Hazards B) Protection Methods C) Physical & Chemical Properties D) Shipping Cost

5 . The MSDS's for the chemicals you work with are required to be stored: A) At the State Capitol B) In Washington D.C. C) In the Employer files D) At the Post Office

UNITI P A G E I ~

Unit I - Module 2 - Hazard Communication Standard

Pre/Post Test

1.

2.

5.

4.

5 .

The Hazard Communication Standard is a law that does all of the following except: A)

B) C)

D)

Prepare an inventory of all chemicals and hazardous substances used at the facility which require a Material Safety Data Sheet (MSDS). Requires an employer to properly dispose of hazardous wastes. Conduct employee training so they will h o w what materials are hazardous. Provide access of MSDS's to every employee.

Material Data Safety Sheets (MSDS) are: A) Shipping Information B) Hazardous Materials C) Technical Data Sheets D) General Information Sheets

MSDSs are required to tell you whether a hazardous substance would be a hazardous waste when disposed. A) True B) False

The MSDS contains the information shown below, except for: A) Explosion Hazards B) Protection Methods C) Physical & Chemical Properties D) Shipping Cost

The MSDS's for the chemicals you work with are required to be stored: A) At the State Capitol B) In Washington D.C. C) In the Employer files D) At the Post Office

UNIT1 PAGE 14


Hazard Communication Standard

The Hazard Communication Standard (HCS), frequently called the "Employee Right to Know," is a law administered by the Occupational Safety and Health Administration (OSHA) and equivalent state labor agencies.

Under the HCS, manufacturers and importers of hazardous substances must evaluate the hazards of the chemicals they supply to customers. To explain the hazards of the chemicals, the manufacturers must complete detailed technical bulletins called Material Safety Data Sheets (MSDS) and properly label their containers. MSDS sheets should be available for oil, solvents, cleaners in spray cans. Less obviously, MSDSs are often required for soaps and detergents that contain only small amounts of hazardous chemicals. MSDS sheets must be kept on file by the employer and must be made available to the people using the chemicals.

Suppliers are required to send an MSDS along with the first shipment of a hazardous substance to a company and supply any updates when any significant changes are made to the MSDS.

The MSDS document contains information regarding hazardous ingredients, physical and chemical characteristics, fire and explosion hazards, health hazards, safe handling, use and disposal, control and protection methods.

Employers and operators of Automotive Servicing facilities must:

1. Prepare an inventory of all chemicals and hazardous substances used at the facility which require an MSDS.

2. Develop a written hazard communication program which describes how the HCS will be implemented at the facility.

3. Conduct training of all employees so they will know a) what materials are hazardous, b) how to find information on those materials, c) how to protect themselves and d) how to handle the chemicals and what to do in case of an emergency.

4. Provide access of MSDS's to every employee.

5 . Ensure all containers are properly labeled.

While discussing how to read an MSDS, teachers may want to bring out their file of MSDSs to show their students. Teachers may want to also note that there is a now a

UNITI PAGE 15


suggested format for MSDS sheets from the American National Standards Institute. This format is described below. OSHA does not require that companies follow any specific format, only that the MSDSs contain certain required information. Hence, MSDS sheets that you and your students encounter may be in a number of different formats. The MSDSs included in this chapter are in two different formats.

American National Standards Institute MSDS Format

Section 1: Chemical Product and Company Wormation Section 2: Composition, Information or Ingredients Section 3: Hazard Identification Section 4: First Aid Measures Section 5: Fire-Fighting Measures Section 6: Accidental Release Measures Section 7: Handling and Storage Section 8: Exposure Controls and Personal Protection Section 9: Physical and Chemical Properties Section 10: Stability and Reactivity Section 1 1 : Toxicological Information Section 12: Ecological Information Section 13: Disposal Considerations Section 14: Transport Information Section 15 : Regulatory Information Section 16: Other Information

UNITI PAGEIG


’roduct Identity (Chemical ’roduct and Company . dormation)

A

Allows you to match the MSDS with the product.

~ ~~ -

lazardous Ingredients Composition, Information, ngredients) harm.

Bow does this chemical behave?

?hysical Data (physical and aemical Properties)

[s this product dangerous?

Fire and Explosion Data (Fire- Fighting Measures) extinguish the fire.

Reactivity Data (Stability and Reactivity) in sunlight or air.

Can this product hurt my health?

Health Hazards Data (Hazard Identification, First Aid Measures, Toxicological Information)

How should I work with this stuff?

Precautions for Handling (Accidental Release Measures, waste. Handling and Storage, Disposal Considerations)

How should I be protected?

Names the hazardous ingredients and tells you the m a x i ” amount you can be exposed to without

Helps to figure out where to store the chemical and how likely it is to evaporate and give off vapors. (leading to exposure andor fires)

Discusses when a chemical will ignite and how to

Tells you if the substance will explode or breakdown

Tells you how the chemical can get into your body. (via breathing) Explains what the health effects may be if you are exposed (e.g. difficulty breathing) and whether it can cause cancer. It also includes first aid procedures.

What to do‘in the case of a spill. How to dispose the

,

Control Measures (Exposure Controls and Personal Protection)

Includes respirators, ventilation, eye protection or special clothing.

Note: Make sure to check if the MSDS is written with your intended use of the product in mind. For

UNITI P A G E I ~


Class Exercise: Just the Facts

Use an MSDS for engine oil for auto repair programs and tar and grease remover for auto body programs. (See end of this chapter for a copies of MSDS sheets)

1.

2.

3.

4. 5.

6.

7. 8. 9.

Assemble the students in groups of no more than four and ask students to name their teams the name of an auto maker. Write the team names on the board in separate columns. Pass out an MSDS on engine oil or tar and greaser remover and give them 5 minutes to study it. Starting with the h t team, ask them a question from the MSDS and give them 20 seconds to respond. Once they respond ask the other teams if they agree with the answer. Assign 1 point to the teams who got it right. Subtract 1 point from the teams who got it wrong. Teams can pass on questions two times before incurring a 1 point penalty per question unanswered. Be sure each team has a chance to answer at least five questions. End the game and tally up the points. The Team with the most points wins!

Class Exercise: Comparison of MSDS With Label

1. Divide the class into groups of 4 - 5. Ask each small group to compare the MSDS of the engine oil or tar and grease remover with the warning label on the product.

2. What information is the same? 3. What information is different?

UNITI P A G E I ~

Unit 1 - Module 2 - Hazard Communication Standard ~~ ~

Class AssignmenKlass exercise: Have Students go get an MSDS

1. 2.

Break the class into groups of 4 - 5. Ask each group to appoint one person to go a local auto parts store to get an MSDS sheet. (The teacher can assign a certain type of MSDS sheet for each group and let the local store know that students may be coming by to request MSDSs.) During the next class, ask the following questions: 3. 0 What is the product technical information phone number?

What are the potentially hazardous ingredients? What are the effects of overexposure? What is the first aid remedy for skin contact? What are the unusual fire and explosion hazards? What procedures should be followed if this material is released or spilled? What special respiratory protection is required? Who prepared this MSDS sheet? Where can they be reached for further information?

0 Who is the supplier? 0

UNITI PAGEIS

Unit I - Module 2 - Hazard Communication Standard ~~

MSDS Sheet for Motor Oil

MOPAR SAE 1OW-30

470617-00

1. PRODUCT AND COMPANY IDENTIFICATION

APPROVAL DATE: 12/11/97 PRODUCT NAME: MOPAR SAE 1OW-30 SUPPLIER: MOBIL OIL COW.

AMERICAS MARKETING AND REFINING 3225 GALLOWS RD. FAIRFAX, VA 22037

24 - Hour Emergency (call collect): 609-737-441 1 Product and MSDS Information: 800-662-4525 703-849-5700 CHEMTREC: 800-424-9300 202-483-7616

- 2. COMPOSITION/INFORMATION ON INGREDIENTS

CHEMICAL NAMES AND SYNONYMS: PET. HYDROCARBONS AND ADDITIVES INGREDIENTS CONSIDERED HAZARDOUS TO HEALTH: This product is not formulated to contain ingredients which have exposure limits established by US. agencies. It is not hazardous to health as defined by the European Union Dangerous SubstancesIPreparations Directives. See Section 15 for a regulatory analysis of the ingredients. See Section 15 for European Label Information. See Section 8 for exposure limits (ifapplicable).

3. HAZARDS IDENTIFICATION

US OSHA HAZARD COMMUNICATION STANDARD: Product assessed in accordance

EFFECTS OF OVEREXPOSURE: No significant effects expected. EMERGENCY RESPONSE DATA: Dark Amber Liquid. DOT ERG No. - NA

4. FIRST AID MEASURES

EYE CONTACT: Flush thoroughly with water. If irritation occurs, call a physician. SKIN CONTACT: Wash contact areas with soap and water. INHALATION: Not expected to be a problem. INGESTION: Not expected to be a problem. However, if greater than 112

liter (pint) ingested, seek medical attention.

--_------_I------__-__________________I_-------------------------

____-----_--------_______I______________---------------------------

with OSHA 29 CFR 1910.1200 and determined not to be hazardous.

__-___--_-------_--__________c__________--------------------------------

____________----___------------------------------------------------------

......................................................................... 5. FIRE-FIGHTING MEASURES ......................................................................... EXTINGUISHING MEDIA: Carbon dioxide, foam, dry chemical and water fog. SPECIAL FIRE FIGHTING PROCEDURES: Water or foam may cause frothing. Use water to keep fire exposed containers cool. Water spray may be used to flush spills away from exposure. Prevent runoff from fire control or dilution from entering streams, sewers, or drinking water supply.

UNITI PAGE~O

Unit I- Module 2 - Hazard Communication Standard

SPECIAL PROTECTIVE EQUIPMENT: For fires in enclosed areas, fire fighters must use self-contained breathing apparatus. UNUSUAL FIRE AND EXPLOSION HAZARDS: None. Flash Point C(F): 200(392) (ASTM D-92). Flammable limits - LEL: NA, UEL: NA. NFPA HAZARD ID: Health: 0, Flammability: 1, Reactivity: 0 HAZARDOUS DECOMPOSITION PRODUCTS: Metal oxides. Carbon monoxide. Elemental oxides.

6. ACCIDENTAL RELEASE MEASURES

NOTIFICATION PROCEDLJRES: Report spills as required to appropriate authorities. U. S . Coast Guard regulations require immediate reporting of spills that could reach any waterway including intermittent dry creeks. Report spill to Coast Guard toll free number (800) 424-8802. In case of accident or road spa notify CHEMTREC (800) 424-9300. PROCEDURES IF MATERIAL IS RELEASED OR SPILLED: Adsorb on fire retardant treated sawdust, diatomaceous earth, etc. Shovel up and dispose of at an appropriate waste disposal facility in accordance with current applicable laws and regulations, and product characteristics at time of dsposal. E"MENTAL PRECAUTIONS: Prevent spills from entering stonn sewers or drains and contact with soil. PERSONAL PRECAUTIONS: See Section 8

7. HANDLING AND STORAGE

HANDLING No special precautions are necessary beyond normal good hygiene practices. See Section 8 for additional personal protection advice when handling this product. STORAGE: Do not store in open or unlabelled containers. Store away from strong oxidizing agents or combustible material,

8. EXPOSURE CONTROLSPERSONAL PROTECTION

VENTILATION No special requirements under ordinary conditions of use and with adequate ventilation. RESPIRATORY PROTECTION: No special requirements under ordinary conditions of use and with adequate ventilation. EYE PROTECTION: Normal industrial eye protection practices should be employed. SKIN PROTECTION: No special equipment required. However, good personal hygiene practices should always be followed. EXPOSURE LIMITS: This product does not contain any components which have recognized exposure limits. However, a threshold limit value of 5.00 mg/m3 is suggested for oil mist.

9. PHYSICAL AND CHEMICAL PROPERTIES

Typical physical properties are given below. Consult Product Data Sheet or specific details. APPEARANCE: Liquid COLOR. Dark Amber ODOR Mild ODOR THRESHOLD-ppm: NE pH: NA BOILING POINT C(F): > 316(600) MELTING POINT C(F): NA

FLAMMABILITY: NE

-I_ --___---

--- -----_ -

__--__-_____-__-__-I~~--------------------------------

--__---_-----_--____---------------------------------------

.........................................................................

.........................................................................

FLASH POINT C(F): 200(392) (ASTM D-92)

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AUTO FLAMMABILITY: NE EXPLOSIVE PROPERTIES: NA OXIDIZING PROPERTIES: NA VAPOR PRESSURE-mdIg 20 C: < 0.1 VAPOR DENSTTY: > 2.0 EVAPORATION RATE: NE RELATIVE DENSITY, 15/4 C 0.878 SOLUBILITY IN WATER Negligible PARTITION COEFFICIENT: > 3.5 VISCOSITY AT 40 C, cSt 67.0 VISCOSITY AT 100 C, cSt: > 10.0

FREEZING POINT c(F): NE VOLATILE ORGANIC COMPOUND: NA NA=NOT APPLICABLE NE=NOT ESTABLISHED D=DECOMPOSES FOR FURTHER TEcXNICAL INFORMATION, CONTACT YOUR MARKETING REPRESENTATIVE

POUR POINT c(F): < -33(-27)

10. STABILITY AND REACIWITY

STABILITY (THERMAL, LIGHT, ETC.): Stable. CONDITIONS TO AVOID: Extreme heat. INCOMPATIBILITY (MATERIALS TO AVOID): Strong oxidizers. HAZARDOUS DECOMPOSITION PRODUCTS: Metal oxides. Carbon monoxide. Elemental oxides. HAZARDOUS POLYMERIZATION. Will not occur.

1 1. TOXICOLOGICAL DATA ----------_-_--__---- ---_-I---

--------_____--_________l________l______-------

--ACUTE TOXICOLOGY- ORAL TOXICITY (RATS): Practically non-toxic (LD50: greater than 2000 mgkg). ---Based on testing of similar products andor the components. DERMAL TOXICITY (RABBITS): Practically non-toxic (LD50: greater than 2000 mgkg). --Based on testing of similar products andor the components. INHALATION TOXICITY (RATS): Practically non-toxic (LC50: greater than 5 mgA). ---Based on testing of similar products andor the components. EYE IRRITATION (RABBITS): Practically non-irritating. (Drake score: greater than 6 but 15 or less). ---Based on testing of similar products andor the components. SKIN IRRITATION (RABBITS): Practically non-irritating. (Primary Irritation Index: greater than 0.5 but less than 3). ---Based on testing of similar products and/or the components. OTHER ACUTE TOXICITY DATA: The acute toxicological results summarized above are based on testing of representative Mobil products. Exposure to vapors generated at 400F at levels 400 times the TLV for oil mists (5 mg/m3), then cooled to room temperature, resulted in no significant adverse effects.

Representative Mobil formulations have been tested at the Mobil Environmental and Health Sciences Laboratory by dermal applications to rats 5 daydweek for 90 days at doses significantly higher than those expected during normal industrial exposure. Extensive evaluations, including microscopic examination of intemal organs and clinical chemistry of body fluids, showed no adverse effects.

Dermal exposure of pregnant rats to representative formulations did not cause adverse effects in either the mothers or their offspring.

---SUBCHRONIC TOXICOLOGY (SUMMARY)---

---REPRODUCTIVE TOXICOLOGY (SUMMARY)---

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---CHRONIC TOXICOLOGY (SUMMARY)--- The base oils in this product are severely solvent refined andlor severely hydrotreated. Chronic mouse skin painting studies of severely treated oils showed no evidence of carcinogenic effects. These results are confirmed on a continuing basis using various screening methods such as the Mobil Modified Ames Test and IP-346.

-SENSITIZATION (SUMMARY)---

-OTHER TOXICOLOGY DATA- Representative Mobil formulations have not caused skin sensitization in guinea pigs.

Used gasoline engine oils have shown evidence of skin carcinogenic activity in laboratory tests when no effort was made to wash the oil off between applications. Used oil &om diesel engines did not produce this effect

12. ECOLOGICAL INFORMATION

ENVIRONMENTAL FATE AND EFFECTS: This product is expected to be inherently biodegradable. There is no evidence to suggest bioaccumulation will occur. Acute LCEC50 Fish Juvenile Rainbow Trout Practically non-toxic -Based on testing of similar products. Accidental spillage may lead to penetration in the soil and groundwater. However, there is no evidence that this would cause adverse ecological effects.

13. DISPOSAL, CONSIDERATiCNS

WASTE DISPOSAL: Product is suitable for burning in an enclosed, controlled burner for fuel value or disposal by supervised incineration. Such burning may be limited pursuant to the Resource Conservation and Recovery Act. In addition, the product is suitable for processing by an approved recycling facility or can be dsposed of at an appropriate government waste disposal facility. Use of these methods is subject to user compliance with applicable laws and regulations and consideration of product characteristics at time of disposal. RCRA INFORMATION The unused product, in our opinion, is not specifically listed by the EPA as a hazardous waste (40 CFR, Part 261D), nor is it formulated to contain materials which are listed hazardous wastes. It does not exhibit the hazardous characteristics of ignitability, corrosivity, or reactivity and is not formulated with contaminants as determined by the Toxicity Characteristic Leaching Procedure (TCLP). However, used product may be regulated.

14. TRANSPORT INFORMATION

USA DOT NOT REGULATED BY USA DOT. RID/ADR. NOT REGULATED BY RID/ADR. IMO: NOT REGULATED BY IMO. IATA: NOT REGULATED BY IATA.

1 5. REGULATORY INFORMATION

Governmental Inventory Status: All components comply with TSCA, EINECSELINCS, and MITI. EU Labeling: EU labeling not required. U.S. Supefind Amendments and Reauthorization Act (SARA) Title 111: This product contains no "EXTREMELY HAZARDOUS SUBSTANCES". S A R A (31 1/312) REPORTABLE HAZARD CATEGORIES: None.

- -- ------

-_I_p-- ----- -----

.........................................................................

______--___--_-----------------------------------------------------------

.........................................................................

______________--________________________---~--------~-------------------~

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Unit 1- Module 2 - Hazard Communication Standard

This product contains the following SARA (3 13) Toxic Release Chemicals: CHEMICAL NAME CAS NUMBER CONC.

PHOSPHORODITHOIC ACID, 0,O-DI 68649-42-3 1.09%

(2:l) (ZDDP)

-------I ----e-- ---

Cl-14-ALKYL ESTERS, ZINC SALTS

The following product ingredients are cited on the lists below: CHEhaCALNAME CAS NUMBER LIST CITATIONS

ZINC (ELEMENTAL ANALYSIS) (0.12%) 7440-666 22 CHLORINE (ELEMENTAL ANALYSIS) (0.01%) 7782-50-5 22 PHOSPHORODITHOIC ACID, 68649-42-3 18,20,2 1 , 22,24,25

1) (ZDDP) (1.09%)

l=ACGM ALL 6=IARC 1 ll=TSCA 4 16=CA P65 CARC 21=LA RTK 2=ACGIH AI 7=IARC 2A I2=TSCA 5a2 17=CA P65 REPRO 22=MI 293 3=ACGIH A2 8=IARC 2B I3=TSCA 5e 18=CA RTK 23=MN RTK 4=NTP CARC M S H A CARC 14=TSCA 6 19=FL RTK 24=NJ RTK 5=NTP SUS IO=OSHA Z 15=TSCA 12b 2+IL RTK 25=PA RTK

26=RI RTK Code key: CARC=Carcinogen; SUS=Sqected Carcinogen; REPRO=Reproductive

16. OTHER INFORMATION

0,O-DI Cl-14-ALKYL ESTERS, ZINC SALTS (2:

- REGULATORY LISTS SEARCHED -

----------

USE: AUTOMOTIVE ENGINE OIL NOTE: MOBIL PRODUCTS ARE NOT FORMULATED TO CONTAIN PCBS.

Please call the Customer Response Center on 800-662-4525 for formulation disclosure.

For Internal Use Only: MHC: 1 * 1 * O* 1* 1*, MPPEC: A, REQ: US - MARKETING, SAFE USE: L

Information given herein is offered in good faith as accurate, but without guarantee. Conditions of use and suitability of the product for particular uses are beyond our control; all risks of use of the product are therefore assumed by the user and WE EXPRESSLY DISCLAIM ALL WARRANTIES OF EVERY KIND AND NATURE, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN RESPECT TO THE USE OR SUITABILITY OF THE PRODUCT. Nothing is intended as a recommendation for uses which infringe valid patents or as extending license under valid patents. Appropriate warnings and safe handling procedures should be provided to handlers and users. Alteration of this document is strictly prohibited. Except to the extent required by law, republication or retransmission of this document, in whole or in part, is not permitted. Mobil assumes no responsibility for accuracy of information unless the document is the most current available from an official Mobil distribution system. Mobil neither represents nor warrants that the format, content or product formulas contained in this document comply with the laws of any other country except the United States of America.

___-__-___---__-_---_______I____________---------------

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copyright 1996 Mobil Corporation, All rights reserved

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MSDS Sheet for Tar and Grease Remover (R7K156)

MANUFACTURERS NAME EMERGENCY TELEPHONE NO.

101 Prospect Avenue N.W. Cleveland, OH 441 15 DATE OF PREPARATION INFORMATION TELEPHONE NO.

SHERWIN-WILLIAMS AUTOMOTIVE FINISHES (21 6) 566-2917

15-JUN-98 (216) 566-2902

Section I - PRODUCT IDENTIFICATION PRODUCT NUMBER HMlS CODES Health 2 R7K156 Flammability 3 Reactivity 0 PRODUCT NAME SHER-WILL-CLEAN' Wax and Grease Remover PRODUCT CLASS Reducer

Section II - HAZARDOUS INGREDIENTS INGREDIENT ACGIH OSHA CAS No. % by WT TLV PEL UNITS V.P.

V. M. & P. Naphtha. 32 300 300 PPM 12.00

Mineral Spirits. 54 100 100 PPM 2.00

Toluene. 11 so 100 PPM (Skin) 22.00 108-88-3 STEL 150 PPM (Skin)

Dipentene. 2 Not Established 2.00

64742-89-8 STEL 400 PPM

64742-88-7

138-86-3

Section 111 - PHYSICAL DATA _______l_l_l_ I_ _______--_________-___________ PRODUCT WEIGHT 6.40 Ib./gal. EVAPORATION RATE Slower than Ether SPECIFIC GRAVITY 0.77 VAPOR DENSITY Heavier than Air

VOLATILE VOLUME 100 - SOLUBILITY IN WATER N.A. VOC (Theoretical) 6.40 Ib. 766 gm. (less Federally Exempt Solvents)

BOILING POINT 222-395 F MELTING POINT N.A.

UNUSUAL FIRE AND EXPLOSION HAZARDS Keep containers tightly closed. Isolate from heat, electrical equipment, sparks, and open flame. Closed containers may explode when exposed to extreme heat. Application to hot surfaces

UNITI PAGE^^


requires special precautions. During emergency conditions overexposure to decomposition products may cause a health hazard. Symptoms may not be immediately apparent. Obtain medical attention. SPECIAL FIRE FIGHTING PROCEDURES Full protective equipment including self-contained breathing apparatus should be used. Water spray may be ineffective. If water is used, fog nozzles are preferable. Water may be used to cool closed containers to prevent pressure build-up and possible autoignition or explosion when exposed to extreme heat.

Section V - HEALTH HAZARD DATA ROUTES OF EXPOSURE Exposure may be by INHALATION andlor SKIN or EYE contact, depending on conditions of use. To minimize exposure, follow recommendations for proper use, ventilation, and personal protective equipment. ACUTE Health Hazards EFFECTS OF OVEREXPOSURE Irritation of eyes, skin and respiratory system. May cause nervous system depression. Extreme overexposure may result in unconsciousness and possibly death. SIGNS AND SYMPTOMS OF OVEREXPOSURE Headache, dizziness, nausea, and loss of coordination are indications of excessive exposure to vapors or spray mists. Redness and itching or buming sensation may indicate eye or excessive skin exposure. MEDICAL CONDlTiONS AGGRAVATED BY EXPOSURE None generally recognized. EMERGENCY AND FIRST AID PROCEDURES If INHALED: If affected, remove from exposure. Restore breathing. Keep warm and quiet. If on SKIN: Wash affected area thoroughly with soap and water. Remove contaminated clothing and launder before reuse. If in EYES: Flush eyes with large amounts of water for 15 minutes. Get medical attention. If SWALLOWED: Never give anything by mouth to an unconscious person. DO NOT INDUCE

VOMITING. Give conscious patient several glasses of water. Seek medical attention. CHRONIC Health Hazards No ingredient in this product is an IARC, NTP or OSHA listed carcinogen. Prolonged overexposure to solvent ingredients in Section II may cause adverse effects to the liver, urinary, cardiovascular and reproductive systems. Reports have associated repeated and prolonged overexposure to solvents with permanent brain and nervous system damage.

-------_-__----__--_---- Section VI -- REACTIVITY DATA--- STABILITY -- Stable CONDITIONS TO AVOID None known. INCOMPATIBILITY None known. HAZARDOUS DECOMPOSITION PRODUCTS By fire: Carbon Dioxide, Carbon Monoxide HAZARDOUS POLYMERIZATION Will not occur

Section VI1 _- SPILL OR LEAK PROCEDURES -__________-____________________________--~~--~--~-~--~-~---__--- -------- STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED Remove all sources of ignition. Ventilate and remove with inert absorbent. WASTE DISPOSAL METHOD Waste from this product may be hazardous as defined under the Resource Conservation and Recovery Act (RCRA) 40 CFR 261. Waste must be tested for ignitability to determine the applicable EPA hazardous waste numbers. Incinerate in approved facility. Do not incinerate closed container. Dispose of in accordance with Federal, State, and Local regulations regarding pollution.

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Section VI I I - PROTECTlON INFORMATION --_-_I --__________-_____-_- - _-I-----------_-- -_------- PRECAUTIONS TO BE TAKEN IN USE Use only with adequate ventilation. Avoid breathing vapor and spray mist. Avoid contact with skin and eyes. Wash hands after using. VENTILATION Local exhaust preferable. General exhaust acceptable if the exposure to materials in Section I I is maintained below applicable exposure limits. Refer to OSHA Standards 191 0.94, 1910.107, 191 0.1 08. RESPIRATORY PROTECTION If personal exposure cannot be controlled below applicable limits by ventilation, wear a properly fitted organic vapor/particulate respirator approved by NIOSH/MSHA for protection against materials in Section II . When sanding or abrading the dried film, wear a dust/mist respirator approved by NlOSHlMSHA for dust which may be generated from this product, underlying paint, or the abrasive. PROTECTIVE GLOVES Wear gloves which are recommended by glove supplier for protection against materials in Section II. EYE PROTECTION Wear safety spectacles with unperforated sideshields.

Section IX - PRECAUTIONS DOL STORAGE CATEGORY 1B PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING Contents are FLAMMABLE. Keep away from heat, sparks, and open flame. During use and until all vapors are gone: Keep area ventilated - Do not smoke - Extinguish all flames, pilot lights, and heaters - Tum off stoves, electric tools and appliances, and any other*sources of ignition. Consult NFPA Code. Use approved Bonding and Grounding procedures. Keep container closed when not in use. Transfer only to approved containers with complete and appropriate labeling. Do not take intemally. Keep out of the reach of children. OTHER PRECAUTIONS Intentional misuse by deliberately concentrating and inhaling the contents can be harmful or fatal.

Section X -- OTHER REGULATORY INFORMATION ----------------------------- SARA 313 (40 CFR 372.65C) SUPPLIER NOTIFICATION CAS No. CHEMICAUCOMPOUND % by WT % Element

108-88-3 Toluene. 11 CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. TSCA CERTIFICATION All chemicals in this product are listed, or are exempt from listing, on the TSCA Inventory.

--

---_I-- ---- -----------

The above information pertains to this product as currently formulated, and is based on the information available at this time. Addition of reducers or other additives to this product may substantially alter the composition and hazards of the product. Since conditions of use are outside our control, we make no warranties, express or implied, and assume no liability in connection with any use of this information.

Sherwin Williams Automotive Finishes 101 Prospect Avenue N.W. Cleveland, OH 441 15

UNIT^ PAGE^^

Unit 1 - Module 3 - Pollution Prevention

Learning Objectives

1.

2.

3.

4.

Understand concept of pollution prevention vs. pollution control.

Understand how pollution prevention can save money.

Describe the 3 R s of pollution prevention - Reduce, Reuse and Recycle.

Understand how to evaluate and choose pollution prevention techniques.

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1. In your own words, explain the difference between “preventing” pollution &d “controlling” pollution.

Preventing pollution means not creating it in the f m place through using non-toxic substances or reducing the amount or toxicity of waste by changing the way you do things around the shop. Pollution control means making certain that when pollution is created, it is carefully controlled. I.E., Not spilled, stored in proper containers, stored in an area with a sealed floor and berms, proper treatment and disposal.

2. Rank the following in the order of what is the best (1) to least desirable (4):

A) Reducing use of hazardous materials to avoid creating waste - 1 - 3 B) Treating hazardous waste to make it less harmful - - 4 C) Dumping hazardous waste in your backyard - -

2 handling - - D) Generating a smaller amow of hazardous waste by careful

3. Which of the following is NOT a pollution prevention technique?

A) B) C) D)

Burning used oil to heat the shop Using funnels and spigots when dispensing fresh oil to prevent spilling Changing the place where hazardous waste is sent Switch from a solvents parts cleaner to an aqueous parts cleaner solution

4. A pollution prevention project will always cost more money to implement than the current methods in place. A) True B) False

5 . Pollution prevention includes energy and water conservation as well as recycling of nm-hazardms mterials . A) True B) False

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Unit I - Module 3 - Pollution Prevention

Pre/Post Test

1.

2.

3.

4.

5 .

In your own words, explain the difference between “preventing” pollution and pollution “control.

Ranlr the following in the order of what is the best (1) to least desirable (4):

A) B) Treating hazardous waste to make it less harmful - C) Dumping hazardous waste in your backyard -

handling -

Reducing use of hazardous materials to avoid creating waste -

D) Generating a smaller amount of hazardous waste by careful

Which of the following is NOT a pollution prevention technique?

A) B) C) D)

Burning used oil to heat the shop Using funnels and spigots when dispensing fresh oil to prevent spilling Changing the place where hazardous waste is sent Switch from a solvents parts cleaner to an aqueous parts cleaner solution

A pollution prevention project will always cost more money to implement than the current methods in place.

A) True B) False

Pollution prevention includes energy and water conservation as well as recycling of non-hazardous materials.

A) True B) False

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~- ~~

Pollution Prevention

Replace hazardous solvent with a nonhazardous cleaner

What is Pollution Prevention?

~~ ~~~

Reduce the quantity of water being used: Use cleaning methods not involving water on the floors. Use drip pans a i d spills prevention to reduce the amount of oil, solvents etc. on the floor.

