Protect valued employees and avoid regulatory fines by developing an effective shop health and safety program.

Tom grew up in the collision repair industry. He painted cars years before anyone ever considered the health ramifications of not wearing masks or respirators. But even after the government, paint suppliers and his employer warned painters to protect themselves, Tom donned only a particulate mask when shooting a car.

After years of exposure to isocyanates--chemicals found in the hardener of two-part coatings and primers--Tom became sensitized. Individuals who are sensitized