Pollution prevention is really a very simple idea. Instead of having to carefully manage waste so it doesn't get into the environment as pollution, with pollution prevention (P2) you don't create waste in the first place. It can involve using non-hazardous materials or can mean changing shop practices to create either smaller amounts of hazardous waste or hazardous waste with lower toxicity. Pollution prevention encourages more efficient use of

, Increase and improve transfer

1 amount of overspray. efficiency to reduce the

hazardous materials

0 water other natural resources

enerjg

Type of Waste

Parts cleaning waste solvents

Wastewater from cleaning vehicle or floor cleaning

P2 is not a new concept. Reducing waste by reexamining the source of the waste not only decreases expensive waste transportation, disposal and regulatory costs, but can improve efficiency, increase production and save money.

Pollution Prevention is a matter of attitude as much as a matter of taking action. The first step in reducing waste is to rethink the ways you look at waste. Don't think of waste as an unavoidable part of normal operations. Think of waste as money going out of a business that could be converted to increased profits. This change in attitude from "how do I get rid of waste" to "how do I prevent waste" is the place to start.

)

Pollution Control

Ship solvents off-site to be burnedrec ycled

Send wastewater to the waste water treatment plant or

~~~ ~~

Paint overspray from auto body painting r

septic system

Use a paint arrestor to catch solid paint particles from spray operations DisDose of used arrestors.

:ontrol

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Pollution Prevention Can Save Money

When a company generates waste (both hazardous and non-hazardous), it may be wasting money in several ways:

1. Health costs resulting from employee exposure to hazardous materials. When employees are exposed to hazardous materials, the risk of illness and accidents increases. In addition to harming employees, these illnesses may result in lost work t h e and workers compensation claims which cost the business money.

2. Wasted raw materials. When wastes are generated because of careless operating practices, materials are wastes and the business has to buy more to replace the wasted materials. Examples of careless operating practices are: spilling materials, no keeping storage containers covered or in good condition, using more materials than needed and allowing volatile pmdwts (those with low vapor pressures such as solvents) to evaporate by leaving lids and caps OK

3. Hazardous waste disposal costs. State and federal laws requke hazardous waste to be transported, stored, and disposed of or recycled by EPA-permitted hazardous waste management companies. These services are expensive. Hazardous waste disposal can cost as much as $700 to $800 per 55-gallon drums, depending on the waste. Reducing hazardous waste will save money in disposal fees.

4. Costs for managing wastes. In addition to disposal fees, other costs for managing wastes include: Time spent handling wastes (labeling, storing wastes, inspecting and maintaining storage areas). Time spent filling out paperwork. Federal and local fees for waste generation and air emissions. Facility work space used for waste storage.

5 . Environmental liability. “Cradle-to-grave” liability means that the company that generates the waste is responsible for waste fiom the time it is generated until it is disposed of. If the waste is accidentally spilled during transportation, or is disposed of improperly, the generator is responsible and can be heid liable for clean-up costs. Hazardous waste cleanup can cost fiom hundreds of thousands to tens of millions of dollars. The best way to reduce liability is to reduce waste generated. Another way to is disposing of or recycle wastes properly through an EPA-permitted hazardous waste management company.

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There are three ways to do “pollution prevention” 1) Reduce - don’t create the waste in the first place; 2) Reuse - give it a second life; and 3) Recycle - recover valuable resources. Considering the three ways to do pollution prevention, which of the following examples do you think is the best way to deal with solvents?

A. Solvent distillation (solvent recycling) B. C.

Extending the life of the solvent by reusing it a second time. Eliminating the solvent altogether by using an alternative water-based solvent.

C is best, then B, then A. Since C doesn’t use hannfd solvents at all, it is the best approach. B uses less solvents because it reuses the same batch of solvents twice. Choice A also reuses the solvents but only after the solvent has been recycled using special equipment, energy and other natural resources. The three different types of pollution prevention will help to evaluate how you use chemicals and manage wastes. Although your strategies will be a blend of these practices, it is best to aim to toward reducing or reusing.

Reduce

Reducing waste means eliminating the creation of the waste at the source of generation, usually within a process. Reduction increases efficiency because it minimizes the environmental and financial impact of wastes through substituting materials or changing processes so that fewer waste materials are produced.

The most cost-effective and desirable approach to sound waste management is to prevent wastes from being produced at all. A few general tips can be applied to the automotive industry and waste streams to help prevent waste generation. Some options are:

0 Good Housekeeping Practices refer to an improved operation and maintenance (including preventive maintenance) of existing facilities, inventory controls, and spill and leak prevention.

Substitution with Non-Toxic Substances by replacing a toxic substance used in a process with a nontoxic or less toxic substance.

Changing How You Do Your Work such as process redesign, process modification and equipment changes. One example is pre-cleaning a part with a brush before using the solvent parts cleaner.


Reuse is the use of a material at least twice, without changing its original form. The secondary use may be the same as, or different from, the original use. Each time a material is reused, raw material does not need be manufactured, purchased, or disposed. In other words, don't throw away a good thing! For example, solvent used to clean an automobile carburetor may be used a second time to clean a crankcase cover.

Recycle

Recycling is the collection, separation, and recovery of useful materials which cannot be directly reused or would otherwise be discarded as waste.

At an auto repair shop, you can recycle waste antifreeze to remove metal contaminants. Or, your shop can have its waste oils picked up to be recycled. Waste oil can be filtered and blended with virgin fuel oil so it can be burned again. Another form of recycling is buming of waste oils to recover the energy.

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Steps for Doing Pollution Prevention

Before spending a lot of money buying new chemicals and equipment, a shop needs to determine the best places and ways to incorporate pollution prevention.

Step 1: Look at all the chemicals and oils you buy and use: Which ones come in with the car and which ones end up as waste? Look at purchasing information, waste shipping papers and take an inventory of the chemical and wastes you have in the shop. Ask:

0 Why do we use this chemical?

Why is this waste generated?

Can the ways we are doing things be changed to use fewer or less

Can the ways we are doing things be changed to produce less or no

0 Is it necessary?

0 Is it necessary? 0

toxic chemicals?

waste? 0

Then, figure out what options you have to reduce chemical usage or generate less or no waste. Talk to other people in the shop to generate ideas.

Step 2: Decide What Pollution Prevention Technique(s) You Want to Do Evaluate all the chemicals and waste streams to determine which ones are:

0 The most expensive to manage The riskiest to your health Which pollution prevention option will pay for itself the fastest Which pollution prevention option is the easiest to do Which pollution prevention option ensures the best quality work

0

0

0

0

Pick the chemical or waste stream that needs the most attention and then pick a pollution preventiofi technique to decrease or elininate it.

Step 3: Put the New Pollution Prevention Technique(s) in Place Once you and your management have chosen the P2 technique, put it in place. All employees need to be trained and everyone must keep an eye out to see how well the change is working. Is it affecting the quality of the paint job? Is it affecting the quality of the brake work? You may need to adjust how you’re doing the pollution prevention to get it to work correctly.

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Class Exercise: Fender Bender Experiment (For Auto Body Classes)

Business manufactures products in response to consumer demands. Body shops face difficult decisions in determining how to get the best quality finish without harming workers or the environment. In order to refinish cars to meet customer demands, businesses usually need to use hazardous materials to create a product with characteristics which are attractive to the public.

Learning Objectives - Students will gain an appreciation of the hard choices involved in doing quality auto body work and understand the basic process of pollutiop prevention as it applies to auto body work.

List of Equipment and Materials per Group

1. 2. Reducers and hardeners 3. Plastic Measuring Cups 4. Wooden paint paddle 5. Sheet metal or fender

7. Solvents for cleanup

Paint for mixing using a formula.

6- spraygun

Steps for Experiment

1.

2. 3.

4.

Assemble the students into groups of five or six and seat each group at a separate table with the equipment listed above. Ask each group to invent a shop name, and write the team names on a blackboard. Ask the students to mix the paint, paint the fender or sheet metal and cleanup the spray gun. The goup that uses the smallest amount of raw materials and creates the smallest amount of waste wins.

Contioned discussioo

1. 2.

Were any raw materials were not used? Could any have been eliminated? What can be done with the hazardous waste that was generated? Are there landfills nearby? Are there incinerators nearby? Is there a sewage treatment plant nearby? What happens if they are not managed properly? Is the landfill better than an incinerator? What do they do with the air pollutants and the ash that are byproducts of incineration? Who will be responsible to clean it up if there is a problem?

UNITI PAGE^^


3. While reducing the amount of waste is good, the best idea is not to create it in the first place. How could this be done? Could you make a car without a fender? Could you make a fender with no colors or a single color? Would you make a fender with non-toxic colors even though only a few muted colors (soft greens and browns) are available and they are more expensive? If non-toxic paints cost $.15 per ounce while "regular" paint costs only $.05, which would you use? Hazardous waste disposal costs $300 per drum and each drum holds 100 lbs. If disposal costs are added to purchase costs, which is the better deal? What could you do if a competitor undersold you by producing the products with environmentally unsound practices? How would you compete? If it is consistently more profitable to use environmentally damaging products over environmentally friendly ones, what can be done to persuade businesses to use the environmentally friendly product?

4.

5.

Class Exercise: Fender Bender Experiment (For Auto Repair Classes)

Business manufactures products in response to consumer demands. Auto Repair shops face difficult decisions in determining how to get their work done with the best quality in a the most efficient manner and without harming workers or the environment.

Learning Objectiyes - Students will gain an appreciation of the hard choices involved in doing quality auto repair work and understand the basic process of pollution prevention as it applies to auto repair work.

List of Equipment and Materials per Group

1. Automatic Transmission Fluid 2. Drippan 3. Shop wipers 4. Absorbent 5. Dust pmi and Sru~h

Steps in the Experiment

1.

2. 3.

Assemble the students into groups of five or six and have each group working on a different car. Ask each group to invent a shop name, and write the team names on a blackboard. Each group is to change automatic transmission fluid on a car paying attention to reduce spills on the shop floor as much as possible. The group that does not spill or has the smallest spill (and has the cleanest clothes) is the winner. If all the groups spill some of the ATF, the group who is able to pick up the most of their spill to the waste oil drum and who has the cleanest floor using the fewest cleanup materials is the winner.

UNIT^ PAGE^^


Continued discussion

1. Is the ATF a hazardous waste? When would it have to be managed as a hazardous waste?

2. What can be done with any hazardous waste that is generated? Are there landfills nearby? Are there incinerators nearby? Is there a sewage treatment plant nearby? What happens if they are not managed properly? Is the landfill better than an incinerator? What do they do with the air pollutants and the ash that are byproducts of incineration? Who will be responsible to clean it up if there is a problem?

3. While recycling waste oil is good, the best idea is not to create it or as much of it in the first dace. How could this be done? Could you change the oil less often? Use a Merent oil? Change engine design so it did not contaminate or break down the oil as much?

4. What could you do if a competitor undersold you by doing ATF changes quickly and dripped ATF all over their shop? At the end of each day, they throw some absorbent on the shop floor and then throw the absorbent in the dumpster. How would you compete?

UNIT^ PAGE^^


Material Data Safety Sheet for AUTOMATIC TRANSMISSION FLUID

566158-00

APPROVAL DATE: 12/04/97 PRODUCT NAME: AUTOMATIC TRANSMISSION FLUID SUPPLIER: MOBIL OIL CORP.

AMERICAS MARKETING AND REFINING

3225 GALLOWS F!D. FAIRFAX, VA 22037

24 - Hour Emergency (call collect): 609-737-4411 Product and MSDS Information: 800-662-4525 703 - 84 9- 5700 CHEMTREC : 000-424-9300 202-483-7616

CHEMICAL NAMES AND SYNONYMS: PET. HYDROCARBONS AND ADDITIVES

INGREDIENTS CONSIDERED HAZARDOUS TO HEALTH: This product is not formulated to contain ingredients which have exposure limits established by U.S. agencies. 'It is not hazardous to health as defined by the European Union Dangerous Substances/Preparations Directives. See Section 15 €or a regulatory analysis of the ingredients.

See Section 15 for European Label Information.

See Section 0 for exposure limits (if applicable).

US OSHA HAZARD COMMUNICATION STANDARD: Product assessed in accordance with OSHA 29 CFR 1910.1200 and determined not to be hazardous.

EFFECTS OF OVEREXPOSURE: No significant effects expected

EMERGENCY RESPONSE DATA: Red Liquid. DOT ERG No. - NA

UNIT? PAGE^^


EYE CONTACT: Flush thoroughly with water. If irritation occurs, call a physician.

SKIN CONTACT: Wash contact areas with soap and water.

INHALATION: Not expected to be a problem.

INGESTION: Not expected to be a problem. flowever, if greater than 35 liter(pint1 ingested, immediately give 1 to 2 glasses of water and call a physician, hospital emergency room or poison control center for assistance. Do not induce vomiting or give anything by mouth to an unconscious person.

EXTINGUISHING MEDIA: Carbon dioxide, foam, dry chemical and water fog.

SPECIAL FIRE FIGHTING PROCEDURES: Water or foam may cause frothing. Use water to keep fire exposed containers cool. Water spray may be used to flush spills away from exposure. Prevent runoff from fire control or dilution from entering streams, sewers, or drinking water supply.

SPECIAL PROTECTIVE EQUIPMENT: For fires in enclosed areas, fire fighters must use self-contained breathing apparatus.

UNUSUAL FIRE AND EXPLOSION HAZARDS: None. Flash Point C(F) : > 170(338) (ASTM D-92). Flammable limits - LEL: NA, UEL: NA.

NFPA HAZARD ID: Health: 0, Flammability: 1, Reactivity: 0

HAZARDOUS DECOMPOSITION PRODUCTS: Metal oxides. Carbon monoxide.

NOTIFICATION PROCEDURES: Report spills as required to appropriate authorities. U. S. Coast Guard regulations require immediate reporting of spills that could reach any waterway including intermittent dry creeks. Report spill to Coast Guard toll free number (800) 424-8802. In case of accident or road spill notify CHEMTREC (800) 424-9300.

PROCEDURES IF MATERIAL IS RELEASED OR SPILLED: Adsorb on fire retardant treated sawdust, diatomaceous earth, etc. Shovel up and dispose of at an appropriate waste disposal facility in accordance with current applicable laws and regulations, and product characteristics at time of disposal.

ENVIRONMENTAL PRECAUTIONS: Prevent spills from entering Storm sewers or drains and contact with soil.

PERSONAL PRECAUTIONS: See Section 8

UNITI PAGE~O


HANDLING: No special precautions are necessary beyond normal good hygiene practices. See Section 8 for additional personal protection advice when handling this product.

STORAGE: Do not store in open or unlabeled containers. Store away from strong oxidizing agents or combustible material.

VENTILATION: No special requirements under ordinary conditions of use and with adequate ventilation.

RESPIRATORY PROTECTION: No special requirements under ordinary conditions of use and with adequate ventilation.

EYE PROTECTION: Normal industrial eye protection practices should be employed.

SKIN PROTECTION: No special equipment required. However, good personal hygiene practices should always be followed.

EXPOSURE LIMITS: This product does not contain any components which have recognized exposure limits. However, a threshold limit value of 5.00 mg/m3 is suggested for oil mist.

Typical physical properties are given below. Consult Product Data Sheet

for specific details.

APPEARANCE: Liquid COLOR: Red ODOR: Mild ODOR THRESHOLD-ppm: NE pH: NA BOILING POINT C(F) : > 316(600) MELTING POINT C(F) : NA FLASH POINT C(F) : > 170(338) (Asnil D-92) FLAMMABILITY: NE AUTO FLAMMABILITY: NE EXPLOSIVE PROPERTIES: NA OXIDIZING PROPERTIES: NA VAPOR PRESSURE-"Hg 20 C: < 0.1 VAPOR DENSITY: > 2 . 0 EVAPORATION RATE: NE RELATIVE DENSITY, 15/4 C: 0.869 SOLUBILITY IN WATER: Negligible PARTITION COEFFICIENT: > 3.5 VISCOSITY AT 40 C, cSt: VISCOSITY AT 100 C, CSt: >

3 6 . 0 6.8

UNIT^ PAGE^^

Unit 1 - Module 3 - Pollution Prevention POUR POINT C(F) : c -45(-49) FREEZING POINT C(F) : NE VOC: c 5-00 (Wt. % ) ; 0.358 lbs/gal NA=NOT APPLICABLE NE=NOT ESTABLISHED D=DECOMPOSES FOR FURTHER TECHNICAL INFORMATION, CONTACT YOUR MARKETING REPRESENTATIVE

STABILITY (THERMAL, LIGHT, ETC.): Stable. CONDITIONS TO AVOID: Extreme heat. INCOMPATIBILITY (MATERIALS TO AVOID) : Strong oxidizers. BAZARDOUS DECOMPOSITION PRODUCTS: Metal oxides. Carboq monoxide. HAZARDOUS POLYMERIZATION: Will not

11. TOXICOLOGICAL DATA occur- ____________________-- - - - - - - - -__-- - - - - - - - - - - - -_- - - - - - - - - - - - - - - - - - -_- -_- -

-ACUTE TOXICOLOGY --

ORAL TOXICITY (RATS): Practically non-toxic (LD50: greater than 2000 mg/kg). ---Based on testing of similar products and/or the components.

DERMAL TOXICITY (RABBITS): Practically non-toxic (LD50: greater than 2000 mg/kg). ---Based on testing of similar products and/or the components.

INHALATION TOXICITY (RATS): Not applicable --- Harmful concentrations of mists and/or vapors are unlikely to be encountered through any customary or reasonably foreseeable handling, use, or misuse of this product.

EYE IRRITATION (RABBITS): Practically non-irritating. (Draize score: greater than 6 but 15 or less). ---Based on testing of similar products and/or the components.

SKIN IRRITATION (RABBITS): Practically non-irritating. (Primary Irritation Index: greater than 0.5 but less than 3). ---Based

on testing of similar products and/or the components. - - - SUBCHRONIC TOXICOLOGY (SUMMARY) - -

Severely solvent refined and severely hydrotreated mineral base oils have been tested at Mobil Environmental and Health Sciences Laboratory by dermal application to rats 5 days/week for 90 days at doses significantly higher than those expected during normal industrial exposure. Extensive evaluations including microscopic examination of internal organs and clinical chemistry of body fluids, showed no adverse effects.

- - - CHRONIC TOXICOLOGY (SUMMARY) - -

The base oils in this product are severely solvent refined and/or severely hydrotreated. Chronic mouse skin painting studies of severely treated oils showed no evidence of carcinogenic effects. These results are confirmed on a continuing basis using various screening methods such as the Mobil Modified Ames Test and IP-346.

ENVIRONMENTAL FATE AND EFFECTS: This product is expected to be inherently

UNITI PAGE^^

Unit I - Module 3 - Pollution Prevention biodegradable. There is no evidence to suggest bioaccumulation will occur. it is not expected to be toxic to aquatic organisms. Accidental spillage may lead to penetration in the soil and groundwater. However, there is no evidence that this would cause adverse ecological effects.

WASTE DISPOSAL: Product is suitable for burning in an enclosed controlled burner for fuel value or disposal by supervise-incineration. Such burning may be limited pursuant to the Resource Conservation and Recovery Act. In addition, the product is suitable for processing by an approved recycling facility or can be disposed of at an appropriate government waste disposal facility. Use of these methods is subject to user compliance with applicable laws and regulations and consideration of product characteristics at time of disposal.

specifically listed by the EPA as a hazardous waste ( 4 0 CF’R, Part 261D), nor is it formulated to contain materials which are listed hazardous wastes. It does not exhibit the hazardous characteristics of ignitability, corrosivity, or reactivity and is not formulated with contaminants as determined by the Toxicity Characteristic Leaching Procedure (TCLP) . However, used product may be regulated.

RCRA INFORMATION: The unused product, in our opinion, is not

USA DOT: NOT REGULATED BY USA DOT. RID/ADR: NOT REGULATED BY RID/ADR. IMO: NOT REGULATED BY IMO. IATA: NOT REGULATED BY IATA.

Governmental Inventory Status: All components comply with TSCA. EU Labeling: EU labeling not required. U . S . Superfund Amendments and Reauthorization Act (SARA) Title 111: This product contains no “EXTREMELY HAZARDOUS SUBSTANCES1‘. SARA (311/312) REPORTABLE HAZARD CATEGORIES: None. This product contains no chemicals reportable under SARA (313) toxic release program. The following product ingredients are cited on the lists below:

- - - REGULATORY LISTS SEARCHED - -

21=LA RTK l=ACGIH ALL 6=IARC 1 11-TSCA 4 16=CA P65 CARC 2=ACGIH A1 7=IARC 2A 12=TSCA 5a2 17=CA P65 REPRO 22=MI 293

13=TSCA 5e 18=CA RTK 23=MN RTK 3=ACGIH A2 8=IARC 2B 4=NTP CARC 9=OSHA CARC 14=TSCA 6 19=FL RTK 24=NJ RTK 5=NTP SUS lO=OSHA 2 15=TSCA 12b 20=IL RTK 25=PA RTK

26=RI RTK

UNITI PAGE^^

Unit I - Module 3 - Pollution Prevention Code key: CARC=Carcinogen; SUS=Suspected Carcinogen; REPRO=Reproductive

Please call the Customer Response Center on 800-662-4525 for formulation disclosure.

For Internal Use only: MHC: 1* I* NA 1* I*, MPPEC: A, REP: us - MARKETING, SAFE USE: L

Information given herein is offered in good faith as accurate, but without guarantee. Conditions of use and suitability of the product for particular uses are beyond our control; all risks of use of the product are therefore assumed by the user and WE EXPRESSLY DISCLAIM ALL WARRANTIES OF EVERY KIND AND NATURE, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN RESPECT TO THE USE OR SUITABILITY OF THE PRODUCT. Nothing is intended as a recommendation for uses which infringe valid patents or as extending license under valid patents. Appropriate warnings and safe handling procedures should be provided to handlers and users. Alteration of this document is strictly prohibited. Except to the extent required by law, republication or retransmission of this document, in whole or in part, is not permitted. Mobil assumes no responsibility for accuracy of information unless the document is the most current available from an official Mobil distribution system. Mobil neither represents nor warrants that the format, content or product formulas contained in this document comply with the laws of any other country except the United States of America. (Copyright 1996 Mobil Corporation, All rights reserved)

UNITI PAGE^^

Unit 2 - Module 1 - Surface Preparation 1 Learning Objectives

1. Learn ways to reduce solvent usage during surface preparation including a) prewashing with soap and water, b) using water-based cleaners and c) Using solvent-based cleaners as a last resort.

2. Be able to list the wastes generated fiom surface preparation. Know how to properly dispose of the wastes including vehicle washing wastewater.

3. Learn the health hazards associated with sanding and ways to reduce them.

Unit 2 - Module 1 - Surface Preparation


1. The first stage of vehicle washing is to wash with mild soap and water.

A) True B) False

2. Washwater fiom vehicle washing may contah

A) Dirt B) Oil

D) Solvents E) AU of the above

C) soaps

3. Since vehicle washwater is not a hazardous waste, it doesn’t matter where it goes when you are done washing the car.

A) True B) False

4. Rank in order of best to worst for your health and the environment.

2 3 1

A) Water-based cleaners _ - B) Solvent-based cleaners -- C) Soap and water --

5. A good way to reduce your exposure to dust contaminated with lead and chromium from sanding is to use ventilated sanders.

A) True B) False

UNIT^ PAGE^


PrePost Test

1. The first stage of vehicle washing is to wash with mild soap and water.

A) True B) False

2. Washwater from vehicle washing may contain:

A) Dirt B) Oil C) Soaps D) Solvents E) All of the above

3. Since vehicle washwater is not a hazardous waste, it doesn’t matter where it goes when you are done washing the car.

A) True . B) False

4. Rank in order of best to worst for your health and the environment.

A) Water-based cleaners B) Solvent-based cleaners C) Soap and water

5 . A good way to reduce your exposure to dust contaminated with lead and chromium from sanding is to use ventilated sanders.

A) True B) False

UNIT2 PAGE3


Pollution Prevention in Surface Preparation

The surface of a vehicle must be clean prior to refinishing so that undercoats andor topcoats will adhere to it. Many cleaners commonly used to remove surface contamination contain toluene, which is an EPA-listed hazardous waste and volatile organic compound (VOC). The use of hazardous solvents should be avoided whenever possible. Here are three basic tips to reduce solvent waste in surface preparation:

1. Prewash dirt and grime from vehicles with water or a soap and water mixture.

2. Use water-based cleaners when possible for subsequent cle&g to remove tar, grease, wax etc.

3. If necessary, use solvent-based cleaners as a last resort to remove stubbom silicone, tar and grease. Additional cleaning operations should be performed using water-based cleaners.

Prewash using soap and water

Much of the contamination on the surface of a vehicle is dirt that should be washed off using water alone, or a mild soap and water mixture. Not only are soap and water safer for the environment than hazardous solvents, they are also less expensive.

Don't forget to conserve water when washing vehicles - use only as much water as necessary. And remember, don't discharge untreated wastewater outdoors. Discharge wastewater to the city sewer.

Use water-based cleaners

After washing with mild soap and water, there may be grease, tar, wax or other contaminants remaining on the vehicle. Use water-based cleaners whenever possible for subsequent cleaning to remove stubbom contaminants. Water-based cleaning products have been developed as a substitute for hazardous solvents. These water-based cleaners are stronger than traditional car wash soap, but not as toxic as petroleum-based solvents.

Prior to cleaning, make sure that the cleaning product is compatible with the surface to be cleaned.

Note that many water-based cleaners are not recommended for use on waterbased or acrylic lacquer finishes. Consult the product manufacturer for specific information.

.i

Unit 2 - Module I - Surface Preparation

Use solvent-based cleaners as a last resort

If waterborne cleaners prove unsatisfactory, solvent-based cleaners may be necessary to remove heavy silicon and grease contamination. When solvent-based cleaners must be used, do so sparingly. Don't use more solvent than is necessary. Replace the lid on the solvent containers when not in use. Keep solvent-laden dirty rags in a closed container prior to disposing of them properly. If possible, avoid painting sequences that would require multiple pre-paint cleaning operations. For example, apply the undercoat after performing operations that could contaminate the surface with grease or oil. A contaminated undercoat will have to be washed again.

Wastewater

Wastewater generated from vehicle cleaning operations may contain oil, dirt, soaps and solvents. This wastewater can pollute soil, groundwater, lakes and streams, and should not be discharged outdoors, to a septic system, or to a storm sewer. Avoid washing vehicles outdoors where wastewater can run off onto soil or into a storm sewer. Instead, discharge the wastewater to a wastewater system with an oiYwater separator that removes oil and solids before releasing the wastewater to the city sewer. Or, the wastewater can go to a tank. Oil should be removed from the wastewater and put in the waste oil container. Oil removal can be accomplished when the wastewater settles in a sump - solids will settle to the bottom, oil will float to the top, and water will be discharged to the sanitary sewer. If an oiYwater separator is not present, oil skimming equipment can be purchased. (See Unit 3, Module 9 on Floor drains)

Sludge

The solids that settle out from wastewater form a sludge. This sludge may be hazardous if hazardous wastes (such as solvents) have been put down the drain..This is one reason not to use hazardous solvents for vehicle cleaning. Hazardous sludge should be disposed of by a hazardous waste management company.

Rags

Rags used for surface preparation are potentially hazardous because they may be contaminated with grease, paint, or solvents. All rags (disposable and launderable ones) that are contaminated with hazardous solvents should be stored in sealed containers to prevent evaporation of solvent vapors into the air.

To reduce soiled rags, make sure they are appropriately sized for the job - cutting rags in half or in quarters can reduce waste. If possible for your application, use launderable cloth rags instead of disposable ones for surface cleaning. Launderable rags are not considered

UNIT^ PAGE^

Unit 2 - Module 1 - Surface PreDaration

a waste if they are cleaned through a contractual agreement with a commercial laundry and reused. If it is not possible to use cloth rags, and disposable rags must be used, they need to be classified as hazardous or nonhazardous prior to disposal. Nonhazardous rags can be disposed in the trash. (See Unit 3, Module 1 on Used Oil and Filters, Shop Wipers and Absorbents).

Controlling Dust from Sanding Operations

During auto body repair, sanding removes paint from the car surface and smooths body panels repaired with body filling operations. As a result, the dust from sanding may contain heavy metals such lead and chromium fiom the paints, abrasives fiom the sanding discs as well as contaminants fiom the fillers. All of these contaminants are harmful to the lungs and nervous systems of workers. Using ventilated mechanical sanders, workers will breathe in less dust.

UNIT2 PAGE6


HAZARD CONTROLS

Control of Dusts From Sanding in Autobody Repair Shops

During autobody repair, sanding removes paint from surfaces and smoothes body panels repaired with body filling compounds. Airborne dusts produced during these operations may contain hazardous substances, such as lead and chromium from surface coatings and abrasives from sanding discs, that are harmful to the lungs and nervous system of workers. Dust concentrations may also exceed OSHA standards. Effective control of worker exposure to dusts from sanding operations on autobody surfaces has been achieved by use of ventilated mechanical sanders.

VENTILATED SANDERS

Rotary/orbital and straight linelreciprocating sanders, equipped with HIGH VELOCITY, LOW VOLUME (HVLV) local exhaust ventilation as part of the tool's design, are recommended because they have been shown to be effective in reducing total dust concentrations during the sanding of body filling compounds. HVLV ventilated sanders have cut total dust concentrations to one-tenth the levels produced using unventilated sanders. (See ILLUSTRATION)

Increased cost of sanders equipped with HVLV ventilation is minor compared with nonventilated sanders. The amount of air used in the ventilated systems is also relatively low. Use of ventilated sanders can be enhanced by making them convenient to use, for example by installing retractable, flexible hosing attached to a central vacuum system. Although initial costs for this system including an air mover, air cleaners, and duct work can be substantial, the system will help eliminate expensive repaints, shorten clean up time, and extend sandpaper life. Workers prefer using these HVLV sanders and also reported their use results in a cleaner shop.

US. DEPARTMENT OF HEALTH AND HUMAN SERVICES Public Health Service Centers for Disease Control and Prevention National Institute for Occupational Safety and Health January 1996

UNIT^ PAGE^


For More Information

For a free copy of the report Evaluation of Ventilated Sanders in the Autobody Repair Industry, or for information on other occupational safety and health issues, call the National Institute for Occupational Safety and Health* (NIOSH),at:

1-800-35-NlOSH (1 -800-356-4674)

"NIOSH is the Federal agency responsible for conducting research and making recommendations for preventing work-related illness and injuries. HAZARD CONTROLS are based on research studies that show reduced worker exposure to hazardous agents or activities.

The principal contributors to this HAZARD CONTROLS are William A. Heitbrink, Division of Physical Sciences and Engineering, and Jerome P. Flesch, Education and Information Division, NIOSH.

This document is in the public domain and may be freely copied or reprinted. NIOSH encourages all HAZARD CONTROLS be made available to all interested

employers and workers.

DHHS (NIOSH) Publication No. 96-105

UNIT2 PAGE8

Unit 2 - Module 2 - Paint Spray Application Process

Learning Objectives

1. Learn to identi@ paint-related waste including air emissions in the form of volatile organic compounds (VOCs) and particulates and solid and hazardous wastes including waste paints and solvents.

2. Explain how to reduce VOC emissions in each phase of auto body surface coating.

3. Describe how to reduce VOC emissions through increasing transfer efficiency, using proper spray techniques, and improving paint mixing.

UNIT^ PAGE^

Unit 2 - Module 2 - Paint Spray Application Process ~~

PrePost Test - Teacher Version

1. VOC stands for:

A) VeryOldCar B) Volatile Organic Compound C) Vehicle Occupancy Capacity D) None of the above

2. Improving the transfer efficiency of spray painting means you use less paint to cover the same area.

A) True B) False

3. Which of the following factors affect transfer efficiency: A) Spray distance

C) Spray equipment type D) Spray technique E) All of the above

B) SPraYgunSetuP

4. Paint-related wastes are sometimes hazardous because of heavy metals used as pigments in paints. List one heavy metal potentially found in paint-related wastes.

Arsenic, barium, cadmium, chromium, lead, mercury, seleniumor silver

5 . The paints that are most likely to harm the ozone layer are those with the highest quantities of VOCs. Topcoats generally contain the most VOCs.

A) True B) False

UNIT^ PAGE 10

Unit 2 - Module 2 - Paint Spray Application Process I

PrerPost Test

1. VOC stands for:

A) VeryOldCar B) Volatile Organic Compound C) Vehicle Occupancy Capacity D) None of the above

2. Improving the transfer efficiendy of spray painting means you use less paint to cover the same area.

A) True B) False

3. Which of the following factors affect transfer efficiency:

A) Spray distance B) Spray gun setup C) Spray equipment type D) Spray technique E) All of the above 1

4. Paint-related wastes are sometimes hazardous because of heavy metals used as pigments in paints. List one heavy metal potentially found in paint-related wastes.

5 . The paints that are most likely to harm the ozone layer are those with the highest quantities of VOCs. Topcoats generally contain the most VOCs.

A) True B) False

Unit 2 - Module 2 - Paint Spray Application Process ~~

Wastes Associated With Automotive Painting

There are two general types of wastes from auto body shops: 1) air emissions, in the form of volatile organic compounds (VOCs) and particulates and 2) solid and hazardous wastes

l'opcoats (55%) -

including waste paints and solvents. We are concerned about volatile organic compounds because they form smog which can interfere with proper lung functioning, causing chest pain, shortness of breath, and aggravation of asthma. The majority of VOCs come from topcoats. Equipment cleaning using solvents, undercoats and surfice preparation are also important contributors to total VOC emissions.

In 1990, over 20 million tons of VOCs were emitted in the U.S. 28% or 6 million tons came fiom consumer

and commercial coatings. Automotive refinish coatings represent a significant source of VOCs in consumer and commercial coatings. The US. Environmental Protection Agency is now requiring (August 1998) that manufacturers that make automotive refinish coatings meet strict VOC limits for their coatings. The majority of the VOCs come fiom topcoats (55%). Equipment cleaning (20%) and undercounts (17%) also account for a significant amount of VOCs.'

The new low VOC finishes are more expensive to buy than the older higher VOC formulations. In tlus chapter, we will discuss how to select coatings with the lowest levels of VOCs and other hazardous components and how to apply coatings to achieve the highest possible transfer efficiency to reduce paint costs and minimize VOC emissions.

Wastes fkom painting operations include waste paint and solvent and ail materials contaminated with paint such as used paint booth arrestors (also called exhaust filters), disposable rags, masking tape and paper, floor sweepings, disposable mixing cups and sticks and disposable paint strainers. ~-

1 Chart from Auto Body Surface Coating: A Practical Guide to Reducing Air Emissions, Small Business Pollution Prevention Center, University of Northern Iowa, 1994, p.3.


Low solids 6040% Low Ambient I Average -

High Solids Wxl Medium Bake Good Watehme 4% -20% Low Ambient / Average

Muiticomponent 4% Low Ambient Very Good '

(Conventional) Bake Good

(4% - 30%) Bake

(W or E.B.)

Powder Coating 4%

1ooord solids liauid

Average -

Goods High

~ o o d I . High

Pollution Prevention for Industrial Painters and Auto Body Repair Shops. Metro Dade Country, Department of Environmental Management, June 1995, p. 6 .

Minimize the Hazardous Nature of Paint

0 Use undercoats and topcoats that contain no heavy metals. (Heavy metals include arsenic, barium, cadmium, chromium, lead, mercury, selenium, and silver.)

Use low-VOC paint and solvent products. See the chart below detailing the advantages and disadvantages of low-VOC paints.

0 Use water-based coatings when practical;

UNIT2 PAGE 13


Reducing VOC Emissions in each Phase of Auto Body Surface Coating

In each phase of auto body surface coating, there are opportunities to reduce the amount of VOCs emitted and wastes generated. The following chart provides some suggestions:

~ ~~~

Prep Coats

Primer-Surfacer

Primer-Sealer

Sealers

Topcoats

1. Use versatile products such as epoxy primers or self-etching primers. (May not need primer-surfacing or primer-sealing.) 2. Use a wash-primer or metal conditioner conversion coating system.

1. Minimize the number of coats applied. 2. Ensure that all major body imperfections are removed prior to priming. (Do not use prima as a body filler.) 3. Use a primer gun with correct fluid tip/air cap combination for each type of primer-surfacer. 4. If the curing time of waterborne products is too long, consider using versatile urethane primers. 5. Use a minimal amount of primer-surfacer. 6. If clear sealer is used, make sure the primer-surfacer is a color that is easily covered with the desired topcoat.

1. Use low VOC urethane primer-sealers as an alternative when possible. 2. Choose a primer-sealer in a color that is easily covered with the desired topcoat, or choose a tintable primer-sealer and tint it to an easily-covered color shade.

1. Choose a sealer appropriate for each job. 2. If filling capabilities are required, use a primer-sealer in place of a sealer. 3. Choose a sealer of a color that can be easily covered with the coating to be sprayed, or choose a tintable sealer.

1. Mix color coats in-house, making certain the formula for the proper shade of the specific color code is used. 2. Keep good records of paint match information, including spray-out cards and detailed notes. Use record keeping to help determine how much material should be mixed for the job. 3. Avoid the use of lacquer-based topcoats. 4. Choose low VOC topcoats that require fewer than three coats to achieve adequate coverage (polyurethane or urethane) 5 . Apply only the number of coats needed to achieve a quality finish. 6. Use high solids/low VOC clears to topcoat color coats. 7. Keep the addition of paint additives to a minimum.

UNIT2 PAGE 14


Paint Booths

To control particulates, painting should be performed inside a paint booth that is equipped with paint arrestors and a ventilation system sufficient to draw the air fi-om the booth through the arrestors. Paint arrestors are filters that remove paint particles from the air before the exhaust goes to the outside. Painting inside a booth is also important since the incoming air can be filtered to remove dust that can ruin a finish.

Transfer Efficiency

A common reason for excessive paint and solvent waste is poor transfer efficiency. Transfer Efficiency (TE) is the ratio of the mass of solids (in the paint) reaching the surface being coated to the mass of solids sprayed. The higher the transfer efficiency, the less paint that is wasted in overspray.

Transfer Efficiency = Mass of Coating (Solids) Sprayed Mass of Coating (Solids) Applied

Factors Affecting Transfer Efficiency

Many factors affect transfer efficiency. Some are under the control of the spray operator and some are not. For example, the operator has no control over the size and shape of the parts sprayed, atmospheric conditions, or the finish quality requirements.

Studies have shown that operator spray technique is the most important element in achieving good transfer efficiency. A skilled operator should be able to adjust spraying style and gun set up with each job according to the type of coating sprayed, the weather conditions (heat and humidity), the size and shape of object being coated and the spray equipment used. The following factors may be able to be controlled by the spray operator:

Spray equipment type 8 Gun set up

Spray angle 8 Spray distance 8 Spray techniques

Spray equipment maintenance and practices

Some suggestions to improve spray technique for better transfer efficiency are described below.

UNIT2 PAGE15


Spray Equipment Type

Consider using spray equipment that provides a better transfer efficiency. Newer spray equipment has been developed that has the capability to achieve a higher transfer efficiency than conventional spray guns. One type of spray gun that can provide improved transfer efficiency is high-volumeAow pressure (HVLP) guns. Low pressurellow volume (LPLV) guns also provide good transfer efficiency. LPLV guns require a lower volume of air, and thus a smaller air compressor than HVLP guns.

In order to choose the best spray equipment for your application, you need to first determine how much you can afford to spend and what types of coatings you will be spraying. Next, consult your paint representative to determine which type of gun will work best with the product(s) you will be using. Choose the spray equipment that will achieve the highest transfer efficiency while providing the required atomization properties while remaining within your price range. Be sure to use the proper fluid tip/air cap combination and gun settings for the material being sprayed. Consult your paint or spray gun representative for assistance. Always remember that a paint gun is only as good as the operator using it. Even if a particular spray gun has the potential to have a high transfer efficiency, this will only be achieved if the operator sets up the gun properly and uses proper spray techniques.

Gun Set-up

Choose the correct size of fluid tip/air cap combination. The fluid tip size is determined by the viscosity of the coating. With low VOC coatings, it is particularly important to pick the correct fluid tip size to prevent clogging. Viscosity is measured using a Zahn cup measuring system. Choice of air cap depends on the fluid tip size. Generally, spray gun manufacturers will give recommendations for what air cap should be used with a fluid tip.

Set the air pressure at the lowest possible setting that will provide the required degree of atomization. Never exceed the coating manufacturer's recommended air pressure settings.

Keep records of gun set ups used with each type of coating to reduce set up time and material wasted during set up.

Spray Angle

Always hold gun perpendicular to the surface being sprayed, using parallel strokes. Do not arc the gun except when performing blending operations or panel spotting.

Study your spray pattem. Make sure the pattem is uniform and the coating is atomized properly.

UNIT^ PAGEIG

Unit 2 = Module 2 - Paint Spray Application Process

Spray Distance

Hold the spray gun at an appropriate distance fkom the surface being sprayed.Usually this distance is between 6 and 8 inches, but some gun and coating combinations may require a distance as close as 4 inches.

Make sure gun distance is kept constant throughout the coating operation. Use a 50 percent overlap for each pass, feathering the trigger at the beginning and end of each pass.

Note: This technique may need to be altered slightly when applying high metallic, high solids base coats and some three stage systems.

Spray Techniques

When painting small and medium sized panels, make each pass the full length of the panel. If possible spray larger panels in the same way, walking the length of the panel. If the panel cannot be done using this method, use a comfortable stroke, with a 4-5" overlap of the strokes.

If blending is necessary, keep the blend area as small as possible without jeopardizing appearance.

Spray the border edges of the substrate first (banding). This will assure all edges are covered without extending the spray pattem well beyond the borders of the object.

Have a "plan of attack": Before you start spraying, know how you are going to perform the operation. Do a "dry run" before you spray to practice your spraying strategy.

Spray Equipment Maintenance and Practices

Maintain equipment in clean and good working order to ensure proper atomization and a full, consistent spray pattem.

Mixing Systems

The addition of an in-house paint mixing system can greatly reduce the material costs of topcoat applications while increasing productivity. Payback times on such systems will depend mainly on the refinishing production rate of the facility. Paint mixing systems have the following benefits:

Lower material costs of the topcoat per volume. The ability to mix only the amount of topcoat required for the specific job. The ability to track the amount of coating each

UNIT2 PAGE17


technician mixes per job. The ability to add mixing colors as needed to assure color match (increases the ability to accurately duplicate the pigmentation of the original finish). Reduces the dependency on the paint supplier, i.e, mixing or tinting coatings as needed.

Also, when mixing, it is important to follow the manufacturer’s instructions. Otherwise, paints that are designed to have VOCs that meet federal limits, may exceed the allowable amounts of vocs. Minimizing the Amount of Painting Waste

0 Use reusable mixing cups and sticks and wash them in a mechanical gun wash system. Where possible, use cloth rags that are cleaned by a laundry service and returned. Improve transfer efficiency. When transfer efficiency is improved, more of the coating is applied to the vehicle, and less paint and solvent are lost into the air andor into booth arrestors or as overspray on masking. Recycle solvent on site with a solvent distillation unit. When a solvent distillation unit is not available, let waste solvent sit in drum until the paint solids settle to the bottom. Pour the solvent off from the top and reuse it for precleaning equipment. Keep all solvent container lids tightly closed except when adding or removing material. Use a mechanical gun wash system to reduce solvent waste. Keep track of the type and quantity of materials used on different types of

Use a material usage tracking form.

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b

vehicles to better estimate future jobs. 0

Disposal of Paint-Related Wastes

Liquid paint and solvent waste should be managed as a hazardous waste. This mems it should be stored in sealed containers labeled “Hazardous Waste” and disposed of through a hazardous waste management company.

Dry paint-related wastes (such as used paint booth arrestors, disposable rags, floor sweepings, etc) are potentially hazardous because they may contain heavy metals (lead, chromium, etc.) and solvents. If these wastes are landfilled, hazardous materials may leach out of the waste into the groundwater. According to federal regulations, all industrial wastes must be determined hazardous or nonhazardous before disposal. Wastes determined to be hazardous either through testing or knowledge of the waste, must be managed as a hazardous waste.

UNIT2 PAGE18

) Unit 2 - Module 2 - Paint Spray Application Process

Class Exercise: Show a video on proper spray painting technique.

Class Exercise: Demonstrate solvent distillation equipment to students. This demonstration can be through a vendor demonstration or a field trip to a shop with distillation equipment.

UNIT^ PAGEIS


Local Hazardous Waste Management Program In King County FACT SHEET

Autobody Pollution Prevention Tips from King County Autobody Shops

"Pollution prevention" is a way of thinking that may challenge current practices. Ask yourself: Why do we have this waste? Is this "waste" raw materials for others? Is this process necessary? What other method or procedure could work as well? What less toxic material could we use to achieve required results? Is a less volatile compound available? The following ideas are based on interviews and surveys of autobody shops in King County, Washington.

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a

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General housekeeping ideas Involve all employees. Try their ideas for cutting waste. Keep inventory small, up-to-date and properly stored to avoid expired or unusable materials.

If a waste isn't generated:

Train and retrain employees to reduce wastefulness. Cover containers tightly. Sweep floors and spot-clean drips and spills before washing down to keep soils and other contaminants out of washwater. Follow a preventive maintenance program to avoid, detect and repair leaks in shop equipment. Use spigots, pumps and funnels when dispensing and transferring liquids to reduce spills. Do not use or dispense hazardous materials where they may spill to drains. Keep spill containment materials near potential spill sites. Use shop towels sparingly and recycle them through an industrial laundry service that has the approval of its sewer utility. Use drip pans underneath leaking vehicles. Label containers of waste oils and solvents. Store separately to prevent contamination and make recycling easier. Keep ch!orinated solvents separate from other wastes and products to avoid contamination. Capture and collect leaking liquids in pans, trays or pads where possible.

- it doesn't need to be handled, recycled, treated or dispose& - it doesn't impact human health or the environment

Preparation

redos.

baking soda blasting.

e Spend time doing quality body work. Poor bodywork. is the main cause of

Use safer alternatives to chlorinated paint strippers, such as dry media or

Reuse paper masking where possible.

0

0

UNIT^ PAGE~O


Painting 0 Mix the minimum amount of paint needed for a job.

Match color carefully; check color before spraying. Minimize color changes to reduce the number of times equipment must be

Use a high-transfer efficiency (such as HVLP) paint system.

Maintain booth filters. Try reusable filters. Use leftover paints to tint primer and improve coverage.

Switch to a paint system that has no chromium or lead.

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cleaned. 0

A computerized paint-dispensing system helps match colors and mix right amounts.

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0 Use high-solids paint. 0

Cleanup 0 Use reusable cloth wipes, laundered by an industrial laundry, in place of

Cut solvent use by using gunwashers. Where possible, clean parts in two

Schedule parts cleaning service to fit your volume and frequency needs. Where possible, clean parts mechanically by dry brushing, sweeping or

Substitute aqueous cleaners or low VOC solvent, if possible. Explore

disposables.

stages first with used solvent, then with a cleaner solvent - so that solvent lasts longer.

0

0

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wiping prior to a solvent or water-cleaning step.

onsite recycling or distillation of solvents. 0

Recycling potential 0 Environmentally sound recycling is an important part of pollution

prevention. Has your business explored recycling for cleaning solvents, paint thinners, cloth rags, lead-add batteries, tires, air conditioning refrigerants, scrap metal, or rubber bumper covers?

UNIT^ P A G E ~ I

Unit 2 - Module 2 - Paint Sprav Application Process

HAZARD CONTROLS Control of Paint Overspray in Autobody Repair Shops

,

Hazardous components of paint spray include metals such as lead and chromium, polyisocyanates, and liquid organic solvents. Autobody workers may develop nervous disorders, skin and eye irritation, respiratory sensitization, asthma and reduced lung function from exposure to paint.

Effective control of worker exposure to paint overspray requires the proper selection of spray painting equipment, a properly designed and ventilated spray painting booth, and personal protective equipment. Formal training and maintenance programs will help ensure that all equipment operates properiy. Three types of control are recommended:

SPRAY PAINTING GUNS HIGH VOLUME, LOW PRESSURE (HVLP) spray painting guns are recommended instead of conventional gravity or siphon-feed spray painting guns because HVLP guns cut paint overspray concentrations in half. HVLP guns transfer paint more efficiently and can reduce paint usage.

PAINT BOOTH VENTILATION DOWNDRAFT VENTILATION spray painting booths are recommended instead of Crossdraft or Semi-Downdraft Ventilation spray painting booths. Properly operated DOWNDRAFT booths produce lower concentrations of paint overspray compared to the other two types of booths. DOWNDRAFT booths produce a cleaner paint job that requires less buffing.

RESPIRATORY PROTECTION Properly used and maintained HVLP spray painting guns and downdraft booths will greatly reduce paint overspray concentrations, but they will not completely eliminate overspray from the air workers breathe. Therefore, PERSONAL RESPIRATORY PROTECTIVE EQUIPMENT is ais9 recommended and a RESPIRATORY PROTECTION PROGRAM that contains all elements required by the OSHA standard (such as worker evaluation, selection of appropriate air-purifying or supplied-air respirators, fit-testing, training, and maintenance) will be needed to fully protect workers from this hazard.

U.S. DEPARTMENT OF HEALTH AND HUMAN SERVICES Public Health Service Centers for Disease Control and Prevention National Institute for Occupational Safety and Health, January 1996

I

\ Unit 2 - Module 2 - Paint Sorav Amlication Process

For More information

For a free copy of the report Control of Paint overspray in Autobody Repair Shops, or for information on other occupational safety and health issues, call the National Institute for Occupational Safety and Health* NIOSH), at:

1-800-35NIOSH (1 -800-356-4674)

*NIOSH is the Federal agency responsible for conducting research and making recommendations for preventing work-related illness and injuries. HAZARD CONTROLS are based on research studies that show reduced worker exposure to hazardous agents or activities.

The principal contributors to this HAZARD CONTROLS are William A. Heitbrink, Division of Physical Sciences and Engineering, and Jerome P. Flesch, Education and Information Division, NIOSH.

This document Is in the public domain and may be freely copied or reprinted. NIOSH encourages all HAZARD CONTROLS be made available to all interested employers

and workers.

DHHS (NIOSH) Publication No. 96-1 06

UNIT^ PAGE^^


FACT SHEET - HVLP PAINT GUNS

MANY AUTO BODY SHOPS ARE ALREADY SUCCESSFULLY USING HIGH VOLUME, LOW PRESSURE (HVLP) PAINT GUNS. IF YOU HAVE NOT YET TRIED HVLP GUNS IN YOUR SHOP, NOW WOULD BE A GOOD TIME TO LOOK INTO THIS.

WHAT ARE THE ADVANTAGES OF HVLP? HVLP GUNS CAN ACHIEVE A MUCH GREATER TRANSFER EFFICIENCY THAN CONVENTIONAL GUNS, -5045% FOR HVLP VS. -2540% FOR CONVENTIONAL. ASSUMING AN INCREASE IN TRANSFER EFFICIENCY OF 30% WITH CONVENTIONAL TO 50% WITH HVLP, THIS WOULD MEAN A DECREASE IN PAINT

VOLATILE ORGANIC COMPOUNDS (VOCs). COSTS OF 40% (1 --3/.5), AS WELL AS A 40% DECREASE IN EMISSIONS OF

FOR EXAMPLE, IF YOU CURRENTLY USE 20 GALLONS OF (SPRAYABLE) PAINT AND THINNER PER MONTH AT $ IOO/GAL, YOU COULD SAVE 40% OF YOUR PAINT COSTS. (40% x 20 GAL. = 8 GAL.) THAT MEANS YOU WOULD SAVE $800/MONTH (8 GAL x $100/GAL) OR $9600NR ON YOUR PAINT COSTS. IN

FILTER COSTS, SINCE THERE WOULD BE LESS OVERSPRAY. YOUR EMPLOYEES WOULD ALSO ENJOY A HEALTHIER WORK ENVIRONMENT, WITH 40% LESS VOC EMISSIONS.

ADDITION YOU WOULD SAVE ON YOUR BOOTH CLEAN-UP COSTS AND PAINT

ARE THERE ANY DISADVANTAGES? OPERATORS MUST BE TRAINED TO PROPERLY USE THE NEW GUNS, AND THE ATOMIZATION MAY NOT BE SUFFICIENT FOR FINE FINISHES. ALSO, HIGH PRODUCTION RATES MAY NOT BE POSSIBLE. SOME PEOPLE ADVOCATE USING HVLP FOR THE PRIMER AND CLEAR COATS (TO ACHIEVE THE ASSOCIATED COST SAVINGS AND EMISSIONS REDUCTIONS), WHILE STILL USING CONVENTIONAL GUNS FOR THE COLOR COAT, AT LEAST UNTIL ANY QUALITY CONCERNS WITH HVLP CAN BE OVERCOME. SOME SHOPS USE HVLP FOR THE COLOR COAT WITHOUT ANY MAJOR DIFFICULTIES.

HOW DO I KNOW IT WILL WORK IN MY SHOP? TALK TO A FEW BODY SHOPS ALREADY USING HVLP GUNS. ASK YOUR TRADE ASSOCIATION OR THE P2 PROGRAM AT THE MAINE DEP FOR A FEW NAMES IF NECESSARY.

HOW MUCH WILL IT COST TO MAKE THE: CHANGE?

AND MANUFACTURER. CALL YOUR PAINTING EQUIPMENT SUPPLIER FOR MORE DETAILED INFORMATION. TRAINING YOUR STAFF IN THE PROPER USE OF HVLP GUNS WILL ALSO REQUIRE SOME STAFF TIME.

HVLP GUNS COST ABOUT $250-500 EACH, DEPENDING ON THE SPECIFIC MODEL

Initially prepared by the Colorado Department of Public Health and the Environment. Modified for use in Maine.

UNIT^ PAGE^^

Unit 2 - Module 3 - Spray Equipment Cleaning

Learning Objectives

1. Understand the steps involved in manual gun cleaning and why it can generate substantial solvent waste.

2. Learn how to reduce waste during manual gun cleaning.

3. Introduce the pollution prevention advantages of using an enclosed mechanical gun wash system.

4. Demonstrate the costs and benefits of pollution prevention opportunities at an auto body shop by reviewing a case study.

i

UNIT^ PAGE^^

Unit 2 - Module 3 - Sorav Eauioment Cleanina


1. Manual gun cleaning releases the smallest amount of VOCs compared to other forms of gun cleaning.

A) True B) False

2. If guns are cleaned manually, solvent should be sprayed against a backdrop or into an enclosed container.

A) True B) False

3. All of the following are benefits of mechanical gun wash systems except one:

A) B)

C)

D) Increased VOC emissions.

Reduced employee exposure to hazardous solvents. A reduction in the amount of thinner necessary for cleaning by 50% or more. Decreased time spent gun cleaning by up to 60 percent over manual cleaning.

4. Washing out spray guns creates paint sludge. Paint sludge is a hazardous waste.

A) True B) False

5 . A computerized paint mixing system, a gunwasher, a solvent distillation unit, a refiigerant recovery unit and a vacuum sanding system are all pollution prevention methods.

UNIT^ PAGE^^


Pre/Post Test

1. Manual gun cleaning releases the smallest amount of VOCs compared to other forms of gun cleaning.

A) True B) False

2. If guns are cleaned manually, solvent should be sprayed against a backdrop or into an enclosed container.

A) True B) False

3. All of the following are benefits of mechanical gun wash systems except one:

A) B)

C)

D) Increased VOC emissions.

Reduced employee exposure to hazardous solvents. A reduction in the amount of thinner necessary for cleaning by 50% or more. Decreased time spent gun cleaning by up to 60 percent over manual cleaning.

4. Washing out spray guns creates paint sludge. Paint sludge is a hazardous waste.

A) True B) False

5 . A computerized paint mixing system, a gunwasher, a solvent distillation unit, a refiigerant recovery unit and a vacuum sanding system are all:

UNIT2 PAGE27

Unit 2 - Module 3 - Smav EauiDment Cleanina

Manual Gun Cleaning Processes

Equipment cleaning generates a great deal of unnecessary waste if not done properly. In manual gun cleaning, solvent is exposed to the air during most of the cleaning operation, and much of it evaporates. Approximately 20 percent of VOCs (volatile organic compounds) released fiom auto refinishing occurs during equipment cleaning operations. This figure reflects the volume of organic solvents emitted to the atmosphere during conventional equipment cleaning (purging) procedures. The majority of commercial spray equipment cleaners found on the market today are made entirely of organic solvents.

Proper cleaning and maintenance of spray equipment has always been an essential part of achieving a quality finish. This is especially true with newer high transfer efficiency spray technologies. These new spray guns are machined to very close tolerances and are highly susceptible to dried paint or other obstructions that can affect the performance of the gun.

Manual Cleaning Processes

Prior to the introduction of paint gun cleaning systems, all spray equipment was cleaned by hand using the following basic steps:

1. 2.

3. 4. 5 .

6 . 7.

8.

9.

All paint is removed fiom the cup. The air hose and cup are removed, the gun is triggered to remove all remaining paint fi-om the siphon tube The cup is rinsed with a small amount of thinner. Clean thinner is poured into the cup and reattached to the gun. With the air supply reattached, the thinner is sprayed through the gun to remove any paint remaining in the interior orifices. During this process the operators finger is place over the fluid tip several times while spraying to backwash the gun. The cup is removed and thinner poured out. The outside of the gun and the inside and outside of the cup are wiped down using a rag or paper towel. The air cap is removed and cleaned with a cleaning brush. A cleaning brush is also used to clean other extemal moving parts and behind the trigger. The gun is reassembled and returned to the storage area. Many painters remove the air cap fiom the gun and place it in the cup. A small amount of thinner is left in the cup so the cap can soak during storage.

A metal object is used to clean the small passageways and often results in severe damage which greatly reduces the efficiency of the spray gun.

UNIT2 PAGE28

Unit 2 - Module 3 - Spray Equipment Cleaning 1

From this description, it is easy to understand how 20 percent of VOCs are generated during the manual cleaning process.

Improved Manual Gun Cleaning

Manual gun cleaning processes can use up to three times the solvent as the same operation performed in an enclosed gun wash system. However, if an enclosed gun cleaning system is not available, guns must be cleaned manually. When spraying solvent through the gun, spray into an enclosed backdrop or container to catch solvent for reuse or recycling. Take precautions to avoid solvent spraying back on the person cleaning the gun. To reuse dirty solvent, store the solvent in a closed container to let the solids settle to the bottom. Then pour off the clear solvent and save it to use it again for cleaning. Be sure to properly store and dispose the paint waste that settles to the bottom. If passageways are clogged, use a broom straw or a soft wood toothpick to clear them. Do not use metal objects to clear passageways as this can enlarge the spray orifices, reducing spray efficiency.

Mechanicar Enclosed Gun Cleaning System

Within the last few years the mechanical gun wash system has gained popularity in the refinishing industry. Mechanical gun washers provide a safe, quick way to effectively clean paint equipment, including HVLP and LPLV spray guns. In general, the mechanical cleaning process follows these basic steps:

e Remove all the remaining paint from the cup.

e With the air hose removed, pull the trigger of the gun to remove all remaining paint from the siphon tube andor from the fluid passages inside the gun.

e Rinse the ciip with a sma!l mount of thh 1 aer.

When cleaning pressure cup systems, place a small amount of solvent in the cup and comect to the d r line to pressure the cup. Disconnect the air line from the gun, purge the gun, and drain the solvent into the hazardous waste storage drum.

e Place the disassembled gun (with all pressure gauges removed) in the gun washer. For siphon or pressure cup-type guns, the siphon tube is placed on the cleaning jet, and the gun trigger is locked open using a locking plate. For gravity-feed guns, the gun is placed upside down with the fluid orifice on the cleaning jet,

e Close the lid and turn the washer on.

UNIT^ PAGE^^


Let the washer run for the manufacturer's recommended amount of time (often only 1-3 minutes). Then the gun and parts are ready to be removed and used again. Don't forget to shut the lid after using the gun washer to prevent solvent evaporation.

With proper use and maintenance, these systems can reduce the amount of thinner used during the cleaning process by more than 50 percent (some mandacturers boast a 75 - 90 percent reduction). Mechanical systems also reduce the labor time needed for equipment cleaning by over 60 percent.

VOC emissions from enclosed gun washing systems have yet to be accurately measured, but the reduction should be substantial.

To further reduce air emissions, use cleaning solvents that are low in volatile organic compounds (VOCs). In high volume shops, two gun wash systems can be used. Use the first system for initial cleaning, and the second for final cleaning. When the final cleaning solvent becomes too dirty, switch it to use for pre-cleaning. When the pre-cleaning solvent becomes too dirty, it should be recycled.

Wastes from Mechanical Cleaning Systems

Paint sludge from the dirty equipment will collect in the gun washer and must be removed on a regular basis to keep the washer in good working order. This sludge is hazardous and should be stored in a closed container that is labeled "Hazardous Waste," and disposed of through a hazardous waste management company. Cleaning solvent that becomes laden with paint can be recycled either on site or off site and be reused.

A summary of the advantages of mechanical gun wash systems are:

Reduced employee exposure to hazardous solvents.

A reduction in the amount of thinner necessary for cleaning by 50% or more.

Save time spent gun cleaning by up to 60 percent over manual cleaning.

Reduced VOC emissions.

Class Exercise: Demonstrate use and operation of a mechanical gun wash system. If an enclosed gun washer is available for use on site, train students on the operation and maintenance of the gun cleaner. Post instructions above the gun cleaner to remind students to pre-clean the gun, how long a cleaning cycle is, and to shut the lid after use.

UNIT^ PAGE~O


Zompany

hdustry :ode

‘aste stream

-0cess

hange

:ost

Savings

Humes Collision Center, Inc.; Hermantown, Minnesota.

Auto body repair shop (SIC

7535)

Paint, solvent and sludge, antifreeze, sanding dust and refrigerant.

Auto body repair and maintenance services.

Installed refrigerant recycling equipment, a vacuum sanding system, waterwash spray and bake booth, computerized paint mixing system, gunwasher and a distillation unit. Replaced protective tape and paper with an overspray masking liquid. Also uses a mobile antifreeze recycling service.

$7,000 for a computerized paint mixing system.

* $1,300 for a gunwasher. $3,300 for a solvent distillation

* $2,800 for a refrigerant

* $9,000 for a vacuum sanding

unit.

recovery unit.

system.

Reduced 60 percent of all hazardous wastes generated.

* Saved approximately $34,000 in reduced costs.

Auto body Repair Shop Waste Reduction Measures Minnesota Technical Assistance Program CASE STUDY - Background

H u e s Collision Center, an Auto body repair shop located in Hermantown, Minnesota, constructed a new facility in 1992 that was designed to be efficient and to minimize the amount of wastes produced. To accomplish its waste reduction goals, a variety of waste reduction measures and new equipment were implemented when the new shop was constructed.

During the summer of 1993, a chemical engineering student from the University of Minnesota Duluth (UMD) worked with Humes Collision to determine and document the actual cost savings and total amount of wastes reduced as a result of the changes at the new shop. The intern. found that compared to the amount of waste generated at the old facility, the waste reduction measures and new equipment at the new facility had reduced hazardous waste output by 60 percent. This percentage was determined by comparing the average amount of materials used and wastes produced at the old shop with the amount of materials used and wastes produced during the first months of operation at the new shop.

MnTAP is funded by a grant from the Minnesota Office of Environmental Assistance to the University of Minnesota, School of Public Health. Reprinted with permission from MnTAP.

MnTAP 1313 5th Street SE, Suite 207 Minneapolis, Minnesota 554144504


Incentives for Reducing Wastes

The incentives for Humes Collision Center to reduce the amount of wastes generated at its new shop were to:

- reduce waste disposal costs, - reduce regulatory burdens and achieve compliance, -increase operating efficiency, and -.increase profits. To accomplish its waste reduction goals, Humes Collision Center installed specialized equipment and implemented operating procedures that reduced waste. These included the following:

Refrigerant Recycling

Refrigerants for automobile air-conditioning systems cost $lOperpound in 1993, and continue to increase in cost every year. In addition, these refrigerants are for sale only to licensed operators. Humes purchased an RTI refrigerant recycling unit at a cost of $2,975 to reduce the amount of refrigerants purchased. Humes uses it for an average of one job per day, recovering and recycling between two and two-and-one-half pounds of reiiigerant daily. This recycling unit prevents refrigerants from escaping into the air and reclaims enough refrigerant to reduce purchase costs by $5,900 per year.

.

Antifreeze Recycling

Humes uses a mobile recycling service provided by Coolant Recovery Company of Minneapolis' Minnesota. This service costs $15 for the initial deposit followed by a purchase cost of $1.35 per gallon for the recycled 50/50 water/ antifreeze mixture. By recycling the used antifreeze, Humes purchases smaller amounts of new antifreeze, thereby reducing costs. Recycling used antifreeze also eliminates generating antifreeze wastes.

Humes purchased a contained vacuum sanding system made by US Turbine Corporation, at a cost of $9,000 (includes installation cost). The sanding system consists of a vacuum pump connected to a hose at each work station, and a sanding head attached to each hose. During the sanding process, the dust is pumped out and collected in a sealed container outside the shop- The sanding dust was tested as nonhazardous, and is disposed of as nonhazardous solid waste. The new contained sanding system prevents sanding dust from being emitted into the shop, and has greatly reduced employee labor costs for cleaning dust off cars and in the shop. The need to redo work on cars for damage from dust particles has almost been eliminated. In addition, air filters are changed less frequently, and the amount of sandpaper used has been reduced Since it started using the vacuum sanding system, Humes has realized an estimated cost savings of $7,300 per year, primarily from reduced labor costs (costs of maintenance or replacement parts is not part of this figure).

Overspray Masking Liquid

Humes uses 3M Overspray Masking Liquid as an alternative to plastic car bags for protecting cars during painting. The masking liquid is sprayed only onto the area of a car that needs to be protected during painting, instead of covering the entire car. This liquid can be applied by one person and with the same spraying equipment used for painting cars. The liquid is removed with water (no detergent needed), and then disposed of with the shop's wastewater. Humes uses one 16-gallon drum of the masking liquid every three months at a cost of $232.80 per drum. By using this liquid instead of the plastic car bags, the cost per car has reduced from $3.50 to $1.90,.resulting in cost savings of $1,900 per year in reduced bag purchasing costs. Eliminating the plastic car bags has also reduced the amount of solid waste generated by the shop.

Vacuum Sanding System NOVA Verta. Spray and Bake Booth


The NOVA Verta spray and bake booth installed at Humes is a completely sealed downdraft booth with a water wash filtration system in the floor. This filtration system allows proper air flow to prevent the booth f?om becoming pressurized, which is a potential problem with a dry filter system. It also eliminates the need to dispose of hazardous waste paint filters. The booth has a very accurate temperature control system that has eliminated uneven drying and has enhanced the quality of the paint finishes.

Computerized Paint Mixing

A computerized paint mixing system made by DuPont was purchased by Humes to replace an older microfiche system used at the old shop. The new computerized system can break down a paint formula to 1/16 of a pint, while the old microfiche system could break down a formula only to the nearest pint. Humes uses less paint with the new system, which has reduced the average paint cost for each car from $36 to $16, and reduced the amount of paint waste generated. Based on painting 10 cars per week, Humes is using 50 percent less paint and is saving $10,000 per year on reduced paint purchase costs. The computerized system cost $7,000 to purchase and install.

Gunwasher

Humes installed a new Uni-ram Cascade gunwasher for cleaning spray painting equipment, which replaced the old system of cleaning equipment by hand. The gunwasher holds 7.5 gallons of solvent, and 5 gallons of replacement solvent are added every two months. By using the gunwasher instead of cleaning by hand, Humes

uses significantly less solvent for cleanup and has greatly reduced labor costs-paint guns are cleaned much faster with the gunwasher. Savings from reduced labor and solvent costs are estimated at $7,600 per year. The gunwasher purchase cost was $1,300.

Distillation Unit

Humes uses a Paulee brand distillation unit to reclaim solvent used in the spraygun cleaning process. The still reclaims approximately 100 gallons of solvent annually, which is reused in the gunwasher. By reducing solvent waste and the amount of new solvent purchased, Humes realizes an annual cost savings of $1,300. The initial purchase cost of the still was $3,300,.

Summary

Implementing these waste reduction measures at the new Humes Collision Center has saved the shop an estimated $34,000 in operating costs annually. These cost savings are based on a combination of reduced labor, new materials and hazardous waste disposal costs for work done on approximately 500 cars annually. Costs of maintenance or replacement parts is not a part of the total estimated savings.

This project, documenting. waste reduction at Humes Collision Center, was funded by the Minnesota Pollution Control Agenry throzgh ~1 grmt from the US. Environmental Protection Agency as part of the Lake Superior Hazardous Waste Initiative during the summer of 1993. MnTAP was a subcontractor on this project.

Disclaimer: The product information in this case study was provided solely as a service io Minnesota companies. This infcrma!ion may not include all available services or suppliers and does not represent an endorsement by MnTAP. All users of this information are responsible for insuring ihat any company with whom they contract for products or services complies with the requiremenis of state and federal law.

Unit 3 - Module ‘l -Waste Oil, Waste Oil Filters, Oil Contaminated Wastes

Learning Objectives

1. Explain why used oil has special waste disposal requirements.

2. IdentifL the best management practices for handling used oil and used oil filters.

3. Learn the regulatory concerns and best management practices for absorbents contaminated with waste oil andor solvents.

4. Understand the regulatory concerns and best management practices for rags contaminated with waste oil andor solvents.

U N I T 3 PAGE 1

Unit 3 - Module 1 -Waste Oil, Waste Oil Filters, Oil Contaminated Wastes


1. Fresh engine oil removed from a sealed container is: A) Ahazardouswaste B) Likely contaminated C) An automotive lubricant D) Highly toxic

2. Waste oil is contaminated with heavy metals and other chemicals from the breakdown of oil and gasoline during normal use. A) True I B) False

3. AU of the practices listed below are good ways to decrease waste oil spills and releases except for: A) B) C ) D)

Place oily parts on drip pans instead of on the floor. Use drip pans to avoid spills. Use a funnel when transferring waste oil into dnun. Use a squeegee to push spilled waste oil into the floor drain..

4. The best management practice for a waste oil filter includes all of the practices listed below except for: A) B) C) D)

"Hot Drain" the filter after removal. Allow filter to drain for 2 hours before disposal. Ship used oil filters to a recycler. Collect used oil during the "Hot Drain" into a drum.

5. Used engine oil can be mixed with parts cleaner prior to burning. A) True B) False

UNIT^ PAGE^

Unit 3 - Module I -Waste Oil, Waste Oil Filters, Oil Contaminated Wastes

1

I

Pre/Post Test

1. Fresh engine oil removed fiom a sealed container is: A) A hazardous waste. B) Likely contaminated. C) An automotive lubricant. D) Highly toxic.

2. Waste oil is contaminated with heavy metals and other chemicals fiom the breakdown of oil and gasoline during normal use. A) True B) False

3. All of the practices listed below are good ways to decrease waste oil spills and releases except for: A) B) C) D)

Place oily parts on drip pans instead of on the floor. Use drip pans to avoid spills. Use a funnel when transferring waste oil into drum. Use a squeegee to push spi€led waste oil into the floor drain..

4. The best management practice for a waste oil filter includes all of the practices listed below except for: A) B) C) D)

"Hot Drain" the filter after removal. Allow filter to drain for 2 hours before disposal. Ship used oil filters to a recycler. Collect used oil during the "Hot Drain" into a drum.

5 . Used engine oil can be mixed with parts cleaner prior to burning. A) True B) False

UNIT3 PAGE3


Used Automotive Oils

Health and Safety Issues Motor oil becomes contaminated through normal use by the breakdown of the additives in the oil and gasoline. The lead found in used motor oil is a result of contamination by leaded gasoline and is slowly declining with the change in the formulation of gasoline. Other contaminants which may be present in used oil are zinc, chlorinated solvents, benzene, toluene, xylene, and naphthalene. These contaminants can also produce toxic effects in those who come in contact with it. Breathing difficulty, skin irritation, and headaches are some of these symptoms. It is recommended that technicians use gloves when performing oil change service.

Regulatory Issues Waste oil must be picked up by a licensed transporter or bumed on site in an approved space heater. Shops must comply with the following management Standards.

1. Ensure that &e used oil is stored in U.S. Department of Transportation approved containers or in structurdly sound tanks.

2. Clearly label the containers, tanks or the fillpipe for an underground tank with the words "USED OIL".

3. Do not mix waste oil with any other hazardous waste.

4. Keep containers and tanks sealed except when adding or removing oil.

5. Ensure that used oil is managed to prevent spills or other discharges onto the ground, into storm or sanitary sewers, or into ground or surface waters.

6. Place containers on a surface made from any nonporous material, such as concrete, that waste oil cannot pass through. The surface should have no cracks or gaps.

Used oil may be recycled by either being bumed on-site in a suitable space heater or waste oil bumer, or by being picked up by a company who recycles waste oil. Shops which bum waste oil on-site, or who deliver their waste oil directly to a person who bums it for energy recovery, are subject to additional regulatory requirements.

Best Management Practices

1. Use drip pans or other portable containment to avoid the need for absorbents during oil and filter changes. Make sure they're big enough and won't tip over

Unit 3 - Module I -Waste Oil, Waste Oil Filters, Oil Contaminated Wastes

2.

3.

4.

5.

6.

(See Unit 3 - Module 2 - Spill Procedures).

Use dry clean up methods such as reusable absorbent pads, a bristle broom and brush or mops that only absorb oily liquids. Wring out or pour the waste oil into a waste oil drum or tank. Clean any leftover waste oil with a rag.

Disposable shop rags that are contaminated only with oil may be put in the trash if they are dry. The best option is to use rags that can be laundered. Store the towels in metal containers with tight-fitting lids. Label “Contaminated Shop Towels Only.”

When absorbents are necessary, select a material which may be reused or burned for eoergy recovery such as wood chips or “absorbent socks.” Oil contaminated absorbents and debris may be put into the trash. Larger quantities must be handled as a “special waste. Store the absorbents in metal containers with tight-fitting lids. Label “Oily Waste Absorbents Only.”

Designate a waste storage area. Instruct workers to keep waste oil separate from other liquid wastes.

Store used oil on an impervious surface with some type of cover and secondary containment.

Pollution Prevention Opportunities Store drip pans carefully so they do not leak on the floor. Designate drip pans for specific use, for example, do not use an oil drip pan to collect antifreeze or solvent. When purchasing disposable oil absorbent materials, be sure to consider their reusability. Absorbent “socks” for example, may be reused about 10 times before disposal. Roller-wringers are available to remove the maximum amount of oil fi-om the socks but the socks cannot be laundered and must eventually be disposed.

Purchase re-refined used oil when possible. Use of new longe:-!asting synthetic oils may reduce the number of oil changes required in any given vehicle. Electric-powered vehicles do not use oil. Increased availability of public transportation is another way of reducing the volume of waste oil.

Used Oil Filters

Health and Safety Issues Oil filters are designed to remove particulate matter fkom the oil. Both lead and benzene, known toxics, have been found in spent filter paper. To avoid skin contact, workers should wear impervious clothing and gloves during handling.


Regulatory Issues Spent oil filters are exempt fiom state and federal hazardous waste regulations provided the oil is removed to the greatest extent possible prior to disposal. This can be accomplished by either puncturing and hot-draining, hot-draining and crushing, dismantling and hot-draining or some other equivalent method. The state of Maine requires hot draining for at least 12 hours. Draining and crushing is the preferred method since it removes considerably more oil than d r a i i g alone. Once the oil has been properly drained, the filter is considered a solid waste and may be recycled or must be disposed at a permitted solid waste facility.

Pollution Prevention Opportunities Use of new longer-lasting synthetic oils may reduce the number of oil changes required in a vehicle. Electric-powered vehicles do not contain oil filters.

The Filter Manufacturers Council maintains a toll-free hotline 1 -800-99-FILTER (993- 4383) Monday-Friday, 9:OO a.m. to 6:OO p.m. which supplies information on regulations, recycling options and lists of facilities which manage spent oil filters.

Best Management Practices The engine should be at operating temperature before performing an oil and filter change service to enhance the flow rate of the oil. Although, a properly drained, used automotive oil filter may be disposed as solid waste, the filter is comprised of scrap metal which can be recycled. Contact your nearest scrap metal dealer for more information. Also consider purchasing a filter crusher, to increase your recovery of the waste oil and to reduce storage space. The drained filters should be stored in a container which will capture any remaining oil.

Waste Oil and Solvent Soaked Absorbents

Regulatory Issues When absorbents are necessary, select a material which may be reused or burned for energy recovery such as wood chips or “absorbent socks.” Small amounts of oil contaminated absorbents and debris may be put into the trash. Larger quantities must be handled as a ”specid wzste.” Store the absorbents in metal containers with tight-fitting lids. Label “Oily Waste Absorbents Only. ”

Absorbents contaminated with solvents are sometimes considered to be hazardous waste. The contaminated absorbent is hazardous only if the solvent mixed in it is one of the solvents listed specifically as hazardous waste. The solvents listed as hazardous wastes are the F001, F002, F003, F004 and F005 wastes which include methylene chloride and 1 , 1 , 1 trichloroethane. However, if the solvent, prior to mixing with the absorbent, is only hazardous because it fails the characteristic test for ignitability , then the solvent contaminated absorbent is not a hazardous waste and can be thrown in the trash or

I Unit 3 - Module I -Waste Oil, Waste Oil Filters, Oil Contaminated Wastes

handled as a special waste. Please see Unit 1, Module 2 for further explanations of listed and characteristic hazardous wastes.

Pollution Prevention Opportunities To the greatest extent possible, workers should “ i z e the use of absorbents for cleanup by avoiding spills. Choose reusable absohents until they are l l l y used up but not dripping instead of discarding the partially used absorbents in the trash.

There are a variety of absorbent products on the market. Clay absorbents are the most common. Other products include peat, corn cobs and wood chips. The altematives are biodegradable and can be burned.

Waste Oil and Solvent Soaked Rags

Health and Safety Issues Petroleum distillates (naphtha) may be used as cleaning agents in a variety of work places. When rags are used to clean up after such use, workers should be carefbl to avoid bringing the rags into contact with skin and eyes. Used wipers should be placed in containers such as lidded drums or sealed laundry bags. Contact lenses should not be worn when working with petroleum distillates. If eye contact occurs, wash the eyes immediately with large amounts of water occasionally lifting the lower and upper lids. For skin, soap wash promptly.

Regulatory Issues DEP currently allows wipers contaminated with waste oil that are not saturated or dripping to be thrown in the regular trash as solid waste, rather than to be managed as hazardous waste, provided that certain best management practices are followed. Send oil contaminated rags to a commercial laundry licensed to wash rags. Hand wringing or use of a mechanical compactor to recover as much liquid as possible is recommended. Intentional air-drymg of saturated wipers is considered to be illegal disposal and may result in adverse health effects.

Rags contaminated with solvents follow sbilar rules as for solvent contaminated absorbents. There are thee niles that xcst be fdlowed so the rags do not become hazardous wastes: 1) the solvent contaminating the rags can not be ignitable, 2) the solvent is not a F001-FO05 listed hazardous waste and 3) the rags do not contain free liquids. Rags meeting these three rules can be disposed in the trash.

Pollution Prevention Opportunities To the greatest extent possible, workers should minimize the use of wipers for cleanup by avoiding spills. Managers are encouraged to choose reusable wipers in preference to incineration or landfilling the used contaminated wipers. To prevent pollution and protect worker health, the use of non-toxic alternative cleaning products is recommended.

UNIT^ PAGE^


Best Management Practice Contaminated wipers that are not saturated may be sent to a commercial laundry and re-used. Any free-flowing solvent or oil must be collected and managed as a hazardous waste unless it is reused on-site for its intended purpose. If the wiper cannot pass the “one drop test” (as long as one drop can flow fiom the mixture, the mixture is saturated and therefore hazardous) it must be managed according to hazardous waste storage requirements.

To “ i z e potential fiscal and environmental liability, managers are advised to select a laundry service which has a valid permit for wastewater discharge. Call DEP at 207-287- 6188 for verification of the laundry‘s compliance status.

Class Exercise: View video “Larry’s Auto Works’’

Class Exercise: Calculate the Total Amount of Waste Oil Generated on Your Street

1. 2. 3. 4. 5 .

6. 7. 8.

The average automobile has 4 quarts of oil in the crankcase. Elm street residents have 20 automobiles. The manufacturer suggests that engine oil should be changed every three months. Every vehicle owner follows the manufacturers’ recommendations. How many gallons of used oil will be collected and recycled fiom Elm street in a 12 month period? Where can you return used oil in your town? Have you seen any signs in your town indicating the town accepts used oil? What are some suggestions to reduce waste oil on Elm Street?

Answers

Question 5: 20 vehicles

Question 6: 4 quarts times 4 equals 16 quarts per vehicle per year.

Question 7: 20 vehicles on Elm street x 16 quarts = 320 quarts per year or 80 gallons per year for one street!

UNIT3 PAGE8


~

Class Exercise: Identify Waste Oil Generators

1. Have the students form teams of no more than four members.

2. Have each group make up a list of possible places where there may be used oil. A. Gasoline Service Station B. Automobile repair shop C. New Car Dealerships D. Fast lube specialty shop E. Chain Stores (Sears, Kmart) F. Auto Recycle yards G. Auto Rental Shops (Avis) H. Town or State garages

3. Are the places that sell engine oil required to take back the used oil?

4. Discuss the pros and cons of placing a deposit on new oil to help remind people that their used oil should be brought back for recycling. How is th is recycling opportunity different from the bottle bill?

Class Exercise: '' List Alternative Methods For Cleanup"

1. Break the class up into teams of no more than four.

2. Have each team complete the following exercises. Then ask each team to present its findings. List the different absorbent materials one might find being used in a automotive repair shop.

Example: A. Clay ("Speedi Dry") B. Saw dust c. CQEICObS D. Mop E. Absorbent blanket F. Cloth wipers G. Paper wipers H. Newspaper

3. Now ask each student to consider the following questions and provide answers. A. B. C. D. E.

What do you do with the soiled material? Is it okay to just throw away this material? Can the materials be separated and recycled? What is the cost factor to the shop owner? What is the cost factor to the environment?

UNIT^ PAGE^


Case Study: Issues of Waste Oil Management and Storage at Service Stations and Repair Shops by W. David McCaskill, ME DEP

The gang's all here-the excavator with his Jurassic Park earth-eating excavator, the environmental consultant with his space age soil sniffer, and the checklist-toting state inspector, who's overseeing the whole shebang. A gaping hole remains where the gasoline and diesel tanks used to be. Now it's time to deal with that itty bitty 500-gallon waste oil tank.

The state inspector casts a suspicious eye at the soil staining around the f i l l pipe. He puts the sniffer aside, dons rubber gloves, and takes some soil samples ... the old fashioned way. The samples are whisked off to a laboratory for analysis. The top six-inch layer of soil (14 tons) has been set aside until the lab results come back.

"So," you ask, "what's so all-fired special about this waste oily soil?" The rest of the dirty dirt fi-om this site was trucked off to the asphalt batch plant, all for the tidy sum of $45 a ton. Well, here's the answer. A week later, the state inspector gets the soil test results. It seems that stockpiled soil fiom the waste oil tank removal is "hazardous waste" because it contains elevated levels of lead.

"Well," you declare, "I knew this dirty dirt wasn't the kind of stuff you'd want to sprinkle over your com flakes, but what do you mean when you say 'hazardous waste'?" Here in Maine, hazardous waste means that a special contractor will have to be hired to haul the soil to an out-of-state hazardous waste incinerator, all for the hefty sum of $783 a ton. But, not to worry, the state insurance fund war chest will pick up the tab for the dirty dirt disposal, even the waste oil stuff.

From LUSTLine Bulletin 21, Tanks Down East, p.23.

UNIT^ PAGEIO

Unit 3 - Module 2 - Spill Prevention & Control Procedures 1

Learning Objectives

1.

2.

3.

4.

5.

Identify where spills and leaks are likely to occur.

Learn how to prevent spills from occurring.

Learn how to contain, cleanup and reclaim spills using reusable materials.

Learn proper hazardous waste storage.

Identify the components of a emergency response system.

UNIT3 PAGE13

Unit 3 - Module 2 - Spill Prevention & Control Procedures


1.

2.

3.

4.

5.

As a generator of hazardous waste you are required to: A) Assume the police will come in an emergency. B) Assume the fire department will come in an emergency. C) Prepare for an emergency. D) Provide an action plan to the chemical supplier.

The best method of cleaning up a small oil spill is: A) Clay absorbent B) Papertowel C) Mop and bucket D) Don’tbother

Name two components of a spill cleanup kit: Answer may include: mop and bucket, launderable rags, drain covers, storage container for spill cleanup wastes, absorbent socks or pads

Preventing spills can be done in all of the following ways except: A) B) C) D)

Use drip pans when changing oil. Use a funnel when pouring waste oil into drum. Leave containers of hazardous liquids open and on the floor. Keep a clean, uncluttered work space.

It is ok to dispose of clay absorbents with solvents in them in the landfill. A) True B) False

UNIT^ PAGEILF


Pre/Post Test

Choose the one correct answer:

1.

2.

3.

4.

5 .

As a generator of hazardous waste you are required to: A) Assume the police will come in an emergency. B) Assume the fire department wil l come in an emergency. C) Prepare for an emergency. D) Provide an action plan to the chemical supplier.

The best method of cleaning up a small oil spill is: A) Clay absorbent B) Papertowel C) Mop and bucket D) Don’t bother

Name two components of a spill cleanup kit:

Preventing spills can be done in all of the following ways except: 1. 2. 3. 4.

Use drip pans when changing oil. Use a funnel when pouring waste oil into drum. Keep a clean, uncluttered work space. Leave containers of hazardous liquids open and on the floor.

It is ok to dispose of clay absorbents with solvents in them in the landfill.

A> True B) False

UNIT^ P A G E I ~


Spill Prevention and Cleanup in the Shop

One of the easiest ways to prevent pollution in the shop is to avoid spilling hazardous materials. You can avoid spills by working carefully and taking precautions. Knowing what operations might result in spills is very important.

Some common operations where spills and leaks are likely to occur include:

J radiator fiush and fill J carrying dripping parts across the J radiatorrepair room

J oilchanges J partswashing

PREVENTING SPILLS Good Housekeeping

Avoid clutter - cluttered work areas increase the chance of spills and accidents Put all tools, equipment and materials away when they are not being used. Keep work areas neat and clean.

Manage and control your hazardous liquids Use funnels when filling hazardous materials storage containers to prevent drips

Don’t place containers of liquid where they might be knocked over. Cover drains in work area (with a rubber mat or anything to seal drain)

and spills. Store funnels over a drip pan.

Catch dripping hazardous liquids a Use drip pans underneath work to catch spills.

Set dripping parts on drip pans or racks over drip pans rather than on the floor. A little bit of effort to use a drip pan can save a lot of time.

Storage area Regularly inspect storage area for leaks. Fix leaks immediately.

a Use secondary containment to prevent leaks fiom spreading. For example, concrete floor and walls in storage area, double-walled tank, smaller storage containers inside larger ones. Segregate wastes so different wastes are in different containers.

Store away fiom drains or doorways.

Label containers. a Keep containers closed except when adding or removing waste.

UNIT3 PAGE 16

i

Clay Absorbents

“Ab sorbent socks”

Rags


Dis3osal of Spill Cleanup Materials Contaminated with Contaminated with Waste Oil only Solvents

small quantities ok to be sent to landfill

large quantities are special wastes. Call ME DEP.

special wastes

not hazardous, if sent to a laundry with DEP license

or if dry, can go to landfill

may be a hazardous waste*



Cleaning up Spills

Step 1: step 2:

Quickly stop the source of the spill. (e.g. put the container upright) Prevent the spill fi-om leaving the facility

Cover drains or block doorways. Place absorbent “socks” on floor or around equipment to contain spill. (These socks are reusable.)

step 3:

step 4:

Absorb the spill using a reusable material such as a mop and bucket or bristle broom and brush or launderable rags.. Cleanup remainder of spill using mild soap and water. If the floor is still slippery, use launderable rags or a small amount of disposable oil absorbent. Save the absorbent for reuse whenever possible. If the spilled material can be recovered, put it into the appropriate waste container. (e-g. put the used oil into the used oil container) Store wastes fiom cleanup in labeled, sealed containers prior to disposal.

step 5:

Step 6:

If the liquid can not be recycled, it should be put in a container labeled “Oily Waste Absorbents Only” or “Used Spill Cleanup Materials” as appropriate. A hazardous waste determination may be necessary to figure out whether the waste must be disposed of as a hazardous or nonhazardous waste.

If contaminated with antifreeze or a mixture of oil, antifreeze andor solvents, the absorbents, socks or rags may need to be managed as a hazardous waste. The contaminated wastes are hazardous if the antifreeze is hazardous. Antifreeze is hazardous

UNIT3 PAGE 17


if it fails the toxicity characteristic leaching procedure (TCLP), usually either for benzene or heavy metals. (See Unit 1, Module 2 Hazardous Waste.)

Alternative Cleanup Methods

Often disposable oil absorbent (clay or ‘Icitty litter73 is used to absorb spills. This creates additional waste to be cleaned up and disposed. And, once the liquids are soaked into the oil absorbents, they cannot be recycled and must be disposed of. Instead of throwing disposable oil absorbent on a spill, consider using:

Mop and bucket dedicated to cleaning spills (or a mop that absorbs only oil) Place cleanup liquid in appropriate drum. Use one for oil, one for antifreeze. Label containers properly.

Launderable Cloth Shop Rags Wring out rag into appropriate drum. Use one for oil, one for antifreeze. Label containers properly.

Cleanup Kit

Mop and bucket Launderable rags

Drain covers Storage container for spill cleanup wastes

Absorbent socks or pads

Keep the kit in a location that is easy to reach and make sure every employee knows where it is and how

to use it.

Squeegee and Mop and Bucket, Rag or Flat-Bladed Shovel Use a squeegee to push a larger spill into a smaller area. Use a mop and bucket, rag or flat-bladed shovel to pick up the liquid. Use a different mop and bucket for oil wastes vs. antifieeze vs. solvent wastes.

Emergency Response

As a generator of hazardous waste auto repair shops are required to prepare for emergencies.

1. 2. 3. 4.

Spill control equipment such as speedi-dry or absorbent rags Fire control equipment such as fire extinguishers “No Smoking” signs near ignitable wastes Adequate aisle space between containers, minimum of 2 feet

Note: ANY discharge of hazardous waste that threatens human health or the environment must be reported to the Department of Environmental Protection.

) Unit 3 - Module 2 - Spill Prevention & Control Procedures

Class Exercise: “A Hazardous waste spill has occurred”

1. 2.

Break the class up into teams of no more than four students. Inform each team that a hazardous waste spill of 5 to 10 quarts of used oil has just occurred under a car which is on a lift getting a “Quick” oil change done. The customer is in the waiting room and has observed the spill. Ask the students to create a realistic role play scenario based on the following perspectives:

3.

The first scenario is of a confused technician with no means to immediately handle the spill.

1. 2. 3. 4.

What does the floor look like within 30 minutes? what is the technician thinking? What is the customer thinking? What is the shop owner thinking?

The second scenario is of a quick containment and proper storage of the spill.

1. 2. 3. 4.

What does the floor look like within 30 minutes? What is the technician thinking? What is the customer thinking? What is the shop owner thinking?

The team with the most realistic role play wins!

Class Exercise: Simulated spill

1. 2.

3.

Break the class up into teams of no more than four students. “Spill” 5 gallons of colored water on the floor. Tell the students to pretend that it is waste oii. Ask the students to cleanup the spill using the procedures outlined above.

The group who get the majority of the spill into a container and has the fewest “color” stained rags or absorbents wins.

Unit 3 - Module 3 - Engine Coolant (Antifreeze)

Learning Objectives

1. Identify the chemical composition of engine coolant.

2. Explain the current regulations regarding disposal.

3. Describe the current recycling options including on-site and off-site recycling equipment.

4. Discuss two recycling techniques: distillation and filtration.

5. Introduce an exercise for calculating the cost savings fiom antifieeze recycling.

UNIT^ PAGE~O

Unit 3 - Module 3 - Engine Coolant (Antifreeze) )

PreLPost Test - Teacher Version

1. The active ingredient in engine coolant is usually: A) PropyleneGlycol B) IsoAlcohol C) Methanol D) Ethylene Glycol

2. Current disposal options for used engine coolant include all of the following except: A) On-site recycling B) C) D) Off-site recycling

Disposal down the sewer drain Testing the antifreeze to determine toxicity

3. Wastes generated during antifieeze recycling:

C

&e sometimes called stiil bottoms Are potentially hazardous Contain impurities from the used antifreeze All of the above None ofthe above

:hanging antifreeze, you need to wear a respirator. True B) False

5. Engine Coolant (antifreeze) must not be discharged into a sewer or septic system because:

A) It reacts with water B) It may contain lead C) It will rust the pipes D) It will cause leaks

UNIT3 PAGE21


Pre/Post Test

1.

2.

3.

4.

5 .

The active ingredient in engine coolant is usually: A) Propylene Glycol B) Is0 Alcohol C) Methanol D) Ethylhe Glycol

Current disposal options for used engine coolant include all of the following except: A) On-site recycling B) C) D) Off-site recycling

Disposal down the sewer drain Testing the antifreeze to determine toxicity

Wastes generated during antifreeze recycling: A) B) Are potentially hazardous C) D) All of the above E) None of the above

Are sometimes called still bottoms

Contain impurities fiom the used antifreeze

When changing antifreeze, you need to wear a respirator. A) True B) False

Engine Coolant (antifreeze) must not be discharged into a sewer or septic system because:

A) It reacts with water B) It may contain lead C) It will rust the pipes D) It will cause leaks

UNIT^ PAGE^^


Health and Safety Issues

Ethylene glycol, the active ingredient in most antifreeze, is considered to be moderately toxic. Triethanolamine, a corrosion inhibitor in automotive coolants, has been linked to cancer in laboratory animals. Animals drinking -antifreeze spilled on the ground may suffer adverse effects and possibly death. (Antifreeze has a sweet odor which may attract animals.)

NIOSH (National Institute for Occupational Safety and Health) guidance advises use of protective clothing and goggles, washing immediately upon contamination and change of clothes after work is finished. Symptoms from inhalation, skin absorption, ingestion, or skin or eye contact may be throbbing head, dizziness, skin initation, nausea, vomiting, abdominal pain, flush, palpitation, delirium and angina. Target organs are the cardiovascular system, blood and skin.

Regulatory Issues

Antifieeze drained &om cars is likely to contain lead, benzene and other contaminants which, if present at elevated levels, may cause it to be classified as a hazardous waste by failing the toxicity characteristic leaching procedure (TCLP).

Disposal Issues

Maine DEP does not allow dumping of antifreeze to a sewer, to a septic system, or to the environment because of its toxicity. At all times containers must be kept closed and sealed unless adding or removing waste from the container. Spent antifreeze is classified as a hazardous waste if it fails the Toxicity Characteristic test (TCLP), making it a characteristic waste, or if the total levels of toxic constituents exceeds 100 parts per million, making it a hazardous waste mixture. Spent antifieeze should not be mixed with other wastes, i.e. oil, gasoline or solvents.

Current Recycling and Disposal Options

0 Testing the antifreeze for the hazardous waste characteristic of toxicity characteristic leaching procedure through a laboratory to determine whether or not it is a hazardous waste. If shipped as a hazardous waste, the regulatory burden on the service shop may increase because of the higher total monthly volumes of hazardous waste.

0 On-site recycling equipment is now available, costs range from $2,000- $20,000. Some models, after performing filtration and reintroducing inhibitors back into the antifreeze, will return the antifreeze to the customer's vehicle. Sludges and filters

UNIT^ PAGE^^


from the recycling process should be tested to determine if they are a hazardous waste. Other models perform recycling separate fi-om the customer's vehicle.

0 On-site or Off-site recycling where the generator collects and stores the spent antifreeze and has a service company recycle the antifreeze at the shop or transport the spent antifreeze to a treatment facility for recycling. Prior to recycling, the antifreeze would be considered a waste (if it fails the Toxicity Characteristic Leaching Procedure) and would need to be managed as a hazardous waste.

Antifreeze can be recycled either by distillation or by filtration.

Antifreeze Distillation - In distillation, used antifieeze is removed from the vehicle and placed in the heating unit of the antifreeze "still," where it is heated to the boiling point. A vapor forms and passes through a cooling unit, where it is returned to the liquid state. The recovered liquid will be nearly pure ethylene glycol, and will require anti-corrosion and other additives (in addition to distilled water) before reuse. Recycling equipment vendors provide additive packages.

Antifreeze Filtration - Two types of filtration commonly used to recycle antifieeze in vehicle maintenance shops are chemical filtration and ultra-filtration. In chemical filtration, chemicals are added to used antifieeze to precipitate (cause to settle out) dissolved solids before mechanicaI,filtration. Ultra-filtration involves passing used antifreeze through a series of successively finer filters to remove contaminants suspended in the antifreeze. After filtration, additives must be replenished. Recycling equipment vendors provide additive packages.

After recycling, contaminants removed fiom the antifreeze will remain in the equipment. In a distillation unit, a sludge called "still bottoms" is left at the bottom of the heating unit. Ln the filtration unit, there will be used filters. These wastes are potentially hazardous because they may contain high levels of lead, solvents, fuel, etc. Recycling wastes must be classified hazardous or nonhazardous before disposal (Unit 1 - Module 1). Hazardous still bottoms and used filters must be stored in sealed, labeled containers, and disposed of by a permitted huardous waste management company. Nonhazardous still bottoms and used filters containing no fiee liquids may be landfilled with permission from the landfill operator in accordance with state and local regulations.

Best Management Practice

Antifreeze must be replaced when it becomes corrosive or contaminated and no longer provides adequate protection against fieezing. Replace antifreeze only when necessary.

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1 Unit 3 - Module 3 - Engine Coolant (Antifreeze)

Visually check antifreeze for contaminants, and test for fieeze point and pH. Freeze point can be tested with a hand-held refiactometer and pH can be tested using pH test paper or a pH meter. Fresh ethylene glycol or corrosion inhibitors can be added to adjust these parameters without disposing of the antifreeze.

Wear protective clothing when flushing coolant. Store the spent coolant in containers which are labeled with the words "hazardous waste", the contents of the container, d e EF'A waste code, and the date of accumulation. Keep containers closed and sealed. Containers used to store hazardous waste must be in good condition. Hazardous waste must not be stored near working floor drains and is required to be shipped using special shipping papers required by Maine DEP to a permitted facility. Spent antifreeze should not be mixed with other wastes, i.e. oil, gasoline or solvents.

Some companies are selling "propylene glycol", an antifkeeze used in mobile homes and boats, as a substitute for ethylene glycol in the automotive application. This product is less toxic, but it still has potential to pick up hazardous constituents in the engine. Note, however, that propylene glycol may not be approved by d e automotive manufacturer for use in their engines.

If you are considering use of propylene glycol, make sure to use the antifieeze the vehicle manufacturer recommends. Also, it is important to check the manufacturers' warranties to ensure that the use of recycled antifieeze does not invalidate the warranty.

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Costs of Antifreeze without Distillation Unit

Antifreeze Used Per Week Amount of Antifreeze Replaced m Vehicles (based on two jobs per week)

Class Exercise: Calculate the Cost Savings from Antifreeze Recycling for your school

Example Your School

5 gallons

Cost of Antifreeze Per Week Off-site disposal cost per gallon ($165 for a 55 gallon drum) Cost of new antifkeeze per gallon Total cost per gallon per week

Total cost of antifreeze per week

$3 $5 $8

$40 (5 gal x $8) I Costs of Antifreeze Distillation Unit Example

Amount of Antifreeze Recoverable per Week Average percentage recovered (90%) Amount of antifreeze recovered

Your School

Weekly Operating Cost of On-Site Distillation Unit Cost of Additives per week Still bottoms disposal per week ($300/55 gallon dnun

New antifreeze needed per week Weekly cost of new antifkeeze

over 2 year period)

~~ ~ ~~ ~ ~

Cost of antifreeze distillation unit Total savings per year Payback period in terms of years

I

$7,500 $2,137 ($41.90 x 52) 3.5 years ($7,500/$2,137)

d 4.5 gal (5 gal x -9)

$3.50

$2.90 0.5 gallons (5 gal - 4.5 gal) $2.50 (.5 galx $5)

I Total operating costs per week I $8.90 ($3.50 + $2.90 + $2.50) I I

Cost Savings Per Week yitJ Antifreeze Distillation Unit

Cost savings per week Service charge for recycling per week ($5/customer) Total cost savings per week

Payback Period for Antifreeze Distillation Unit

Example Your School

~

$3 1.90 ($40 - $8.90) $10 $41.90

Your School

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Unit 3 - Module 3 - Engine Coolant (Antifreeze) )

1. What if the cost of purchasing antifreeze went up? How would that affect your decision to purchase an antifreeze distillation unit?

2. What other factors would influence you in buying a distillation unit?

Unit 3 - Module 4 - A/C Refrigerants

Learning Objectives

1. Identify what the "Ozone" layer is.

2. Identify the regulations governing A/C servicing.

3 - Identify the requirements for recycling technician certification and approved recycling equipment.

4. Discuss R-l34a, an alternative to fieon.

5. Leam the methods for reducing refrigerants venting.

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Unit 3 - Module 4 - A/C Refrigerants 1


1. Freon is a Chloroflurocarbon (CFC) A) True B) False

2. Chlorinated chemicals such as CFCs are destroying the ozone layer. A) True B) False

3. Technicians who repair or service a/c systems must be: A) Specialists B) Competent C) Trained and certified D) Master technicians

4. Topping off a leaking air conditioning system rather than repairing is an acceptable practice. A) True B) False

5. The sale of CFCs to anyone other than a certified technician is: A) Not advisable B) Permissible C) Prohibited D) Not regulated

7

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PrelPost Test

1.

2.

3.

4.

5.

Freon is a Chloroflurocaibon (CFC) A) True B) False

Chlorinated chemicals such as CFCs are destroying the ozone layer. A) True B) False

Technicians who repair or service a/c systems must be: A) Specialists B) Competent C) Trainedandcertified D) Mastertechnicians

Topping off a leaking air conditioning system rather than repairing it is an acceptable practice. A) True B) False

The sale of CFCs to anyone other than a certified technician is: A) Not advisable B) Permissible C) Prohibited D) Not regulated

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Unit 3 - Module 4 - A/C Refriaerants


The earth is protected fiom h d radiation by an ozone layer located from 10 to 35 miles above the earth’s surface known as the stratosphere. Stratospheric ozone is subject to destruction by the release of chlorine atoms which cause a chain reaction that destroys ozone. Scientists have proven that approximately 85% of the chlorine comes from chlorofluorocarbons (CFCs) and other chemicals. Only 15% of the chlorine comes fiom natural sources.

As omne is destroyed, higher amounts of ultra violet radiation (VVB) reaches the earths surface. This UVB has been linked to skin cancer, cataracts and harm to crops, animals and marine life. It could also weaken the human immune system.

As a result of the destruction of the stratospheric ozone, an international agreement, the Montreal Protocol, was signed by 75 countries, to protect the stratospheric ozone and phase out the production and eventual use of ozone depleting chemicals such as CFCs. Under the terms of this agreemeat, the United States passed Title VI of the Clean Air Act Amendments in 1990 to prohibit the venting of CFCs and to phaseout the production of CFCs by the year 1996. Production of CFCs has ceased in the US and regulations have been passed that control the repair or refrigeration and air conditioning equipment.

Automobile air ccmditioners manufactured prior to 1994 used Freon R-12 as the refiigerant. This refrigerant has been estimated to account for 20% of the CFCs in use in this country. Automobile air conditioners manufactured after 1994 use R-l34a, a hydrofluorocarbon (HFC) as the refrigerant.

Regulatory Issues

The CFC regulations are written to prevent the release of CFCs to the atmosphere during the servicing of automobile air conditioners. Refrigerants must not be vented to the .

atmosphere. Technicians must be certified by an EPA approved recycling technician certification organization. Certification means that the technician has taken and passed a written test pertaining to the servicing of motor vehicle air conditioners.

In addition to technician certification, the repair facility must use approved refrigerant recycling equipment. This recycling equipment must recover/recycle the refrigerant or do recovery only. Recoverh-ecycle equipment both recovers the refrigerant from the air conditioner and processes it through an oil separator, a filter and a dryer. Recover-only equipment removes the refrigerant from the unit and transfers it to a holding tank for reclamation. Recovered refrigerant is either required to be recycled onsite or shipped to an EPA approved reclamation facility for purification..

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To assure that air conditioning repair is done by qualified technicians, the sale of all refrigerants is restricted to certified technicians only. “Do-it-yourselfers” are prohibited fiom purchasing small cans of refrigerant and are encouraged to take their unit to certified repair technicians who can properly service air conditioners using approved equipment.

Pollution Prevention Opportunities

Federal law required aphaseout of the production of CFCs by the end of 1995. These products may still be used throughout the life of the air conditioning equipment, but the CFC R-12 may be scarce andor extremely expensive. Altemative refigerants such as HFC R-134a or blends will be required to be recovered. The service facility must exercise caution to prevent cross contamination of R-12 with R-134a For instance, if a system with R-12 is evacuated into the reclaimer, and the reclaimer already had R-134a in the unit, all the refrigerant contained in the unit will be contaminated and must be sent to an offsite refiigerant reclamation facility. Any contaminated refrigerant may require disposal as a hazardous waste.

Before evacuating the refrigerant for reclamation, it is important to determine which type of refrigerant is used in a vehicle. A label under the hood should identify refrigerant type. Otherwise, a device is available on the market to identify refigerant in a system as R- 12 or R-l34a, or unknown.

Best Management Practice - Minimize Refrigerant Venting

Refrigerant should not be vented to the atmosphere. Refiigerant reclaiming units must be used during air conditioning (AC) servicing to decrease the possibility of refrigerant loss. Use independently approved equipment certified to the SAE standard J- 1990 to evacuate and recharge AC systems. EPA notification and certifications are required. Consult the local environmental assistance agency or the state environmental agency for details of regulations and requirements for your state.

To prevent refrigerant loss during service, evacuate all refrigerant prior to maintenance or rep& of ~ i r conditioning systems. Manifold hoses must have a shutoff valve locate at the end of each line to prevent leakage. If an air conditioning system comes into the shop leaking refrigerant, evacuate the system immediately. Make it a policy to encourage customers to repair rather than “top off leaking systems. Note that topping off a leaking system will result in unnecessary refrigerant loss. Repairing a system will protect the environment and lessen the need to purchase R-12, which is rising in cost. Instead, find the leak and take corrective measures prior to recharging the system.

Avoid using products containing R- 12 designed to be used in-system to find leaks. Use such products only as a last resort. Many air conditioning system leaks can be detected

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1 Unit 3 - Module 4 - N C Refrigerants

with a simple visual inspection of the hoses, connections and condenser.

Insure all air conditioning technicians are certified by EPA.

Class Exercise: Demonstrate refrigerant recycling equipment to students by evacuating a system. Check for leaks to the system and repair.

Class Exercise: Arrange a field trip to watch a retrofit of a R-12 system for use with newer refrigerants, provide current manufacturer information on retrofitting.

i

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Unit 3 - Module 5 - Parts Cleaners ~

Learning Objectives

1. Identify the health hazards of working with parts cleaners including possible cancer risks.

2. IdentifL the altemative chemicals/operations available to minimize hazardous waste and air emissions such as aqueous (water) or alkaline cleaners and microbial cleaners.

3. Reduce the hazardous wastes associated with parts cleaners.

4. Describe how to properly manage wastes fiom water-based parts cleaning.

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Unit 3 = Module 5 - Parts Cleaners 1


1. The best source for specific information regarding the health and safety features of a parts cleaning fluid is: A) The shipping label B) Theinvoice C) The product brochure D) TheMSDS .

2. If the flashpoint of a chemical is below 140 Degrees F it is: A) Safe near a flame. B) Considered toxic. C) Considered ignitable. D) Considered reactive.

3. Which of the following is not a method to reduce solvent waste? A) B) C ) D)

Close parts washer when not using it Replace solvent only when it is too dirty to be used Removing solvent according to a schedule without checking if it dirty Drain all parts thoroughly before removing them fiom the parts washer

4. A good altemative to a solvent based cleaner is: A) High pressure washing B) Aqueous cleaning machine. C) Alkalinecleaners D) Alternatives A-C.

5. Spent solvents should be disposed of by: A) B) C) Mixing with other wastes. D) Storing indefinitely.

Pouring them down the drain. Having them transported to a recycling facility.

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Unit 3 - Module 5 - Parts Cleaners

PreEost Test

1.

2.

3.

4.

5 .

The best source for specific information regarding the health and safety features of a parts cleaning fluid is: A) The shipping label B) Theinvoice C) The product brochure D) TheMSDS

If the flashpoint of a chemical is below 140 Degrees F it is: A) Safe near a flame. B) Considered toxic. C) Considered ignitable. D) Considered reactive.

Which of the following is not a method to reduce solvent waste? A) B) 3. 4.

Close parts washer when not using it Replace solvent only when it is too dirty to be used Removing solvent according to a schedule without checking if it dirty. Drain all parts thoroughly before removing them fiom the parts washer

A good altemative to a solvent based cleaner is: A) High pressure washing B) Aqueous cleaning machine. C) Alkaline cleaners D) Alternatives A-C.

Spent solvents should be disposed of by: A) B) Storing indefinitely. C) Mixing with other wastes. D)

Pouring them down the drain.

Having them transported to a recycling facility.

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Unit 3 - Module 5 - Parts Cleaners I

Regulatory and Health & Safety Issues

Petroleum based solvents are widely used to remove grease and dirt fiom parts. Use of these solvents can be hazardous to your health and to the environment. Parts washers often contain solvents made up of ‘klogenated” chemicals. People exposed to halogenated chemicals through breathing or skin contact may also develop certain kinds of cancer. For example, methylene chloride, a chemical commonly used in carburetor cleaners is a suspected human carcinogen.

There are several different chemicals used to clean parts, and manufacturers are reformulating products to make them reliable, yet “environmentally fiendly”. Material Safety Data Sheets are the best source of specific information on the health and safety features of each of these products.

f

Often solvent washing chemicals are hazardous wastes because they are either ignitable or toxic. If the flashpoint is below 140 degrees F, the solvent would be an “ ignitable” hazardous waste. Petroleum naphtha or mineral spirits may be ignitable. Certain newer solvents are not ignitable because they have flashpoints above 140 degrees F, but may still be hazardous wastes because of lead, other heavy metals or benzene. Degreasers such as immersion cleaner, cold parts cleaner, or carburetor cleaner are typically classified as hazardous, based on the toxicity of the solvent. Most cleaning solvents emit air toxic fumes which may be subject to regulation.

To keep solvent fiunes fiom escaping, the tubs need to be kept closed except when parts are being added or removed. Rubber gloves and eye protection should be worn during parts cleaning operations.

Aerosol cans offer the automotive industry a wide variety of products in a very convenient package. Brake cleaners and carburetor cleaners are typically sold in aerosol cans. Currently, many landfill authorities are letting people know which aerosol cans they will accept. Aerosol cans must be completely empty for disposal.


Aqueous (water) or alkaline cleaners may be substituted for solvent based cleaners in some applications, particularly for non-aluminum parts. High pressure washing may be an effective method of parts cleaning with either a non-toxic detergent or a microbial cleaner. Wastewater can be treated with an oillwater separator and be recycled.

Microbial cleaners are water-based cleaners that contain soaps and microbes. The soap loosens the grease from parts, and the microbes “eat” the grease, turning it into water and carbon dioxide. Microbial cleaners can be used for parts cleaning, and for cleanup of small

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oil spills. Microbial cleaners are sold with the microbes and nutrient source packaged separately. The mixed solution has a shelf life of about 60 days. These cleaners can be used in traditional parts washers.

Spent microbial cleaners may also be discharged to the city sewer with prior approval. Disadvantages of microbial cleaners include foul odors and limited solution life after mixing. Invite a biology teacher to come into your class to discuss microbes.

Pre-cleaning parts with a rag or wirebrush, followed by steam cleaning, high-pressure wash, or hot bath which recycles an aqueous solution using an oil separator, is an effective approach to “ k i n g or eliminating the use of hazardous solvents.

Shops can also evaluate how many parts washers are necessary and whether they need to be serviced as often as scheduled. Another option is to use dirty solvent to preclean dirty parts or to use the parts washers with the dirtiest solvent “for dirty parts ~nly.” Reserve the parts washers with the new solvent for final cleaning. This extends the life of the solvent in all of the washers.

Replace disposable aerosol cans for degreasing or lubrication by using refillable spray canisters or use portable parts wash units equipped with basins to catch overspray, e.g. brake washers. Use one spray can of a certain type at a time so there will not be duplicates that may spoil. Chlorinated brake cleaners are a health hazard. Avoid using them whenever possible.


1. 2. 3.

4.

5 .

6.

7. 8.

Never mix or add spent or fresh solvents to used oil. Never use gasoline as a cleaner or solvent. If using a chlorinated solvent, consider switching to a less toxic solvent such as a citrus product or an aqueous detergent. Never dispose of solvents into drains, the ground or the air. Disposal by evaporation violates the Maine Hazardous Waste Rules. Consider a two-step, precleaning/final cleaning system. This allows the use of more contminated solvent in_ the precleaning tank, thus extending the usable life of the solvent you purchase. Always keep lids of cleaning tanks closed and spray nozzles off to prevent evaporation and worker exposure. If you own your own solvent sink, consider installing a filter to increase the life of the solvent. Remember to dispose of the filters as hazardous waste. Locate the units way from heat sources and drafts to minimize evaporation. Install drain racks on parts washers so that wet parts can drain before being removed from the wash basin.

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1 Unit 3 - Module 5 - Parts Cleaners

9. Consider the use of a solvent supplier who will pick up and recycle the solvents. Alternatively, consider purchasing a solvent recycling machine (a solvent still) and recycling your solvent on-site. Remember, sludges generated during solvent recycling are typically hazardous. Finally, make sure you get the most from your solvent before recycling or disposing of it.

10. Use all of the material in the can. 11. Recycle empty cam or dispose of in a landfill. 12. Defective cam that still contain hazardous material should be returned to the

mandactwex or disposed of as a hazardous waste.

Proper Management of Wastes From Water-based Parts Cleaning

Dirt and grease fiom the parts will accumulate in the bottom of the washer as sludge. This sludge should be cleaned out frequently. The sludge is potentially hazardous and should be classified as hazardous or nonhazardous before disposal. Hazardous waste must be disposed of by a hazardous waste management company. Contact your local hazardous waste regulatory authority or assistance program for more information.

Some hot soap washers evaporate water during use - more water has to be added, and no wastewater is generated. Other washers generate wastewater that needs to be disposed. This wastewater should not be discharged outdoors or to a septic system. Contact the local wastewater treatment plant supervisor to determine if this wastewater can be discharged to the city sewer. Wastewater should be tested for pH to protect pipes. If the pH is too low, the wastewater may have to be neutralized before being discharged. Before discharge, oil and large dirt particles must be removed fiom the wastewater. Oil skimmers are available as an option on the washers, or can be purchased separately.

Class Exercise: New Clean Technologies

Invite in a vendor or vendors to bring in new “clean” technologies into the school for demonstration such as: microbial or biological parts washer, filtering parts washer, aqueous parts washer, hot soap washer or alternative solvents.

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I Example

$100 ’ 8 hours $10 $80 (8 hrs. x $lO/hr) 5280 (2 x $100) + $80

[ 2

Class Exercise: Cost Savings Estimate for a Hot Soap Degreaser

r

Cost Savings Estimate Worksheet

$2,850 ($2,500 for unit + l $350 testing cost)

~ ~~ ~ ~~ ~

Cost of Solvent Parts Cleaning

Number of parts washer stations Cost of each tank per month Time spent cleaning parts per month Cost of labor per hour Total cost of labor per month Parts wash expenses per month [(AxB) + E]

Costs of Hot Soap Degreasing I Example ~~ ~ ~~~ ~ ~

Costs of Hot Soap Degreasing Biodegradable soap expense per month (bulk buying is cheaper) Operating costs per month (utilities) Cost of labor per hour Total cost of labor per month Total expenses per month Sludge testing ($350)* and disposal ($400)

Cost Savings Yearly expense using solvent Hot soap expenses per year Total cost savings per year

Payback Period Cost of hot soap degreasing unit

$20

$42 $10 $10 572 ($20 + $42 + $10) $750 ($350 + $400)

$3,360 ($280 x 12) $1,264 ($72 x 12) + $400 $2096

Your School

Payback period in terms of years I 1.35 years ($2,850/$2,096) ’lease note that this worksheet uses one hot soap degreaser replacing two solvent parts washing sinks.

* Assumes approximately one 55 gallon drum of hazardous sludge will result per year. The sludge must be tested one-time at $350 and disposed yearly at $400.

1. What are other “costs” to consider?

(Answers: worker safety, decreased fire explosion hazards, employee healtWenvironment improved, reduced liability for off-site disposal, employee time saved (i.e. 7 hours/ month), income potential f?om employee hours saved)

2. Will these other “costs” decrease the payback time, making a switch more affordable? Why?

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Unit 3 - Module 6 - Asbestos

Learning Objectives

1. Identify what asbestos is and why it was used for brakes.

2. Learn the proper techniques for asbestos disposal.

3. Explain how people can be exposed to asbestos during brake work.

4. Demonstrate proper servicing techniques to avoid exposure such as enclosed equipment for brake cleaning with HEPA filters.

i UNIT3 P A G E 4 1



1. How many asbestos fibers can be released into the air during brake or clutch

A) Several B) Hundreds C) Thousands D) Millions

servicing?

2. Long term asbestos exposure can cause scarring of the: A) Brain B) Stomach C) Lungs D) Kidneys

3. A container of asbestos dust must be disposed of by: A) B) Storinginadrum. C ) D) Burning it.

Putting it in the trash.

Transporting it to a special landfill

4. When performing brake service the technician must always: A) B) C) D)

Blow off brake padskhoes with an air gun. Use a respirator which meets OSHA standards. Wash hands after eating lunch. Discard spent asbestos solvent down the drain.

5. The Wet Sink" and "Vacuum Chamber" are tools used to: A) B) Clean greasy brake hardware. C) Assist in brake bleeding. D)

Speed up brake service production.

Contain and collect asbestos fibers during servicing.

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Pre/Post Test

Choose the one correct answer:

1. How many asbestos fibers can be released into the air during brake or clutch

A) Several B) Hundreds C) Thousands D) Millions

servicing?

2. Long term asbestos exposure can cause scarring of the: A) Brain B) Stomach C) Lungs D) Kidneys

3. A container of asbestos dust must be disposed of by: A) B) Storinginadnun. C) D) Burning it.

Putting it in the trash.

Transporting it to a special landfill

4. When performing brake service the technician must always: A) B) C) D)

Blow off brake paddshoes with an air gun. Use a respirator which meets OSHA standards. Wash hands after eating lunch. Discard spent asbestos solvent down the drain.

5 . The " Wet Sink" and "Vacuum Chamber" are tools used to: A) B) Clean greasy brake hardware. C) Assist in brake bleeding. D)

Speed up brake service production.

Contain and collect asbestos fibers during servicing.

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Friction materials, such as brake linings and clutch facings, often contain asbestos. Millions of asbestos fibers can be released into the air during brake and clutch servicing. Grinding and beveling asbestos products can cause even higher level of exposures.

Like germs, asbestos fibers are small enough to be invisible and can remain and accumulate in the lungs. When you see a dust cloud forming during the servicing of a brake assembly, you are seeing clumps containing thousands of fibers.

Asbestos released into the air lingers around a service shop long after a brake job is done. Asbestos can also get on a technician's hand and be swallowed when eating or smoking a cigarette.

Asbestos exposure can cause scar tissue to form in the lungs. This is a very gradual process that usually takes many years before its effects are noticed. The medical term for th is wndition is Asbestosis.

Lung cancer is currently responsible for the largest number of deaths fiom exposure to asbestos. People who smoke and are exposed to asbestos are at an even greater risk of contracting lung cancer.

Regulatory Issues'

It is illegal to throw a container of asbestos dust generated fiom the servicing of automotive brakes into the solid waste trash stream.

The generator must transport the asbestos to a special landfill that has a pennit to receive asbestos.

The asbestos must be wetted down to control dust and doubled bagged prior to transport.


Enclosure equipment for brake cleaning, which slips easily over the brake assembly and forms a tight seal against the backing plate is available. Clear plastic walls or windows allow visibility of the work being done. Brake dust is sucked into a vacuum cleaner equipped with a special filter called an HEPA or "high efficiency particulate air" filter.

Another solution is to use a "wet sink" during the servicing of the brakes. This sink rolls up to the axle you are working on and has a wet solvent brush that allows the technician to

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I

wet brush the asbestos dust into a sink that has a drum under it to collect the solvent. The solvent is then serviced by a company licensed to transport hazardous waste.


1. - 2. 3. 4.

5.

6.

Never use compressed air to clean off brake pad linings or backing plates. Never grind brake shoes or pads. Never eat, drb& or smoke in an area where brake work is being performed. Always wear an OSHA approved respirator when performing brake work or using a brake lathe. Always assume the vehicle you are working on contah asbestos type fiction materials. Always use containment equipment when servicing brake assemblies.

Class Exercise: Asbestos Management

1. Form the class into teams of no more than four. . 2. Ask each team to answer the following questions and be prepared to share the

answers with the class. A. Why is asbestos harmful? B. If someone has confirmed asbestosis, will their lungs ever return to their

normal healthy condition? C. Why must we not blow out drums or brake shoes? D. What should you do after performing brake work to ensure proper handling

of asbestos material? E. What two ways can we capture asbestos dust before servicing? F. What type of safety equipment should the technician wear while servicing

brakes?

Class Activity: See a video on handling asbestos.

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Unit 3 - Module 7 - Scrap Tires ~~

Learning Objectives

1.

2.

Explain the hazards of stockpiling used tires.

Identify the Maine DEP regulations regarding used tire disposal.

3. Discuss the recycling opportunities that are available for used tires.

UNIT3 PAGE46

Unit 3 - Module 7 - Scrap Tires 1 Pre/Post Test - Teacher Version

1. Whole tires that are stockpiled are a serious fire hazard A) True B) False

2. Shredded or chip tires can be used for: A) Fuel in industrial boilers B) Asphalt for roads C) Rubber in sandals D) All of the above

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Unit 3 - Module 7 - Scrap Tires

Pre/Post Test

1. Stockpiled tires do not pose any fire risk. A) True B) False

2. Shredded or chip tires can be used for: A) Fuel in industrial boilers B) Asphaltforroads C) Rubberinsandals D) Alloftheabove

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Unit 3 - Module 7 - Scrap Tires J


Tires represent a significant volume of waste. If whole tires are stockpiled in large quantities, they become a serious fire and health hazard. Tires which were bluied whole in landfills years ago may rise to the surface due to natural vibration. Tires will collect water when left outside in the rain. Mosquitos breed in these pools of water.

Regulatory Issues

There are no landfills in Maine accepting tires. Generally, tires are transported by a non hazardous waste transporter licensed by the state of Maine and are brought to a licensed processing facility for shredding or chipping. The chipped tires are used for fuel in industrial boilers.


A number of new technologies for reuse and recycling of used tires have been tried. Engineers have been able to separate the scrap steel and produce a mealy rubber that can be added to asphalt for use on roads. Another technology, a catalytic reduction process, bakes chipped tires bleeding away the carbon black and recovers the hydrocarbons as methane gas and as he1 oil.


Every automotive service facility should be prepared to accept old tires from customers and have arrangements with a removal contractor and chipping facility which will process the tires for use as a fuel or feedstock for a recycled product such as rubberized asphalt.

Class Exercise: '' What goes around comes around"

1. 2.

Break the class up into teams of no more than four students. Have each team complete the following exercises then ask each team to present its findings:

Part A

Small Town USA has 1500 registered vehicles. Every 3 years, each car will get 4 new tires. 1/3 of each of the car owners in town will get new tires every year. How many tires will this town replace in one year ?

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Unit 3 - Module 7 - Scrap Tires

Part B

The average weight of a tire is 22 pounds. How much will Small Town's used tires weigh in one year? The average size of a tire is approximately 2 fi. square. How much room would the tires have taken up in a landfill?

How can we better manage this large waste problem?

Part C

Ask each team to list the different recycling possibilities for used tires.

Examples:

Sandal shoes Hard top filler Roofing material Fuel for generators Play ground equipment Gasket material Blasting mats Guard rail barriers Boamock cushions

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Unit 3 - Module 8 - Used Batteries

Learning Objectives

1. Identify the hazards posed by battery acid fiom used automotive batteries.

2.

3.

Understand the regulations governing recycling and disposal of used batteries.

Identi@ how to recycle spent batteries.

UNIT3 P A G E 5 1

Unit 3 - Module 8 - Used Batteries ~ ~~


1.

2.

3.

4.

Batteries contain acid which can cause which of the following: A) Severebums B) Corrosion of materials C) Eyedamage D) All of the above

Lead acid batteries are banned from landfilling or incineration in Maine A) True B) False

If a battery is open or leaking: A) B) C) D)

It should be disposed of in the trash. It should be sent to a recycler. The acid must be collecteamanaged as a hazardous waste. Stored on a wooden pallet.

All spent batteries should be stored: A) In stacks against a wall. B) Outside on the ground. C) On a pallet, under cover, with strapping to prevent spills. D) Under the work bench.

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Unit 3 - Module 8 - Used Batteries 1

PrePost Test

1. Batteries contain acid which can cause which of the following: A) Severeburns B) Corrosion of materials C) Eyedamage D) All of the above

2. Lead acid batteries are banned fiom landfilling or incineration in Maine A) True B) False

3. If a battery is open or leaking: A) B) C) D)

It should be disposed of in the trash. It should be sent to a recycler. The acid must be collectdmanaged as a hazardous waste. Stored on a wooden pallet.

i

4. All spent batteries should be stored: A) In stacks against a wall. B) Outside on the ground. C) On a pallet, under cover, with strapping to prevent spills. D) Under the work bench.

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Unit 3 - Module 8 - Used Batteries


Automotive batteries are of the lead-acid type and contain a sulfuric acid solution, often called electrolyte or battery acid. This solution is highly corrosive to many materials and can cause serious burns to skin, and permanent eye damage if splashed in the eyes. Because of this, handling automotive batteries demands certain precautions. Persons handling battery acid should wear protective clothing and eye protection. To minimize exposure to battery acid, batteries should be stored so as to prevent breaking or leaking.

Regulatory Issues

Under the hazardous waste regulations, automotive service facilities that collect lead-acid batteries for recycling are required only to store the batteries in a manner which prevents the release of battery acid to the environment. If the battery is open or leaking, the acid must be collected and managed as a hazardous waste. The battery housing is not regulated if it is sent for recycling. Batteries that are to be disposed, rather than reclaimed, are fully regulated as hazardous waste. Accordingly, lead-acid batteries are banned fiom landfilling or incineration in Maine.


Keeping batteries out of our solid waste landfills and incinerators is a significant method of reducing pollution. Every automotive servicing facility can assist by taking back the customer's spent battery upon the purchase of a new battery. Some battery distributors collect spent batteries for reclamation. Many local scrap metal recyclers also collect batteries and ship them to battery reclaimers.


Store all spent batteries on a pallet with strapping to prevent spilling. The storage area should have secondary containment made fi-om acid-resistant material such as plastic or concrete and be indoors. Do not stack batteries since they may crack and fall. Store batteries away fiom flammable liquids, ignition sources and drains.

Class Exercise: Setting Up a Proper Battery Storage Area for the School

If the school does not have a designated battery storage area, set one up. Include secondary containment. Batteries should not be stored outdoors in Maine.

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1 Unit 3 = Module 8 - Used Batteries ~~~ ~

Class Exercise: Battery Acid Demonstration

Demonstration by the chemistry teacher at school on how battery acids burn or react with metals. This demonstration could be followed up by how to neutralize a spill of battery acid.

Class Exercise: *’ Battery Basics”

Part A

Small Town USA has 1500 registered vehicles. 25% of these vehicles will requhe a battery replacement in one year. How many batteries will be replaced in one year?

Part B

The average battery weighs 18 pounds. What will the total weight of the used batteries be in one year?

Part C

How can we best manage this large waste problem? (Most automotive batteries are collected and sent to battery reclamation facilities, sometimes called, “battery breakers.” At these facilities, the batteries are disassembled and lead is recovered fkom the electrolyte & electrodes. The lead is used to manufacture new batteries.)

Unit 3 - Module 9 - Floor Drains ~~

Learning Objectives

1. Identify the route water takes as it goes down the drain. Learn about the possible sources of contamination including soil, ground water and surface water.

2. Understand the regulatory choices auto repi& shops have with regard to floor drains.

3. Describe opportunities to reduce contamination of floor drains.

4. Identify non-toxic bay floor cleaning alternatives.

5. Leam where the floor drain leads from your shop.

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Unit 3 - Module 9 - Floor Drains 1 Pre/Post Test - Teacher Version

1. Floor drains that lead to septic systems or holding tanks can cause: A) Drinking water contamination B) Low water pressure C) Water rates to increase D) Higher water usage

2. Out of all the options below, which one of the methods is an acceptable shop waste water management system? A) Septicsystem B) Dry well C) Subsurface leaching structure D) Municipal Sewer

3. Floor drain sludge from a vehicle maintenance shop may contain: A) Heavymetals B) Fuel C) Solvents D) AU of the above

4. Oil and water separators should be cleaned every: A) 7days B) 30days C) 30 to 90 days D) 60- 120 days

5. When cleaning bay floors you should use: A) Cleaning solvent B) Flooracid C) Non-toxic biodegradable soap D) Kerosene

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Unit 3 - Module 9 - Floor Drains

Pre/Post Test

1. Floor drains that lead to septic systems or holding tanks can cause: A) Water rates to increase B) Low water pressure C) Drinking water contamination D) Higher water usage

2. Out of all the options below, which one of the methods is an acceptable shop waste water management system? A) Septicsystem B) Dry well C) Subsurface leaching structure D) Municipal Sewer

3. Floor drain sludge fiom a vehicle maintenance shop may contain: A) Heavymetals B) Fuel C) Solvents D) All of the above.

4. Oil and water separators should be cleaned every: A) 7days B) 30days C) 30 to 90 days D) 60- 120 days

5. When cleaning bay floors you should use: A) Cleaning solvent B) Floor acid C) Non-toxic biodegradable soap D) Kerosene

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I


When floor drains are connected to pipes which drain onto or into the ground (e.g. connect to a septic system or dry well), fluids entering the drains from the bay area of a vehicle maintenance operation may travel into the soil, to local drinking water supplies and to streams Floor drain wastewater also should not be discharged to a septic system or directly to a ditch, stream, river or any other body of water.

Contamination *om the poor drains canjlow into ground water. Ground water is a source of drinking water and water for irrigation.

From Massachusetts DEP, Industrial Floor Drains Common Questions about the UIC program, Sept. 1996.

Regulatory Issues Under current state regulations there are three options for dealing with facilities with floor drains in areas where regulated contaminants are used or stored:

a Permanently seal the floor drain All previous discharges to the drain must be eliminated at their source.

Holding tank or Water Recycling System These tanks or water recycling systems are for non-hazardous wastewater (Le. commercial and industrial). If solvents, antifreeze, oil and other wastes are washed down the drain, the wastewater is likely to be considered hazardous.

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0 Hook into the Municipal sanitary sewer system This option is only available where there are sewers and the local sewer authority will allow it. This option requires the installation of an oiywater separator before discharge to the system.


Conserve water. Use as little water as possible for floor or vehicle cleaning by using dry cleaning methods such as sweeping and vacuuming. Shut off the faucet when you are not using the water. Wastewater goes into a sump where solids settle out. Collect this water in a holding tank where it can be pumped out and used for the preliminary cleaning of vehicles.

Minimize pollutants entering an open floor drain. If a drain remains open, efforts should be made to “ize the pollutants which enter it. If the drain leads to the sewer, the pollutants will pass through the waste water treatment plant. If the drain leads to a tank, keeping hazardous waste out of the tank reduces the amount of hazardous waste produced, and therefore saving on disposal costs. For example, it costs much more to dispose of 20 gallons of snow melt once a pint of gasoline has been mixed into it, than to dispose of each of those items separately.

Keep oil and water separators clean. (also called sand traps, MDC traps, interceptors) They are intended to promote the separation and containment of solids and oil or grease while allowing passage of the water they are mixed with. Knot properly maintained, they do not operate properly. All designs of oil and water separators require regular cleaning, the fiequency of which depends on the volume of wash water going through the separator.

In general, facilities using petroleum products should clean separators at least every 30 to 90 days. The removed oily solids must be managed as waste oil, drummed and shipped as a hazardous waste. Therefore, the best pollution prevention strategy is to minimize the amount of product going into the separator.

All floor drains which discharge to subsurface leaching structures must be reconfigured, either by sealing the drain is or tying it into a sewer or tank.


Never clean spills by hosing them down with water.

1. Prevent spills by properly maintaining collection equipment.

2. Clean up any spills immediately using a dedicated mop and bucket, using new technology absorbents such as pipe sponges or corn dust or launderable rags.


3. When cleaning bays use a non-toxic, biodegradable soap.

4. Keep oillwater separators maintained at all times.

5. Floor drain sludge is potentially hazardous because it may contain oil, solvents or other chemicals. Test the sludge to determine if it is hazardous. Generally the sludge is disposed as a special waste by the company cleaning out the oil/water separator.

6. Perfom vehicle maintenance work in areas with no floor drains or temporarily seal off the drains during work.

7. Store hazardous materials or waste away fiom drains.

Class Exercise: Finding floor drains in the shop

1. Have the students locate all the floor drains in the shop. Help students figure out where the drains lead. Look for drains in the hazardous material or waste storage areas. Seal these drains off or move the stored items to an area Without drains.

2. Discuss what hazardous materials used in the shop could contaminate wastewater and floor drain sludge. Examples include: oil, solvents, lubricants, antifieeze, windshield washer fluids and floor cleaners.

Class Exercise: Physical Plant - speaker

Invite someone fiom the physical plant at the school to discuss oiVwater separators and tight tanks if your school has a floor drain.

Ask the speaker to discuss what happens to the wastewater before it leaves the school property-

Is it treated? Is it monitored? Does it all go to one central location before it leaves the school property? Or, are there several discharge points from the school?

UNIT3 PAGE61

Unit 3 - Module I O - Storaqe Tanks

Learning Objectives

1. Identify underground vs. above ground storage tanks.

2. Learn that there are daily requirements for inspecting and monitoring tanks.

3. Learn how time c o d g and costly it is to clean up spills from above ground and underground tanks.

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Unit 3 - Module 10 - Storage Tanks

PrePost Test: Teacher version

1. Gasoline is stored in underground tanks because:

A) B) C) D) None of the above.

A large tank for gasoline is ugly so people want it below ground. Gasoline is a fire hazard. There is no room to put a large gasoline tank.

2. New underground storage tanks are required to have a "tank within a tank" @e., have a double-wall).

A) True B) False

3. Leaks fiom tanks occur as often fiom cracked hoses or improper fittings as cracks inthetank:

A) True B) False

4. When pouring fluids into a tank, it is best to use a funnel.

5. The following are above ground tank requirements for waste oil except:

A) Tank must be labeled. B)

C) D)

Tank must be checked for leaks each week and operators must keep a written log. Tank must be emptied every 6 weeks. Tank must be placed on a surface such as concrete (won't allow oil to pass through it)

UNIT^ PAGE^^

Unit 3 - Module I O - Storaae Tanks

PreLPost Test

1. Gasoline is stored in underground tanks because:

A) B) C) D) None of the above.

A large tank for gasoline is ugly so people want it below ground. Gasoline is a fire hazard. There is no room to put a large gasoline tank.

2. New underground storage tanks are required to have a "tank within a ti"' (i.e., have a double-wall).

A) True B) False

3. Leaks from tanks occur as often from cracked hoses or improper fittings as cracks inthetank:

A) True B) False

4. When pouring fluids into a tank, it is best to use a:

5. The following are above ground tank requirements for waste oil except:

A) Tank must be labeled. B)

C) D)

Tank must be checked for leaks each week and operators must keep a written log. Tank must be emptied every 6 weeks. Tank must be placed on a surface such as concrete (won't allow oil to pass through it)

UNIT^ PAGE^^

i

i

Unit 3 - Module I O - Storaae Tanks

Waste Oil Tanks

These days, waste oil tanks are generally situated above the ground. These tanks must be free of rust, dents, bulges, leaks or other kinds of damage. The tank has to be labeled in large letters with the words “Waste Oil.” Auto repair shops need to obtain a pennit fiom their local fire departments to have any tanks, including tanks for virgin oil, at their shops.

Ifthe tanks are underground, additional requirements apply. A tank is considered to be below ground if 10% or more of the tank is below the ground. For more information on the requirements for installation, monitoring, reporting and leak detection for underground storage tanks, contact the Maine DEP at 207-287-265 1.

Only oil (such as crankcase, heating, hydraulic fluid and trammission fluid) can go into a waste oil tank. Fluids such as gasoline, antifireeze, brake cleaners and solvents are .specifically prohibited.

Pollution Prevention

If waste oil tanks are located outside, the Maine DEP recommends that the tanks be either double-walled or be single-walled and water-tight. The tank should be placed on a surface made of nonporous material such as concrete with no cracks or gaps. The DEP also recommends secondary containrnent systems for the above ground tanks - these are systems that capture up to 1 10% of the volume of the largest tank. The system can be curbs around the waste oil storage area or it can be a large plastic tub.

Class ExerciseKase studies:

Please read the following case studies and then ask the class to answer the following questions.

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The owner of the faulty dispenser was required to take it out of service. The Norway Water District shut down the municipal well to prevent drawing the polluted ground water to it, and began purchasing replacement water from the neighboring water district. The Maine Department of Environmental Protection had a hydrogeological investigation done that revealed a "plume" of gasoline polluted ground water that stretched fiom the spill site about half way to the municipal well. The cleanup included pumping ground water to capture the contaminated plume and venting the soil with a large vacuum blower to

water was treated by aeration before it was discharged.

After one and a half years of treatment the pollution problem was determined to be under control and the municipal well was restarted. Only trace levels of a gasoline additive were ever detected in the municipal well. Ground water and soil treatment continued for almost four years. The gas station was shut down for over three years. When the site was dug up to remove the old tanks and install new ones, a substantial amount of contaminated soil near the pump island was discovered, but only minor amounts of contamination was associated with the tanks. Over a quarter of a million dollars was spent by the Department of Environmental Protection on the cleanup.

1 evaporate the gasoline coating soil grqins above the water table. The

Gasoline Spill Site Oxford, Maine by John Beane, Maine DEP

In August 1990 a routine inspection of a retail gasoline sales facility by state regulators brought to light a slow leak of regular unleaded gasoline fiom two loose couplings in a dqenser. The State required the owner of the facility to install a monitoring well near the leaking gas pump, and it showed that gasoline contamination had migrated all the way down to the water table, sixty feet below the land surface.

The buried tanks and piping may not contribute as much to the ground water pollution problem as the leaks inside the dispensers, above the ground surface. Awareness of the environmental threat and careful maintenance of the equipment could probably have prevented the spill.

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I


Those Tanks in America's Backyards and Basements Aboveground and Underground Home Heating Oil Tanks by W. David Mccaskill. Maine DEP

It was a stormy March day. Mrs. Delbert B e 4 wann and snug in her home along Maine's oft tempestuous coast, was troubled by the unmistakat, le odor of fuel oil. She put in a call to her home heating oil dealer, who dispatched a burner technician. After a brief inspection of the furnace and the outside above-ground oil tank, he assured her that things looked fine. But, Mrs. Beal continued to smell fuel oil, so she called her oil dealer again. The technician paid another visit and, after another inspection, reassured her that all was right with the world

was w-rong and that she would have to take up this investigation herself. She crawled under the house. (Because of shallow bedrock conditions, her house has no basement, only a small crawl space.) Before long, she discovered fuel oil running along the surface of the bedrock. She called her oil dealer again and personally escorted the technician under the house for a visual inspection.

After further investigation, the technician determined that the source of the problem was a copper fuel supply line, which was covered along the bedrock. The oil company replaced the line and reported the leak to the Maine Department of Environmental Protection (MDEP).

To make a long story short, Mrs. Beal's well is contaminated, the MDEP has spent $52,000 to date on cleanup, and Mrs. Beal is still looking at a $700 bill from the oil dealer for service calls. At the urging of her lawyer, the oil company agreed to reimburse MDEP for cleanup.

But being 76-years old and of stem Yankee blood, Mrs. Bed h e w something

From LUSTLine Bulletin 20, Tanks Down East, p. 10.

Class discussion:

1. 2. 3.

Why do you think it is so costly to clean up contaminated water and soil? What can be done to prevent spills or leaks? Why is it important to have a daily inspection program? (Notice that these leaks were the result of loose couplings and a leaking fuel supply line. They were not tank leaks.)

UNIT3 PAGE67

Unit 4 = Module 1 - Carbon Monoxide and Exhaust

Learning Objectives

1.

2.

3.

4.

Identify the hazards of exhaust gas exposure.

Learn the symptoms associated with exposure.

Identify the regulations relating to emission controls.

Identify the best methods to avoid exhaust gas exposure.

Unit 4 - Module I - Carbon Monoxide and Exhaust

Pre/Post Test: Teacher Version

1.

2.

3.

4.

5.

Exhaust gases enter the body: A) B) C) Breathing exhaust

When you're eating your lunch Through the pores on your skin

D) A - C

Exhaust gas exposure interferes with the body's use of: A) Carbon monoxide B) Cadmndioxide C) Hydrocarbons D) oxygen

Carbon Monoxide and Carbon Dioxide are: A) B) Redincolor C) Greenincolor D) Odorless and colorless

Gases that smell like rotten eggs

Symptoms of exhaust gas exposure include all of the following except: A) Alertness B) Irritability C) Weakness D) Headache

The following are good exhaust gas exposure prevention techniques. A) B) C) D) All of the above

Inspect exhaust system for leaks before testing. Attach a leakproof hose and check it during testing. Shut vehicle down and exit for fresh air if head hurts.

UNIT^ PAGE^

Unit 4 - Module 1 - Carbon Monoxide and Exhaust

Pre/Post Test

1. Exhaust gases enter the body: A) B) C) Breathingexhaust


D) A - C

2. Exhaust gas exposure interferes with the body's use of: A) Carbon monoxide B) Carbondioxide C) Hydrocarbons D) oxygen

3. Carbon Monoxide and Carbon Dioxide are: A) B) Redincolor C) Green in color D) Odorless and colorless



4. 1

5 . The following are good exhaust gas exposure prevention techniques. A) B) C) D) All of the above

Inspect exhaust system for leaks before testing. Attach a leakproof hose and check it during testing. Shut vehicle down and exit for fi-esh air if head hurts.

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Exhaust gas contains asphyxiants, gases that can cause suffocation by interfering with the body's use of oxygen. Asphyxiants in exhaust deprive the body of oxygen in two ways. Carbon Dioxide at high levels will "thin out" the available oxygen reducing the amount getting into the lungs. Carbon Monoxide will take the place of oxygen in the blood even if there is enough oxygen available. Both of these gasses are colorless and odorless and can concentrate to dangerous levels with little waming.

Symptoms of overexposure include headache, irritability, weakness, impairment of judgment, and confusion. These symptoms often go unnoticed leading to more severe effects including fainting, unconsciousness, and death due to respiratory failure. Therefore, good ventilation is important in areas where asphyxiants, especially carbon monoxide, are a problem.

Regulatory Issues

Contrary to popular belief, removing emission control devices does not increase fuel economy. In fact, removing them may shorten the life and overall performance of your customer's vehicle. It is illegal under federal law to remove, disconnect, damage or in any way render inoperative any emission control device or element of design installed on a motor vehicle or motor vehicle engine. Dealerships, repair shops, fleet maintenance and even individuals are covered by this tampering law. Each violation could cost up to $2,500 in fines.


Catalytic converters are installed on the exhaust system to oxidize hydrocarbons and carbon monoxide and to reduce nitrogen oxides. In large part because of catalytic converters (but also because of better inspection and maintenance and phase-out of leaded gas), today's cars emit about 90% less pollution than cars did in the 1960's.


1.

2.

3.

4.

Inspect the exhaust system of a vehicle which is to be run inside the shop. Be sure there are no leaks that would allow exhaust gas to Attach a leakproof hose to the exhaust pipe of the vehicle and run the hose into a exhaust gas collection hole or to the outside air. Periodically inspect the exhaust hose to be sure it has not fallen off the exhaust pipe during testing. If at any time during vehicle testing, you start to get a headache, suspect carbon monoxide exposure, shut the vehicle down and get some fiesh air.

escape.

UNIT4 PAGE4

Unit 4 - Module I - Carbon Monoxide and Exhaust ~~

Class Exercise: Classroom discussion

As a class, ask the students the following questions:

A. Why are exhaust fumes harmful to humans?

B. How much carbon monoxide does it take to kill?

C. Does carbon monoxide have an odor?

D. Why should every school, shop and garage have a carbon monoxide detector?

E. what are the effects of prolonged cafbon monoxide exposure?

F. Can carbon monoxide poisoning occur while driving in an automobile?

Class Exercise: Find and test the Carbon Monoxide Sensor

In your school shop, find the carbon monoxide sensor and read it.

Is it working? Where is it located? Is it in the breathing zone? If not, where is it? Can you read it? Or, does it register in another location? Is there an alarm attached to it?

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Unit 4 - Module 2 - Personal Protection & Health Issues

Learning Objectives

1. Learn which personal protection and respiratory protection equipment is recommended for auto repair and auto body jobs including safety shoes, gloves, eye and face protection, ear protection and respirators.

2. Identify the common chemical exposures in auto repair and auto body shops including epoxy plastic, solvents and spray paints.

3. Describe the health risks associated with the above exposures.

4. Understand the health risks associated with isocyanates in paint topcoats and ways to reduce these risks.

UNIT4 PAGE6

Unit 4 - Module 2 - Personal Protection & Health Issues ~~


1.

2.

3.

4.

5 .

Personal Protective equipment includes all of the following except: A) Goggles B) Shorts C) Earplugs D) Respirators

The best protection from exposure to paints during spray application is a downdraft spray booth. A) True B) False

List in order of best to worst the following methods used to control exposures to isocyanates (which are often found in topcoats):

1 3 2

A) Using products without isocyanates. -- B) Respirators and protective clothing -- C) Ventilation in an enclosed paint booth. --

Any respirator will work to protect you from solvents or isocyanate exposure. A) True B) False

During or after painting, if you become short of breath, what should you do?

Immediately stop painting and see a doctor about your symptoms.

UNIT4 P A G E 7

Unit 4 - Module 2 - Personal ,Protection & Health Issues

Pre/Post Test

1. Personal Protective equipment includes all of the following except: A) Goggles B) Shorts C) Earplugs D) Respirators

2. The best protection fkom exposure to paints during spray application is a down-

A) True B) False && spray booth.

3. List in order of best to worst the following methods used to control exposures to isocyanates (which are often found in topcoats): A) Using products without isocyanates. B) Respirators and protective clothing C) Ventilation in an enclosed paint booth.

4. Any respirator will work to protect you fkom solvents or isocyanate exposure. A) True B) False

5 . During or after painting, if you become short of breath, what should you do?

UNIT4 P A G E 8


Personal Protection

There are a number of key pieces of equipment to protect you when you are working with equipment or chemicals. They are described below.

;afety Shoes The many tools and car parts found in the body shop are a hazard to your feet. safety shoes will help keep you from getting serious foot injuries in case of accidents.

;loves There are special gloves for almost every job in the shop. Welding gloves, rubber )loves for handling caustics, acids, and solvents, gloves for handling glass, plastic, and jagged netal, and others may all be used in your shop. Your employer will usually provide these. Wear the right gloves for the job you're doing, then put them away for the next time you need hem.

:ye and Face Protection In much the same way as gloves, you need different eye and face xotection for different jobs. Special tinted goggles for gas welding, brazing, and shrinking and ielmets with special lenses for all welding are just two examples. You must use eye and face xotection in any work area where chips, sparks, flying objects, glare, radiation, or splashes of ]armful liquids are a hazard. For example, eye and face protection are very important to you luring grinding operations and when working on air conditioners. The coolant used in air :onditioners can freeze an eyeball on contact-a face shield is a must on this job.

f you normally wear glasses on the job, get a pair of prescription industrial safely glasses. :heck with your supervisor-your shop may pay all or part of the cost of these glasses.

Ear Protection Long exposure to high noise levels can cause permanent damage to your nearing. If you normally work all shift where the noise is so loud that you can't talk to someone about two feet away without shouting, the noise level may be high enough to cause hearing loss. Your employer must try to reduce the noise level with engineering controls. If these controls don't work, you will have to wear ear muffs or ear plugs when you're doing certain noisy jobs. (Plain cotton does nothing to protect your hearing from excessive noise.)

There are a few things to remember about wearing hearing protection. Ear plugs and muffs must fit to help you. If you wear glasses, the side frames may interfere with the way your ear muffs fit. If so, you may have to get glasses with special side frames. Ear plugs must be properly fitted to your ears. One size does not fit everyone. Your ear plugs should be kept clean by washing them frequently with warm, soapy water.

You may think ear protection will keep you from hearing noises you need to hear-warning bells, horns, other workers' voices, etc. But actually you can hear better with hearing protection. Most of the noise around you is masked out. After a few days, you will get used to wearing your ear muffs or ear plugs and will probably find the noise in your area uncomfortable without them.

UNIT4 PAGE9


Respiratory Protection

Near a dust mask when sanding or grinding. Change the filter when you have difficulty lreathing. Some grinding and sanding tools have a built-in dust vacuum system, or local rentilation may he provided at your workbench. Where such systems are working woperly. the dust mask won’t be necessary. Spray painting must only be done in spray moths, spray rooms, or spray areas with good ventilation. You shouldn’t have to wear a ,-pirator while spray painting. You may wear one as back-up protection.

f you do use a respirator, you nust be instructed in how to Jse it and take care of it. ’roper fit is most important. 3eards, sidebums, and glasses nay interfere with a good fit. :heck for leaks each time you wt your respirator on. Your sspirator should be deaned after use in soap and water and then stored in a clean place. Replace defective or worn parts. You must replace the Rlters or cartridges in your respirator if you can smell the vapors while wearing the mask, when you have used the filter or Self-contained Airline cartridge for its specified lifetime, or if you have difficulty breathing while wearing the mask.

Remember one type of respirator will not protect you from all of the harmful materials you are exposed to. For example, a dust respirator will not protect you from solvent vapors. Check with your supervisor to see that the type of respirator you use is the right kind for the job you do. There are instructions with the respirators and cartridges which you should read.

Excerpt from: Safety and Health in Auto Body Repair Shops, Good Practices for Employees, August 1977. NOSH Publication 77-229


Exposures to Common Auto Repair and Body Shop Chemicals

Epoxy plastics

You may use several kinds of epoxy compounds, primarily auto body filler, for various repairs. Wear your gloves when you work with epoxies. Nearly all these epoxies are formed of resins and special hardeners. If you get these hardeners or resins on your skin, you could break out in rashes and sores. If any hardener or resin spills on your skin, wash it off with soap and water immediately.

Solvents

You are exposed to solvents during parts cleaning, degreasing, and spray painting (see below). All organic solvents have some effect on the central nervous system and skin. Inhaling high concentrations of solvent vapors may cause a lack of coordination and drowsiness, or even damage to the blood, lungs, liver, kidneys, and digestive system. Skin contact may cause dermatitis, ranging fiom a simple irritation to actual skin damage. Solvents can dissolve the natural skin barriers of fats and -oils, leaving the skin unprotected.

All solvents should be used in well-ventilated areas. Wear appropriate protective gloves while working with solvents.

Spray painting

Spray painting can be a fire and health hazard. For instance, the paints and lacquers you spray on the cars are very flammable and explosive. The spray paint is also mixed with a solvent which, if inhaled, can harm you.

Keep heat sources away fiom the area where you paint or store painting materials. Welding, use of power tools, and smoking are not permitted in these areas. Storage areas and painting areas should have good ventilation.

No more than one day's supply of paint may be stored near the spray area at any time. The paint must be stored in an approved storage cabinet equipped with locks.

You should not have to wear a respirator while spray painting if you are using a spray booth or room. The ventilation system must remove the contaminated air efficiently enough that you don't need the respirator. Arrange your work so that the exhaust pulls the fumes away fiom you, not past you. Some shops use respirators as back-up protection. Your employer may ask you to do this.

UNIT^ PAGE??


There must be either a gauge or pressure sensitive device which will trigger an alarm when the air supply from the ventilator drops too low. Exhaust ventilators have filters to remove the contaminants from the air. When the filters are dirty, air flow is restricted to and from the work area. Filters should be inspected and cleaned or replaced regularly. Excess paint often clings to the walls and floors in the spray booth or spray room. This is a serious fire hazard. Keep those surfaces as clean as possible.

If you work in a spray painting area, you may also operate the drying equipment. Most of th is equipment is electrical and it must be explosion proof It doesn‘t pay to take chances when using this kind of equipment. Never paint with the heat lamps on. Be sure to let the ventilation system run for several minutes before you turn the heat lamps on. This will clean out all of the paint or thinner vapors.

Health Effects of Isocyanates

In addition to the hazards associated with solvents described above. The topcoats may contain isocyanates. There are many forms of isocynates but the most common is TDI or toluene diisocyanate. To recognize whether a topcoat contains an isocyanate, look for the word “isocyanate” as part of a longer chemical name. If you see “isocyanate” in any part of a longer chemical name, the paint contains isocyanate.

Isocyanates have been shown in numerous scientific studies to cause asthma and in some cases, death. People who smoke are more likely to be affected by the isocyanates than those who don’t. But both non-smokers and smokers are susceptible to health effects as a result of breathing isocyanates.

Irritation - Isocyanates are powerfbl irritants to the mucous membranes of the eyes, gastrointestinal and respiratory tracts.

Sensitization and Asthma - Isocyanates can also sensitize workers, making them subject to severe asthma attacks if they are exposed again--even at concentrations below the govemment recommended levels. Death from severe asthma in sensitized subjects has been reported.

Hypersensitivity Pneumonitis - Sporadic cases of hypersensitivity pneumonitis (HP) have also been reported in workers exposed to isocyanates. Individuals acute HP typically develop symptoms 4 to 6 hours after exposure. Symptoms are often flu-like, with fever, muscle aches, and headaches. Symptoms may also include a dry cough, chest tightness, and difficult breathing. Individuals with chronic HP often experience progressively more difficult breathing, fatigue, and weight loss.

UNIT4 PAGE12

Unit 4 = Module 2 - Personal Protection & Health Issues

t

Cancer - Data fiom recent studies of animals show that cancer is associated with exposure to commercial-grade toluene diisocyante (TDI) (an 80:20 mixture of 2,4- and 2,6-TDI). The National Institute of Occupational Safety and Health therefore recommends that occupational exposure to TDI and its isomers be minimized.

Pollution Prevention and Recommendations to Protect Your Health

Product Substitution - When feasible, employers should substitute a less hazardous material for isocyanates.

Closed Systems and Ventilation - Engineering controls such as closed systems and ventilation should be the principal method for " E n g isocyanate exposure in the workplace. Exhaust ventilation systems should be designed to capture and contain vapors and particulates. Ventilation equipment should be checked for adequate pdormance at least every 3 months.

Worker Isolation - Areas containing isocyanates should be restricted to essential workers. If feasible, these workers should avoid direct contact with these chemicals by using automated equipment operated fiom a control booth or room with separate ventilation.

Protective Clothing and Equipment - When there is potential for isocyanate exposure, workers should be provided with and required to use appropriate personal protective clothing and equipment such as coveralls, footwear, chemical-resistant gloves and goggles, full faceshields, and suitable respiratory equipment.

,

Respiratory Protection - The use of respirators is the least preferred method of controlling worker exposures. Respirators should not be used as the primary control for routine operations, but NIOSH recognizes that they may be used during situations such as implementation of engineering controls, some short-duration maintenance procedures, and emergencies. Only the most protective respirators should be used for situations involving exposures to isocyanates that have poor warning properties, are potent sensitizers, or may be carcinogenic. These respirators include:

any self-contained breathing apparatus with a full facepiece operated in a

any supplied-air respirator with a full facepiece operated in a pressure-demand or other positive-pressure mode, and

pressure-demand or other positive-pressure mode in combination with an auxiliary self-contained breathing apparatus operated in a pressure-demand or other positive-pressure mode.

UNIT4 PAGE13


(WORKER FACTSHEET)

Preventing Asthma and Death from Diisocyanate Exposure

WARNING!

Workers exposed to diisocyanates may develop serious or fatal respiratory disease.

Employers should take the following steps to protect workers from diisocyanate exposure:

e Make workers aware of the serious health effects that may result fiom diisocyanate exposures.

e Make workers aware of any materials that may contain or be contaminated with diisocyanates.

0 When feasible, substitute a less hazardous material for diisocyanates.

e If substitution is not possible, use engineering controls such as closed systems and ventilation to minimize exposures.

Provide appropriate respiratory protection to workers exposed to diisocyanates.

Workers should take the following steps to protect themselves from diisocyanate exposure:

Be aware that the highest diisocyanate concentrations may occur inside containment structures.

Use appropriate respiratory protection when working with diisocyanates.

0 Wash hands and face before eating, drinking, or smoking outside the work area.

e Shower and change into clean clothes before leaving the worksite.

Participate in medical monitoring and examination programs, air monitoring programs, or training programs, offered by your employer.

Preventing Asthma and Deaths from Diisocyanate Exposure--DHHS (NIOSH) Publication N0.96-111

UNIT4 PAGE 14

I


Case Study - Death from Prolonged Exposure to Diisocyanates

A 37 year-old male, seK-employed car painter was admitted to the hospital with asthma symptoms. These symptoms had h t developed 5 years earlier and were thought to be related to his occupation. He had been working in the same environment for 20 years.

The car painter was diagnosed with occupational asthma induced by isocyanates and advised to change his job or avoid the use of polyurethane paints. He nevertheless continued to work as a car painter and used medications such as bonchodilators, comolyn and steriods to treat his asthma.

Six years later, he was wearing a mask and spraying a car with 2-component polyurethane paint when he developed severe, prolonged asthma. Despite medication, he remained symptomatic, especially at night. He returned to work, sprayed the polyurethane paint again, and developed severe asthma requiring emergency treatment. He died in the ambulance en route to the hospital. The manufacturer reported that the paint contained small amounts of toluene diisocyanate (TDI) and a chemical analysis confirmed the presence of TDI mixed with solvents.

Excerpt from: Preventing Asthma and Death from Diisocyanate Exposure, NIOSH Alert: 1996. DHHS (NIOSH) Publication number: 96-1 1 1.

UNIT4 PAGE15

Unit 4 - Module 3 - Health and Safety Checklist

The Occupational Safety and Health Administration (OSHA) was established to protect the health and safety of workers in the United States. The safety and health standards and regulations were implemented to ensure that places of employment would be fiee of recognized hazards that may cause death or physical injury to workers. Included below is a checklist of OSHA concerns:

Health and Safety Checklist

J J J J J J J J

J J

J J J

J

J

J

J J J

J

J

J

J

Are all walking Surfaces kept fiee fiom grease, oil, parts, and tools? Are stairs and rack Surfaces maintained fiee of tripping and slipping hazards? Is housekeeping adequate to prevent the accumulation of materials? Are all exits clear of obstruction? Do you have all exits adequately mafked and lighted and other doors identified? Do you have all electrical equipment double insulated or grounded? Do you inspect extension cords and replace those that are worn or broken? Have employees been told not to use gasoline for cleaning purposes, including hands? Do you have emergency phone numbers posted? Is at least one employee per shift trained in first aid if medical help is not close at hand? Is eye protection used during all repair operations? Are there handrails on all stairs with four or more risers? Is the "No Smoking" rule enforced and "No Smoking" signs posted near gas pumps and areas where work. is done on batteries? Do you have the battery charging area well ventilated and away from flammable liquids? Are compressed gas cylinders separated by a non-combustible barrier and securely held in a cart or against a wall or work bench to prevent them fiom falling? Are all solvent-soaked, greasy, oily rags kept in an enclosed storage room in a metal container with a cover? Are flammable liquids properly stored? Do you have the proper type of fire extinguisher for the material you are using? Are extinguishers mounted so the distance from the top of the extinguisher to the floor is no more than 5 feet if the extinguisher weighs less than 40 lbs., or no more than 3 ?4 feet if it weighs more than 40 lbs? Do you have a monthly program to inspect fire extinguishers for proper location and in operating order? If your employees are expected to use fire extinguishers do they know where the fire extinguishers are located and how to use them? If you have 10 or more employees, do you keep required injury and illness records? Is a vent pipe located so vapors do not discharge inside buildings or become trapped under eaves, etc.?

UNIT4 PAGE16

i

I


J

J

J J J J J J

J

J J

J J J

J J J

J

J

J

Are spray booths and/or proper respirators used when using isocyanate and solvent based paints? If respirators are used is a respirator program, including training, cleaning, fit-testing, medical surveillance, air monitoring and program review in place? Is localized exhaust ventilation used when welding? Is the welding area separated form other work areas by welding curtains? Are all rotating pulleys, belts, wheels, etc. properly guarded? Is the safety let or hoist safety pin always positioned when using lifts? Are your lifts inspected and maintained on a monthly basis? When using the lift, is each vehicle checked for proper positioning just after wheels have left the floor? Are support stands always used when the vehicle has been raised with a hydraulic jack? Do you have line pressure reducing devices where required? Is a heavy cloth used over the radiator cap to protect hands and face fiom steam and hot coolant? Is a battery carrier strap used when removing batteries? Is automobile exhaust piped outside the building? Are all walking surfaces such as aisles and service bays fiee fiom clutter or obstruction? Do you have railings and toeboards around all floor openings and balconies? Are all restrooms maintained in a clean, orderly, and sanitary condition? Do you know that most injuries and illnesses can be prevented by eliminating the hazards? Have all workers been trained on the safe use of chemicals, signs and symptoms of overexposure and what to do in the case of a spill? If you have 5 or more employees, do you have a safety and health committee which meets at least quarterly? If you have 10 or more employees do you have a written health and safety program? Has the annual summary fomi been submitted to the Maine Department of Labor?

If you answered NO to any of these questions look at your operation to establish these practices.

From NJ3 Department of Environmental Service and the NH Small Business Technical Assistance Program, ‘‘Automotive Repair and Refinishing Environmental Compliance Manual”, 1997.


Learning Objectives

1.

2.

3.

4.



Identify the regulations relating to emission controls.

Identify the best methods to avoid exhaust gas exposure.



1.

2.

3.

4.

5.



D) A - C

Exhaust gas exposure interferes with the body's use of: A) Carbon monoxide B) Carbondioxide C) Hydrocarbons D) oxygen

Carbon Monoxide and Carbon Dioxide are: A) B) Redincolor C) Green in color D) Odorless and colorless



The following are good exhaust gas exposure prevention techniques. A) B) C) D) All of the above


UNIT4 PAGE2

I Unit 4 - Module I - Carbon Monoxide and Exhaust

PreLPost Test

1. Exhaust gases enter the body: A) B) C) Breathing exhaust


D) A - C

2. Exhaust gas exposure interfiies with the body's use of: A) Carbon monoxide B) Carbondioxide C) Hydrocarbons D) oxygen



i

4. Symptoms of exhaust gas exposure include all of the following except: A) Alertness B) Irritability C) Weakness D) Headache


Inspect exhaust system for leaks before testing. Attach a leakproof hose and check it during testing. Shut vehicle down and exit for fiesh air if head hurts.

I

UNIT^ PAGE^



Exhaust gas contains asphyxiants, gases that can cause suffocation by interfering with the body's use of oxygen. Asphyxiants in exhaust deprive the body of oxygen in two ways. Carbon Dioxide at high levels will "thin out" the available oxygen reducing the amount getting into the lungs. Carbon Monoxide will take the place of oxygen in the blood even if there is enough oxygen available. Both of these gasses are colorless and odorless and can concentrate to dangerous levels with little warning.


Regulatory Issues





1.

2.

3.

4.

Inspect the exhaust system of a vehicle which is to be run inside the shop. Be sure there are no leaks that would allow exhaust gas to Attach a leakproof hose to the exhaust pipe of the vehicle and run the hose into a exhaust gas collection hole or to the outside air. Periodically inspect the exhaust hose to be sure it has not fallen off the exhaust pipe during testing. If at any time during vehicle testing, you start to get a headache, suspect carbon monoxide exposure, shut the vehicle down and get some fresh air.

escape.

UNIT4 PAGE4




A. W h y are exhaust fiunes h d l to humans?

B. How much carbon monoxide does it take to kill?

C. Does carbon monoxide have an odor?

D. Why should every school, shop and garage have a carbon monoxide detector?

E. What are the effects of prolonged carbon monoxide exposure?

F. Can carbon monoxide poisoning occur while driving in an automobile?


In your school shop, find the carbon monoxide sensor and read it. !



Learning Objectives





UNIT^ PAGE^



1.

2.

3.

4.

5 .


The best protection fiom exposure to paints during spray application is a downdraft spray booth. A) True B) False


1 3 2


Any respirator will work to protect you fiom solvents or isocyanate exposure. A) True B) False



UNIT^ PAGE^


Pre/Post Test

1.

2.

3.

4.

5 .



List in order of best to worst the following methods used to control exposures to isocyanates (which are often found in topcoats): A) Using products without isocyanates. B) Respirators and protective clothing C) Ventilation in an enclosed paint booth.



UNIT4 PAGE8


Personal Protection


Safety Shoes The many tools and car parts found in the body shop are a hazard to your feet. Safety shoes will help keep you from getting serious foot injuries in case of accidents.

3loves There are special gloves for almost every job in the shop. Welding gloves, rubber gloves for handling caustics, acids, and solvents. gloves for handling glass, plastic, and jagged netal, and others may all be used in your shop. Your employer will usually provide these. iNear the right gloves for the job you're doing, then put them away for the next time you need :hem.

Eye and Face Protection In much the same way as gloves, you need different eye and face protection for different jobs. Special tinted goggles for gas welding, brazing, and shrinking and helmets with special lenses for all welding are just two examples. You must use eye and face protection in any work area where chips, sparks, flying objects, glare, radiation, or splashes of harmful liquids are a hazard. For example, eye and face protection are very important to you during grinding operations and when working on air conditioners. The coolant used in air conditioners can freeze an eyeball on contact-a face shield is a must on this job.

If you normally wear glasses on the job, get a pair of prescription industrial safety glasses. Check with your supervisor-your shop may pay all or part of the cost of these glasses.

Ear Protection Long exposure to high noise levels can cause permanent damage to your hearing. If you normally work all shift where the noise is so loud that you can't talk to someone about two feet away without shouting, the noise level may be high enough to cause hearing loss. Your employer must try to reduce the noise level with engineering controls. If these controls don't work, you will have to wear ear muffs or ear plugs when you're doing certain noisy jobs. (Plain cotton does nothing to protect your hearing from excessive noise.)



UNIT^ PAGES

Unit 4 - Module 2 - Personal Protection & Health Issues ~~~ ~


Near a dust mask when sanding or grinding. Change the filter when you have difficulty ireathing. Some grinding and sanding tools have a built-in dust vacuum system, or local lentilation may he provided at your workbench. Where such systems are working xoperly, the dust mask won't be necessary. Spray painting must only be done in spray looths, spray rooms, or spray areas with good ventilation. You shouldn't have to wear a .espirator while spray painting. You may wear one as back-up protection.

f you do use a respirator, you nust be instructed in how to Jse it and take care of it. Jroper fit is most important. Beards, sidebums. and glasses nay interfere with a good fit. Check for leaks each time you put your respirator on. Your respirator should be cleaned after use in soap and water and then stored in a clean place. Replace defective or wom parts. You must replace the

" I

filters or cartridges in your respirator if you can smell the vapors while wearing the mask, when you have used the filter or Self-contained Airline cartridge for its specified lifetime, or if you have difficulty breathing while wearing the mask.

&%r Pi , ur , 14: 4 S %

Remember one type of respirator will not protect you from all of the harmful materia,.. you are exposed to. For example, a dust respirator will not protect you from solvent vapors. Check with your supervisor to see that the type of respirator you use is the right kind for the job you do. There are instructions with the respirators and cartridges which you should read.

Excerpt fiom: Safety and Health in Auto Body Repair Shops, Good Practices for Employees, August 1977. NOSH Publication 77-229

(j



Epoxy plastics

You may use several kinds of epoxy compounds, primarily auto body f3ler, for various repairs. Wear your gloves when you work with epoxies. Nearly all these epoxies are formed of resins and special hardeners. If you get these hardeners or resins on your skin, you could break out in rashes and sores. If any hardener or resin spills on your skin, wash it off with soap and water immediately.

Solvents

You are exposed to solvents during parts cleaning, degreasing, and spray painting (see below). All organic solvents have some effect on the central nervous system and skin. Inhaling high concentrations of solvent vapors may cause a lack of coordination and drowsiness, or even damage to the blood, lungs, liver, kidneys, and digestive system. Skin contact may cause dermatitis, ranging fiom a simple irritation to actual skin damage. Solvents can dissolve the natural skin barriers of fats and -oils, leaving the skin unprotected.


Spray painting


Keep heat sources away from the area where you paint or store painting materials. Welding, use of power tools, and smoking are not permitted in these areas. Storage areas and painting areas should have good ventilation.


You should not have to wear a respirator while spray painting if you are using a spray booth or room. The ventilation system must remove the contaminated air efficiently enough that you don't need the respirator. Arrange your work so that the exhaust pulls the fumes away from you, not past you. Some shops use respirators as back-up protection. Your employer may ask you to do this.


There must be either a gauge or pressure sensitive device which will trigger an alarm when the air supply from the ventilator drops too low. Exhaust ventilators have filters to remove the contaminants from the air. When the filters are dirty, air flow is restricted to and from the work area. Filters should be inspected and cleaned or replaced regularly. Excess paint often clings to the walls and floors in the spray booth or spray room. This is a serious fire hazard. Keep those surfaces as clean as possible.

If you work in a spray painting area, you may also operate the drying equipment. Most of this equipment is electrical and it must be explosion proof It doesnY pay to take chances when using this kind of equipment. Never paint with the heat lamps on. Be sure to let the ventilation system run for several minutes before you turn the heat lamps on. This will clean out all of the paint or thinner vapors.




Irritation - Isocyanates are powerful irritants to the mucous membranes of the eyes, gastrointestinal and respiratory tracts.

Sensitization and Asthma - Isocyanates can also sensitize workers, making them subject to severe asthma attacks if they are exposed again--even at concentrations below the government recommended levels. Death from severe asthma in sensitized subjects has been reported.

Hypersensitivity Pneumonitis - Sporadic cases of hypersensitivity pneumonitis (HP) have also been reported in workers exposed to isocyanates. Individuals acute HP typically develop symptoms 4 to 6 hours after exposure. Symptoms are often flu-like, with fever, muscle aches, and headaches. Symptoms may also include a dry cough, chest tightness, and difficult breathing. Individuals with chronic HP often experience progressively more difficult breathing, fatigue, and weight loss.

UNIT4 PAGE12


Cancer - Data from recent studies of animals show that cancer is associated with exposure to commercial-grade toluene diisocyante (TDI) (an 80:20 mixture of 2,4- and 2,6-TDI). The National Institute of Occupational Safety and Health therefore recommends that occupational exposure to TDI and its isomers be minimized.



Closed Systems and Ventilation - Engineering controls such as closed systems and ventilation should be the principal method for ”in’ng. isocyanate exposure in the workplace. Exhaust ventilation systems should be designed to capture and contain vapors and particulates. Ventilation equipment should be checked for adequate performance at least every 3 months.

Worker Isolation - Areas containing isocyanates should be restricted to essential workers. If feasible, these workers should avoid direct contact with these chemicals by using automated equipment operated fi-om a control booth or room with separate ventilation.

Protective Clothing and Equipment - When there is potential for isocyanate exposure, workers should be provided with and required to use appropriate personal protective clothing and equipment such as coveralls, footwear, chemical-resistant gloves and goggles, h l l faceshields, and suitable respiratory equipment.

Respiratory Protection - The use of respirators is the least preferred method of controlling worker exposures. Respirators should not be used as the primary control for routine operations, but NOSH recognizes that they may be used during situations such as implementation of engineering controls, some short-duration maintenance procedures, and emergencies. Only the most protective respirators should be used for situations involving exposures to isocyanates that have poor warning properties, are potent sensitizers, or may be carcinogenic. These respirators include:

’

8 any self-contained breathing apparatus with a full facepiece operated in a



8

UNIT4 PAGE 13


(WORKER FACTSHEET)


WARNING!



0 Make workers aware of the serious health effects that may result fiom diisocyanate exposures.

0 Make workers aware of any materials that may contain or be contaminated with diisocyanates.

When feasible, substitute a less hazardous material for diisocyanates.

. If substitution is not possible, use engineering controls such as closed systems and ventilation to minimize exposures.

0 Provide appropriate respiratory protection to workers exposed to diisocyanates.


. Be aware that the highest diisocyanate concentrations may occur inside containment structures.

0 Use appropriate respiratory protection when working with diisocyanates.


0 Shower and change into clean clothes before leaving the worksite.

0 Participate in medical monitoring and examination programs, air monitoring programs, or training programs, offered by your employer.

Preventing Asthma and Deaths fiom Diisocyanate Exposure-DHHS (NIOSH) Publication N0.96-111

UNIT4 PAGE14

Unit 4 - Module 2 - Personal Protection 81 Health Issues


A 37 year-old male, self-employed car painter was admitted to the hospital with asthma symptoms. These symptoms had first developed 5 years earlier and were thought to be related to his occupation. He had been working in the same environment for 20 years.



Excerpt from: Preventing Asthma and Death from Diisocyanate Exposure, NIOSH Alert: 1996. DHHS (NIOSH) Publication number: 96-1 1 1.

i

UNIT4 PAGE15


The Occupational Safety and Health Administration (OSHA) was established to protect the health and safety of workers in the United States. The safety and health standards and regulations were implemented to ensure that places of employment would be free of recognized hazards that may cause death or physical injury to workers. Included below is a checklist of OSHA concerns:


J J J J J J J J

J J

J J J

J

J

J

J J J

J

J

J

J

Are all walking d a c e s kept fiee fiom grease, oil, parts, and tools? Are stairs and rack surfaces maintained free of tripping and slipping hazards? Is housekeeping adequate to prevent the accumulation of materials? Are all exits clear of obstruction? Do you have all exits adequately marked and lighted and other doors identified? Do you have all electrical equipment double insulated or grounded? Do you inspect extension cords and replace those that are worn or broken? Have employees been told not to use gasoline for cleaning purposes, including hands? Do you have emergency phone numbers posted? Is at least one employee per shift trained in first aid if medical help is not close at hand? Is eye protection used during all repair operations? Are there handrails on all stairs with four or more risers? Is the "No Smoking" rule enforced and "No Smoking" signs posted near gas pumps and areas where work. is done on batteries? Do you have the battery charging area well ventilated and away from flammable liquids? Are compressed gas cylinders separated by a non-combustible barrier and securely held in a cart or against a wall or work bench to prevent them fiom falling? Are all solvent-soaked, greasy, oily rags kept in an enclosed storage room in a metal container with a cover? Are flammable liquids properly stored? Do you have the proper type of fire extinguisher for the material you are using? Are extinguishers mounted so the distance from the top of the extinguisher to the floor is no more than 5 feet if the extinguisher weighs less than 40 lbs., or no more than 3 ?4 feet if it weighs more than 40 lbs? Do you have a monthly program to inspect fire extinguishers for proper location and in operating order? If your employees are expected to use fire extinguishers do they know where the fire extinguishers are located and how to use them? If you have 10 or more employees, do you keep required injury and illness records? Is a vent pipe located so vapors do not discharge inside buildings or become trapped under eaves, etc.?

! Unit 4 - Module 3 - Health and Safety Checklist

J

J

J J J J J J

J

J J

J J J

J J J

J

J

J

Are spray booths andor proper respirators used when using isocyanate and solvent based paints? If respirators are used is a respirator program, including training, cleaning, fit-testing, medical surveillance, air monitoring and program review in place? Is localized exhaust ventilation used when welding? Is the welding area separated form other work areas by welding curtains? Are all rotating pulleys, belts, wheels, etc. properly guarded? Is the safety let or hoist safety pin always positioned when using lifts? Are your lifts inspected and maintained on a monthly basis? When using the lift, is each vehicle checked for proper positioning just after wheels have left the floor? Are support stands always used when the vehicle has been raised with a hydraulic jack? Do you have line pressure reducing devices where required? Is a heavy cloth used over the radiator cap to protect hands and face from steam and hot coolant? Is a battery carrier strap used when removing batteries? Is automobile exhaust piped outside the building? Are all walking surfaces such as aisles and service bays free from clutter or obstruction? Do you have railings and toeboards around all floor openings and balconies? Are all restrooms maintained in a clean, orderly, and sanitary condition? Do you know that most injuries and illnesses can be prevented by eliminating the hazards? Have all workers been trained on the safe use of chemicals, signs and symptoms of overexposure and what to do in the case of a spill? If you have 5 or more employees, do you have a safety and health committee which meets at least quarterly? If you have 10 or more employees do you have a written health and safety program? Has the annual summary fomi been submitted to the Maine Department of Labor?


From NH Department of Environmental Service and the NH Small Business Technical Assistance Program, “Automotive Repair and Refinishing Environmental Compliance Manual”, 1997.

UNIT4 PAGE17


Learning Objectives

1.

2.

3.

4.



Identifjr the regulations relating to emission controls.

Identifjr the best methods to avoid exhaust gas exposure.

UNIT4 PAGE1


PrePost Test: Teacher Version

1.

2.

3.

4.

5.



D) A - C

Exhaust gas exposure intderes with the body's use of: A) Carbon monoxide B) Carbon dioxide C) Hydrocarbons D) oxygen

Carbon Monoxide and Carbon Dioxide are: A) B) Redincolor C) Green in color D) Odorless and colorless



The following are good exhaust gas exposure prevention techniques. A) Inspect exhaust system for leaks before testing. B) Attach a leakproof hose and check it during testing. C) Shut vehicle down and exit for fresh air if head hurts. D) All of the above


PreLPost Test

1. Exhaust gases enter the body: A) B) C) Breathing exhaust


D) A - C

2. Exhaust gas exposure interferes with the body's use of: A) Carbon monoxide B) Carbon dioxide C) Hydrocarbons D) oxygen




4.



! UNIT 4' PAGE 3



Exhaust gas contains asphyxiants, gases that can cause suffocation by interfering With the body's use of oxygen. Asphyxiants in exhaust deprive the body of oxygen in two ways. Carbon Dioxide at high levels will "thin out" the available oxygen reducing the amount getting into the lungs. Carbon Monoxide will take the place of oxygen in the blood even if there is enough oxygen available. Both of these gasses are colorless and odorless and can concentrate to dangerous levels with little waming.


Regulatory Issues





1.

2.

3.

4.

Inspect the exhaust system of a vehicle which is to be run inside the shop. Be sure there are no leaks that would allow exhaust gas to Attach a leakproof hose to the exhaust pipe of the vehicle and run the hose into a exhaust gas collection hole or to the outside air. Periodically inspect the exhaust hose to be sure it has not fallen off the exhaust pipe during testing. If at any time during vehicle testing, you start to get a headache, suspect carbon monoxide exposure, shut the vehicle down and get some fresh air.

escape.

UNIT4 PAGE4




A.

B.

C.

D.

E.

F.

Why are exhaust h e s handid to humans?

How much carbon monoxide does it take to kill?

Does carbon monoxide have an odor?

Why should every school, shop and garage have a carbon monoxide detector?

What are the effects of prolonged carbon monoxide exposure?

Can carbon monoxide poisoning occur while driving in an automobile?


In your school shop, find the carbon monoxide sensor and read it.


UNIT^ PAGE^


Learning Objectives





UNIT^ PAGE^

Unit 4 - Module 2 - Personal Protection & Health Issues ~


1.

2.

3.

4.

5 .




1 3 2





UNIT^ PAGE^


PrelPost Test

1.

2.

3.

4.

5 .


The best protection from exposure to paints during spray application is a downdraft spray booth. A) True B) False

List in order of best to worst the following methods used to control exposures to isocyanates (which are often found in topcoats): A) Using products without isocyanates. B) Respirators and protective clothing C) Ventilation in an enclosed paint booth.



UNIT^ PAGE^


Personal Protection


i

safety Shoes The many tools and car parts found in the body shop are,a hazard to your feet. safety shoes will help keep you from getting serious foot injuries in case of accidents.

3loves There are special gloves for almost every job in the shop. Welding gloves, rubber gloves for handling caustics, acids, and solvents, gloves for handling glass, plastic, and jagged netal, and others may all be used in your shop. Your employer will usually provide these. Near the right gloves for the job you're doing, then put them away for the next time you need hem.

Eye and Face Protection In much the same way as gloves, you need different eye and face xotection for different jobs. Special tinted goggles for gas welding, brazing, and shrinking and ielmets with special lenses for all welding are just two examples. You must use eye and face xotedion in any work area where chips, sparks, flying objects, glare, radiation, or splashes of rlarmful liquids are a hazard. For example, eye and face protection are very important to you during grinding operations and when working on air conditioners. The coolant used in air conditioners can freeze an eyeball on contact-a face shield is a must on this job.

If you normally wear glasses on the job, get a pair of prescription industrial safety glasses. Check with your supervisor-your shop may pay all or part of the cost of these glasses.

Ear Protection Long exposure to high noise levels can cause permanent damage to your hearing. If you normally work all shift where the noise is so loud that you can't talk to someone about two feet away without shouting, the noise level may be high enough to cause hearing loss. Your employer must try to reduce the noise level with engineering controls. If these controls don't work, you will have to wear ear muffs or ear plugs when you're doing certain noisy jobs. (Plain cotton does nothing to protect your hearing from excessive noise.)



UNIT4 PAGE9



Vear a dust mask when sanding or grinding. Change the filter when you have difficulty weathing. Some grinding and sanding tools have a built-in dust vacuum system, or local fentilation may he provided at your workbench. Where such systems are working roperly, the dust mask won't be necessary. Spray painting must only be done in spray booths, spray rooms, or spray areas with good ventilation. You shouldn't have to wear a espirator while spray painting. You may wear one as back-up protection.

f you do use a respirator, you nust be instructed in how to ise it and take care of it. 'roper fit is most important. 3eards. sidebums, and glasses nay interfere with a good fit. :heck for leaks each time you w t your respirator on. Your respirator should be cleaned after use in soap and water and then stored in a clean place. Replace defective or wom parts. You must replace the filters or cartridges in your respirator if you can smell the vapors while wearing the mask, when you have used the filter or cartridge for its specified lifetime, or

e33 & ;

Self-Con tained Airline

if you have difficulty breathing while wearing the mask.

Remember one type of respirator will not protect you from all of the harmful materials you are exposed to. For example, a dust respirator will not protect you from solvent vapors. Check with your supervisor to see that the type of respirator you use is the right kind for the job you do. There are instructions with the respirators and cartridges which you should read.

Excerpt from: Safety and Health in Auto Body Repair Shops, Good Practices for Employees, August 1977. NOSH Publication 77-229


j

~ ~ ~


Epoxy plastics

You may use several kinds of epoxy compounds, primarily auto body filler, for various repairs. Wear your gloves when you work with epoxies. Nearly all these epoxies are formed of resins and special hardeners. If you get these hardeners or resins on your skin, you could break out in rashes and sores. If any hardener or resin spills on your skin, wash it off with soap and water immediately.

Solvents

You are exposed to solvents during parts cleaning, degreasing, and spray painting (see below). All organic solvents have some effect on the central nervous system and skin. Inhaling high concentrations of solvent vapors may cause a lack of coordination and drowsiness, or even damage to the blood, lungs, liver, kidneys, and digestive system. Skin contact may cause dermatitis, ranging from a simple irritation to actual skin damage. Solvents can dissolve the natural skin barriers of fats and -oils, leaving the skin unprotected.


Spray painting


Keep heat sources away from the area where you paint or store painting materials. Welding, use of power tools, and smoking are not permitted in these areas. Storage areas and painting areas should have good ventilation.


You should not have to wear a respirator while spray painting if you are using a spray booth or room. The ventilation system must remove the contaminated air efficiently enough that you don't need the respirator. Arrange your work so that the exhaust pulls the fumes away from you, not past you. Some shops use respirators as back-up protection. Your employer may ask you to do this.

UNIT^ PAGEII


There must be either a gauge or pressure sensitive device which will trigger an alarm when the air supply fi-om the ventilator drops too low. Exhaust ventilators have filters to remove the contaminants fi-om the air. When the filters are dirty, air flow is restricted to and from the work area. Filters should be inspected and cleaned or replaced regularly. Excess paint often clings to the walls and floors in the spray booth or spray room. This is a serious jire hazard. Keep those swrfaces as clean as possible.

If you work in a spray painting area, you may also operate the drying equipment. Most of t h i s equipment is electrical and it must be explosion proof It doesn’t pay to take chances when using this kind of equipment. Never paint with the heat lamps on. Be sure to let the ventilation system run for several minutes before you turn the heat lamps on. This will clean out all of the paint or thinner vapors.




Irritation - Isocyanates are powerful irritants to the mucous membranes of the eyes, gastrointestinal and respiratory tracts.

Sensitization and Asthma - Isocyanates can also sensitize workers, making them subject to severe asthma attacks if they are exposed again--even at concentrations below the government recommended levels. Death from severe asthma in sensitized subjects has been reported.

Hypersensitivity Pneumonitis - Sporadic cases of hypersensitivity pneumonitis (HF’) have also been reported in workers exposed to isocyanates. Individuals acute HP typically develop symptoms 4 to 6 hours after exposure. Symptoms are often flu-like, with fever, muscle aches, and headaches. Symptoms may also include a dry cough, chest tightness, and difficult breathing. Individuals with chronic HP often experience progressively more difficult breathing, fatigue, and weight loss.


Cancer - Data from recent studies of animals show that cancer is associated with exposure to commercial-grade toluene diisocyante (TDI) (an 80:20 mixture of 2,4- and 2,6-TDI). The National Institute of Occupational Safety and Health therefore recommends that occupational exposure to TDI and its isomers be minimized.



Closed Systems and Ventilation - Engineering controls such as closed systems and ventilation should be the principal method for " k i n g isocyanate exposure in the workplace. Exhaust ventilation systems should be designed to capture and contain vapors and particulates. Ventilation equipment should be checked for adequate performance at least every 3 months.

Worker Isolation - Areas containing isocyanates should be restricted to essential workers. If feasible, these workers should avoid direct contact with these chemicals by using automated equipment operated f7om a control booth or room with separate ventilation.

Protective Clothing and Equipment - When there is potential for isocyanate exposure, workers should be provided with and required to use appropriate personal protective clothing and equipment such as coveralls, footwear, chemical-resistant gloves and goggles, full faceshields, and suitable respiratory equipment.

Respiratory Protection - The use of respirators is the least preferred method of controlling worker exposures. Respirators should not be used as the primary control for routine operations, but NIOSH recognizes that they may be used during situations such as implementation of engineering controls, some short-duration maintenance procedures, and emergencies. Only the most protective respirators should be used for situations involving exposures to isocyanates that have poor warning properties, are potent sensitizers, or may be carcinogenic. These respirators include:

e any self-contained breathing apparatus with a full facepiece operated in a



e

UNIT4 PAGE13


(WORKER FACTSHEET)


WARNING!



0 Make workers aware of the serious health effects that may result fiom diisocyanate exposures.

0 Make workers aware of any materials that may contain or be contaminated with diisocyanates.

. When feasible, substitute a less hazardous material for diisocyanates.

If substitution is not possible, use engineering controls such as closed systems and ventilation to minimize exposures.

0 Provide appropriate respiratory protection to workers exposed to diisocyanates.


. Be aware that the highest diisocyanate concentrations may occur inside containment structures.

0 Use appropriate respiratory protection when working with diisocyanates.


0 Shower and change into clean clothes before leaving the worksite.

Participate in medical monitoring and examination programs, air monitoring programs, or training programs, offered by your employer.

Preventing Asthma and Deaths from Diisocyanate Exposure--DHHS (NIOSH) Publication N0.96-111



A 37 year-old male, self-employed car painter was admitted to the hospital with asthma symptoms. These symptoms had 6rst developed 5 years earlier and were thought to be related to his occupation. He had been working in the same environment for 20 years.



Excerpt from: Preventing Asthma and Death from Diisocyanate Exposure, NIOSH Alert: 1996. DHHS (NIOSH) Publication number: 96- 1 1 1.

UNIT4 PAGE15


The Occupational Safety and Health Administration (OSHA) was established to protect the health and safety of workers in the United States. The safety and health standards and regulations were implemented to ensure that places of employment would be free of recognized hazards that may cause death or physical injury to workers. Included below is a checklist of OSHA concerns:


J J J J J J J J

J J

J J J

J

J

J

J J J

J

J

J

J

Are all walking surfaces kept free fiom grease, oil, parts, and tools? Are stairs and rack surfaces maintained free of tripping and slipping hazards? Is housekeeping adequate to prevent the accumulation of materials? Are all exits clear of obstruction? Do you have all exits adequately marked and lighted and other doors identified? Do you have all electrical equipment double insulated or grounded? Do you inspect extension cords and replace those that are worn or broken? Have employees been told not to use gasoline for cleaning purposes, including hands? Do you have emergency phone numbers posted? Is at least one employee per shift trained in first aid if medical help is not close at hand? Is eye protection used during all repair operations? Are there handrails on all stairs with four or more risers? Is the "No Smoking" rule enforced and "NO Smoking" signs posted near gas pumps and areas where work. is done on batteries? Do you have the battery charging area well ventilated and away fiom flammable liquids? Are compressed gas cylinders separated by a non-combustible barrier and securely held in a cart or against a wall or work bench to prevent them from falling? Are all solvent-soaked, greasy, oily rags kept in an enclosed storage room in a metal container with a cover? Are flammable liquids properly stored? Do you have the proper type of fire extinguisher for the material you are using? Are extinguishers mounted so the distance fiom the top of the extinguisher to the floor is no more than 5 feet if the extinguisher weighs less than 40 lbs., or no more than 3 % feet if it weighs more than 40 lbs? Do you have a monthly program to inspect fire extinguishers for proper location and in operating order? If your employees are expected to use fire extinguishers do they know where the fire extinguishers are located and how to use them? If you have 10 or more employees, do you keep required injury and illness records? Is a vent pipe located so vapors do not discharge inside buildings or become trapped under eaves, etc.?

UNIT4 PAGE16

I


J

J

J J J J J J

J

J J

J J J

J J J

J

J

J

Are spray booths and/or proper respirators used when using isocyanate and solvent based paints? If respirators are used is a respirator program, including training, cleaning, fit-testing, medical surveillance, air monitoring and program review in place? Is localized exhaust ventilation used when welding? Is the welding area separated form other work areas by welding curtains? Are all rotating pulleys, belts, wheels, etc. properly guarded? Is the safety let or hoist safety pin always positioned when using lifts? Are your lifts inspected and maintained on a monthly basis? When using the lift, is each vehicle checked for proper positioning just &er wheels have left the floor? Are support stands always used when the vehicle has been raised with a hydraulic j ack? Do you have line pressure reducing devices where required? Is a heavy cloth used over the radiator cap to protect hands and face from steam and hot coolant? Is a battery carrier strap used when removing batteries? Is automobile exhaust piped outside the building? Are all walking surfaces such as aisles and service bays free from clutter or obstruction? Do you have railings and toeboards around all floor openings and balconies? Are all restrooms maintained in a clean, orderly, and sanitary condition? Do you know that most injuries and illnesses can be prevented by eliminating the hazards? Have all workers been trained on the safe use of chemicals, signs and symptoms of overexposure and what to do in the case of a spill? If you have 5 or more employees, do you have a safety and health committee which meets at least quarterly? If you have 10 or more employees do you have a written health and safety program? Has the annual summary form been submitted to the Maine Department of Labor?


From NH Department of Environmental Service and the NH Small Business Technical Assistance Program, “Automotive Repair and Refinishing Environmental Compliance Manual”, 1997.

UNIT4 PAGE17

, Unit 5 - Module I - Compliance Inspections

Learning Objectives

1. Identi@ who performs compliance inspections such as Maine DEP, OSHA, local fire departments and code enforcement officers and in some cases, the shop’s insurance agency.

2. List the items the inspector is looking for including description of operations, physical inspection of facility, review of parts cleaning equipment, description of sources of hazardous waste and methods of handling, emergency preparedness procedures, inspection of outdoor area around the facility.

3. Understand the process for correcting any violations detected during the inspection.

Unit 5 - Module 1 - Compliance Inspections


1. The DEP Inspector will usually call the shop manager to make an appointment to do an inspection.

A) True B) False

2. An auto repair shop may be -&pected by:

A) Insurance company B) Firedepartment C) D) E) All of the above

Maine Department of Environmental Protection Occupational Safety and Health Administration (OSHA)

3. In addition to detecting violations the DES inspector may also: A) Buy the company lunch. B) C) Provide educational materials. D)

Suggest ways to increase worker exposure to hazards.

Avoid discussion of other environmental laws.

4. The DEP inspector will want to see the operations and areas of waste accumulation. A) True B) False

5. Upon completion of the inspection, the inspector will: A) B) Increase shop production. C) D)

Ask the manager to make out a check for the fines.

Discuss any hazardous waste problems or other violations. Suggest a new product line.

Unit 5 - Module I - Compliance Inspections

PrePost Test

1. The DEP Inspector will usually call the shop manager to make an appointment to do an inspection.

A) True B) False

2. An auto repair shop may be inspected by:

A) Insurancecompany B) Firedepartment C) D) E) All of the above

Maine Department of Environmental Protection Occupational Safety and Health Administration (OSHA)

3. In addition to detecting Violations the DES inspector may also: A) Buy the company lunch. B) C) Provide educational materials. D)

Suggest ways to increase worker exposure to hazards.

Avoid discussion of other environmental laws.

4. The DEP inspector will want to see the operations and areas of waste accumulation. A) True B) False

5 . Upon completion of the inspection, the inspector will: A) B) Increase shop production. C) D)

Ask the manager to make out a check for the fines.

Discuss any hazardous waste problems or other violations. Suggest a new product line.

'\

UNIT^ PAGE^

Unit 5 - Module I - Compliance Inspections

Department of Environmental Protection personnel have the authority to inspect any business or commercial operation which is known to handle hazardous waste, or which the Department has reasonable cause to believe handles hazardous waste, as well as businesses which may be subject to the Clean Air Act, Safe Drinking Water Act and the Clean Water Act.

Here are some tips on what may happen during an inspection:

A DEP inspector or inspectors will usually arrive unannounced. Upon entering your operation, the inspector will introduce him or herself to the receptionist, show DEP identification and ask to see the person in charge of daily operations. The inspector will explain the purpose of the inspection and ask the person in charge for:

1.

2.

3.

4.

5.

6.

A verbal description of the operation, its processes, products, discharges, environmental permits, and the types and quantities of wastes produced. A physical inspection of the facility which will include floor drains in the bay area, the inspector will question where the drains go and what happens to any waste which goes down these drains. A review of parts cleaning equipment use to determine whether units are covered while not in use. A descriptiorddemonstration of the physical waste handling procedures and sources of hazardous waste. The hazardous waste storage area will be checked to ensure proper storage practices are used such as marking of hazardous waste containers including date of accumulation, containers are closed and sealed, and no evidence of leaks are present. (Sloppy housekeeping or poor maintenance of work areas is a clue to the inspector of non-compliance situations.) Records of hazardous waste shipments (manifests) will be checked to veri@ the generator’s status and to ensure hazardous waste is properly shipped off-site. A description about emergency preparation including equipment maintained and emergency postings. A physical inspection of the outdoor area around the facility will be inspected for possible soil contamination and accumulation of hazardous waste. The staining of soil or concrete will be checked for possible releases of wastes.

The inspection will conclude with: 1. A discussion of problems or violations and ways in which the company can correct

them. A written record of the inspection will be mailed with a requirement for a timely correction of any violations. Repeat violations may result in enforcement actions. A discussion on pollution prevention opportunities and the technical assistance resources available from DEP.

2.

UNIT^ PAGE^

Unit 5 = Module 1 - Compliance Inspections

Other inspectors may also visit an auto repair shop for a compliance inspection. The Occupational Safety and Health Administration looks for health and safety concerns. The local fire department inspect compliance with the fire code. A local code enforcement officer is concerned with surface and groundwater contamination and land use issues. Finally, the insurance company may inspect the shop for potential health, environmental and safety concerns.

Class Exercise: Audit of your own shop

Using the checklist in Appendix 1 as a guide, conduct an audit of your own shop.

1. 2.

Break the class up into teams of no more than four students. Ask each team pick a section from the training manual and perform a simulated compliance inspection of the shop in that area. (You may use the compliance checklist at the end of this chapter for a quick reference.) Each team should be prepared to give an oral and written presentation on their "compliance inspection". Each team should make recommendations to improve items they discovered during their "Compliance inspection".

3.

4.

Class Exercise: Is the auto repair shop in compliance? (for auto body students) Is the auto body shop in compliance? (for auto repair students)

Using the checklist in Appendix 1 as a guide, conduct an audit of the other auto shop at school. (If applicable)

1. 2.

3.

4.

Break the class up into teams of no more than four students. Ask each team pick a section from the training manual and perform a simulated compliance inspection of the shop in that area. Each team should be prepared to give an oral and Written presentation on their "compliance inspection." Each team should make recommendations to improve items they discovered during their "compliance inspection."

i

UNIT^ PAGE^

Unit 5 Module 1 - Compliance Inspections

Complying with Environmental, Fire, and Health & Safety Regulations A Checklist for Auto Repair Shops

This self-audit tool is designed to help auto repair shop owners achieve and maintain regulatory compliance. Municipal health, fire prevention, and building inspectors may also find it useful for preliminary screening and for assisting shops. The requirements listed here are based on federal environmental and health and safety regulations, as well as nationally recognized fire code. While the checklist includes the primary concems of regulatory inspections, it is not intended to be a comprehensive statement of compliance requirements.

The regulatory items listed on this form fall into two main categories: those in Section A relate to overall conditions at the site; those in Section B cover specific auto repair shop operations. Section C provides space to comment on any deficiencies observed during an inspection.

Also included with this compliance checklist is a list of tips for preventing pollution, fires, and health and safety hazards. While not required by law, following these practices helps to reduce compliance costs and ensure the well- being of employees.

Check only those items that require remedial action.

Section A General Walk-Through of Site

1. Materials and Waste Storage & Management (including oils, solvents, antifreeze and gasoline) 0 Flammable and hazardous liquids are stored in containers that are either approved by the U.S. Department of Transportation or by the State Fire Marshall, or listed and labeled by the National Registration and Testing Laboratory (UL-listed). 0 Lids are tight-fitting and sealed, and bungs are closed. 0 Containers, tanks, and flammables cabinets are labeled with the name of the material they hold (for example, waste oil) and the type of hazard they present (e.g., flammable). D Flammables are stored in an area (such as an air- tight metal cabinet, metal cabinet vented to the outside, or flarnmables storage room) approved by the local fire department. D Waste storage area is labeled and limits of area are marked. D Flammable liquids are grounded and bonded during transfer, grounded during storage. D There are no leaks or excessive spillage in chemical or waste storage areas, including around solvent sinks, pumps, pipes, hoses, couplings, fittings, and valves. D Drums of materials and wastes stored outside of the building have secondary containment (e.g., berms). Otherwise, drums are empty and clean.

2. Building D Building has two-hour firewalls (two walls of sheetrock or masonry) between repair garage and attached structures.

c1 Fire doors are equipped with automatic closures. 0 All openings in walls and ceilings are sealed. D A 40BC fire extinguisher is available, with 10BC extinguishers positioned every 50 feet. (Additional extinguishers may be necessary if the building is made of combustible materials.) D Employees have been trained in the use of fire extinguishers. D Signs are posted over each extinguisher. D Aisles and emergency exits are clear, and exit signs are posted over doors. D Smoking is prohibited where the repair work is done and allowed only in designated areas. 0 Electrical receptacles have no open grounds or reverse polarity. 0 Circuits are labeled and the circuit box is closed. Access to the circuit box is clear within 5 -1 0 feet. 0 Electrical outlets have cover plates. No wires are frayed, damaged, or taped off. R Wiring is enclosed in Electrical Metallic Tubing (EMT) or rigid metal pipe. D There is adequate central ventilation and adequate local ventilation for carbon monoxide from tailpipe exhaust systems. D Lighting is adequate.

3. Floors R Floor drains are connected to the sewer (with approval from sewer authority) or equipped with an approved oil-water separator or tight tank. D There are no cracks in the floor that would allow leakage. 0 Floors are made of noncombustible material, free of oil and grease, and sealed.

UNIT^ PAGE^

Unit 5 Module I - Compliance Inspections

4. General Equipment D Underground storage tank and above-ground storage tanks are permitted by appropriate state agency or local fire department (as required). D Waste oil fumaces are permitted by appropriate state agency or local fire department (as required). D There are no illegal furnaces or space heaters in use. D Lifts have operable safety locks, and are tested and serviced monthly. 0 Electrical cords are intact and have grounding prongs. D Light bulbs are teflon-coated (rough service).

5. Health and Safety D The shop has written contingency plans for fire prevention, emergencies and spill control. D Spill control materials are available on site. D Material Safety Data Sheets (MSDSs) are available for all toxic chemicals. D No food is consumed in the shop area. D Eyewash and showers providing 15 minutes of continuous flush are available in areas where acids and bases are used. 0 Employees are trained in chemical hazard, safety, and emergency preparedness.

Section B: Auto Shop Operations

6. Routine Car Maintenance (Managing waste oil, oily rags, and absorbents) D Drained waste fluids such as waste oil, antifreeze, and solvents are stored in separate drums or tanks. D Waste oil is removed by a licensed transporter or burned on-site in an approved heater. Ci Oil filters are punctured and hot drained over waste oil drum for the required amount of time, and then recycled or disposed properly. 0 Oily shop rags are placed in sealed, labeled metal containers and are managed properly. D Oily absorbents are disposed according to state regulations.

7. Solvent Parts Cleaning D Solvent parts cleaner is closed. Cl A licensed transporter picks up and recycles solvents or disposes solvents as hazardous waste. D Parts cleaner is labeled with material name and hazard type. 0 If a flammable solvent is used, the parts cleaner has a fusible link that locks shut in the case of fire. D Parts cleaner is registered with the state environmental agency (if required).

.

8. Exhaust System

D Weldingkutting is permitted by the local fire department. D Compressed gas cylinders are firmly installed by chaining to a portable dolly or to the wall in an upright position. D Fire extinguishers are available in the weldingkutting area. D Employees wear protective clothing and welding helmets with shields. D Flammables are not used or stored nearby. R Machinery is grounded. R Local ventilation is adequate.

9. Brake Repair (Grinding drums and turning rotors) 0 Employees wear safety glasses with side shields. D Equipment is bolted into the floor. D Pullies on the grinder are covered with a safety guard. R The grinding wheel offset is no greater than 118 inch. D Shop uses HEPA filtered vacuum system or a wet method of grinding to prevent asbestos exposure.

10. Air Conditioner and Radiator Servicing D Refrigerant recovery machines are licensed by US. EPA. D Refrigerant recovery operators are certified by U.S. EPA. D Antifreeze is labeled and recycled or disposed properly. D If radiator repair includes brazing, procedures are in place to control and monitor lead.

11. Battery and Tire Storage D Batteries are stored in a single layer on pallets or shelving with an impermeable base, and are properly recycled. D Tires stored outside are covered and properly disposed.

Section C: Deficiencies and Recommended Actions Use this section to note areas where the shop is out of compliance, and to provide information about how to correct deficiencies or other comments.

The information in this document is based on regulations of the National Fire Prevention Code (NFPC), Occupational Safety and Health Administration (OSHA), and the U.S. Environmental Protection Agency (EPA). Compliance with this document does not constitute full compliance with NFPC, OSHA or U.S. EPA laws and regulations.

UNIT^ PAGE^

Unit 5 Module I - Compliance Inspections

A Practical Guide to Reducing Toxic Hazards, Preventing Fires ,-and Minimizing Health and Safety

Hazards Tips for Auto Repair Shops

The practices listed on this sheet provide specific ways to save on compliance costs by preventing environmental pollution and protecting the health and safety of workers.

Section A General Site Conditions Materials Storage and Management

Purchasing . Order chemicals in appropriate amounts.

Inspect materials immediately upon delivery

Purchase multi-purpose materials to reduce

Ask your supplier for the least hazardous

Review the Material Safety Data Sheets

Expired chemicals are costly to dispose and may pose a fire hazard.

for leaks or other damage.

the number of hazardous chemicals in the shop.

materials suitable for the job.

(MSDSs) prior to purchase.

. 0

. 0

Storage . Organize and label oils, chemicals, and

Create an inventory system for oils, chemicals,

Keep unused materials in their original

hazardous materials in a single storage area.

and hazardous materials. Rotate your inventory

containers. Inspect storage areas to identify points where spilled chemicals could enter environment, such as floor drains, door ways, loading docks, catch basins, dirt or cracked floors. Avoid storing, dispensing or to mixing chemicals in these areas. Store flammables in a location other than the building where people normally work, in a manner approved by local fire and health departments.

0

.

0

Usage Use self-closing spigots and nozzles for dispensing fluids from bulk containers. Ask employees to return empty containers, such as, spray cans before they use new supplies. Pour and mix chemicals in a well-ventilated area. Use only one spray can at a time of brake or

.

.

.

carburetor cleaners, lubricants, grease, and sealants.

BuildinglFloor . Contract with a fire extinguisher company to test and fill extinguishers once a year. Remove overhead items that could cause head injuries. Keep floors as dry as possible to prevent falls and potential electrical hazards.

Contract with a waste removal company to empty oillwater separators or tanks at least oncea year. Seal floor drains, if approved by local authorities. Use magnetic covers for drains or dry wells.

Ensure that catch basins have oil separators. Keep catch basin sumps empty and dean. Keep wells locked and sealed.

0

0

0 Use non-hazardous cleaning materials. . 0

Outside of Building 0

0

0

Section B: Auto Shop Operations Routine Car Maintenance

Reducing Spills . Build berms to contain 1 10% of the volume of the largest container or tank in the storage area. Prevent waste oil spills by using drip pans. Place oily parts in the drip pan rather than on the floor. Use a resealable funnel to minimize spills from drip pans.

0 . . Cleaning Up Spills 0 If you do spill waste oil, use dry cleanup

methods such as reusable absorbent pads, mops that absorb only oily liquids, or a bristle broom and dustpan. Drain excess oil into drip pans and then into a waste oil drum or tank.

remaining waste oil with rags.

last resort.

find out how to properly dispose or recycle used absorbents.

. After using dry cleanup methods, remove any

Use clay absorbents or sawdust only as the a

Check with your state environmental agency to

0

0

Solvent Parts Cleaning . Use aqueous cleaners instead of solvents. To avoid drips, position the parts cleaner close

Wear gloves and eye protection when handling

. to the work station.

solvents. .

Unit 5 Module 1 - Compliance Inspections 1 . Use a wire brush for cleaning before using

solvents. DeDartment of Environmental Services New Hampshire

. For very dirty parts, use a pre-wash of used cleaner or wipe with old solvent. Remove cleaned parts slowly and allow them to drain over the sink.

. Brake Grinding 0 Capture metal filings in a bin under the brake

grinder and dispose in trash.

Radiator Flushing and Repair 0 Reclaim antiieeze on-site. 0 Never mix used antifreeze with used oil.

BatteriesNireslScraap Metal Parts 0 When recharging batteries on-site, store bulk

Recycle batteries, tires, and scrap metal parts. Store batteries inside the shop.

acid in wooden or plastic cabinets. 0

0

Additional Information Local Resources Contact your local Fire Department, Board of Health, Building Inspector, Code Enforcement Officer, or Local Emergency Planning Committee.

State Resources Each state provides free, confidential technical assistance for preventing pollution and meeting waste management and health & safety requirements.

Connecticut Department of Environmental Protection Hazardous Waste Compliance Assistance

860-424-41 93

Small Business Assistance Program 860-424-3382 Office of Pollution Prevention 860-424-3022

State Fire Marshals Office 860-685-8350 OSHA Consultation Program 860-566-4550

Maine Department of Environmental Protection

Small Business Technical Assistance

Fire Licensing and Inspections Unit

Office of Pollution Prevention 207-287-7881

Program 800-789-9802

OSHA Consultation Program 207-271-61 55 207-624-8744

Massachusetts Department of Environmental Protection Information Center 61 7-338-2255

800-462-0444 Office of Technical Assistance 61 7-727-3260 Department of Fire Services 978-567-31 00 OSHA Consultation Program 61 7-969-71 77

Poilution Prevention Program 800-273-9469

Assistance Program 800-837-0656 Fire Marshals Office 603-271 -3294 OSHA Consultation Program 603-271-6155

Small Business Technical

Vermont Department of Environmental Conservation Small Business Compliance Assistance 800-974-9559 Small Business Development Center 800-464-

SBDC Fire Prevention Division 802-828-21 06 OSHA Consultation Program 802-828-2765

Federal Resources

US. EPA Region i ’

New England Environmental Assistance Team

NEEAT 800-90-

For additional copies of this checklist call 800-90- NEEAT.

Prepared by the Northeast Waste Management Officials’ Association with Funding from U.S. EPA Region 1.

UNIT^ PAGE^

il !s Against the Law It is illegal to discard waste oil in a dumpster, down a sewer, in the water, or on the ground. In addition, any mixture of waste oil and solvents is considered a hazardous waste, which makes disposal costs extremely high.

Waste oil contains harmful contaminants such as benzene and lead, picked up during the operation of a vehicle. Safe management and disposal of waste oil protects not just drinking water, fish, and land, but also the workers in your shop.

Waste oil spills cost money and take time to clean up. Even minor spills can cause major contamination problems. You are legally required to clean up any spills, and you may also be subject to government fines.

JfYcw Need &?@

Keep these telephone numbers handy. I f you have an oil spill, call the nearest Maine Department of Environmental Protection (ME DEP) office. Augusta . . . . . . . . . . . . . . . . . . . .207-2 8 7-7800 Bangor . . . . . . . . . . . . . . . . . . . .207-94 1-4570 Portland . . . . . . . . . . . . . . . . . . .207- 8 22-6 3 00 Presque Isle . . . . . . . . . . . . . . . . ,207-764.0477 (After 5:OO pm on weekdays and on weekends, call . . . . . . . . ,800-482-0777)

If you have questions about state waste oil regulations, contact the ME DEP . . . . . . . . . ,207-287-265 1 If you want free technical assistance for your shop, contact the ME DEP Small Business Assis- tance Program . . . . . . . . . . . . . . .300-789-9802 For any other questions, contact your local fire department, health department or sewer authority. I f you are not sure who to call, contact your city or town hall.

Printed with soy bared inks on recycled paper.

Taking the precautions listed below will help you avoid waste oil accidents, limit your legal liability, and protect both your workers and the environment.

Storing Waste Oil 4 Store waste oil in sturdy, leakproof metal

containers or in a tank approved by your local fire department.

* Label the container, tank, and fillpipe for underground tanks in large letters: "Used Oil."

* Keep containers closed unless you are adding or removing waste oil.

* Place containers on a surface made from any nonporous material, such as concrete, that waste oil cannot pass through. The surface should have no cracks or gaps. Store waste oil away from drains or ignition sources.

inspecting Storage Areas * Check containers and storage areas each week

for spills or leaks from lids, seals, and seams.

Preparing for a SpiD * Keep cleanup and containment materials ready

for immediate use. Write an emergency response plan, post the instructions in an easily visible spot in the shop, and train employees i n the procedures.

R.ecy"k'ing Qr ~~~~~~~~~~ B9a08e Oil 0 Contract with a licensed transporter to pick up

your waste oil for recycling or disposal. (Call the Maine Department of Environmental Protection [ME DEP] at 207-287-2651 for further information including a list of transporters.) ox , . . 0 Burn the waste oil in an approved space heater

in your garage. (Contact a heater oil burner

(Managing wasb oil filters cont.) 4. Store the used filter in a separate, closed metal

container that is labeled "Waste Oil Filters." 5. Ship the used filters to a recycler or discard

them as solid waste after 12 hours of draining. (Contact the ME DEP at 207-287-2651 for further information.)

Hapndhg Shop Towels and ~ ~ $ ~ ~ ~ ~ ~ % ~

To avoid managing towels and absorbents as hazardous waste, they must contain only waste oil and the oil cannot befree-fowing or dripping. 0 Send shop towels to a permitted industrial

laundry. OR . . . Discard dry towels in the trash.

* Handle large amounts of absorbents (spill cleanups) as "special waste." (Contact the Solid Waste Division of the ME DEP at

(Recycling or disposing waste oil conl.) ,

dealer for more information on proper installation of a space heater.)

Managing Waste Oil Filters Follow lhese s teps when chanqinq oil fillers. - - -

Remove the filter from the engine while warm and immediately drain free-flowing oil. Put the drained oil in your waste oil drum or tank. Puncture the filter dome. Place the filter on a rack to drain into a waste oil drum or tank for 12 hours. ON . . . Hot drain andcrush the filter.

,

207-287-265 1 for further information.) Small amounts of absorbents may be disposed in the trash.

* Store shop towels and absorbents in separate metal containers with tight-fitting lids. Label containers "Contaminated Shop Towels Only" and "Oily Waste Absorbents Only", as appropriate.

Good Rouseiceepi~ag reduces lcpills and protects you against Iliabibty Hem are several sruggesi'iens far limiting waste oil problems in your shop. Place drip pans under cars.

0 Use different pans for waste oil and for parts covered with solvents. 0 Fill drip pans only half-way and then use a funnel t o pour the oil into a drum or tank. 0 Use dry cleanup methods when you do have spills.You can use ( I ) reusable absorbent pads, ( 2) a bristle

broom and brush, o r (3) mops that absorb only oily liquids.Wring out o r pour the waste oil you clean up into a container or tank. Clean any leftover waste oil with a rag. Discard the cleanup debris in a separate container from the used oil. As a last resort, use clay absorbents or sawdust, o r alternatives such as corn cobs or peat. Build curbs around your waste oil storage area to contain I 10% of the volume of the largest waste oil container or tank.

pollution prevention for auto body and auto repair vocational … · 2018-06-13 · pollution...

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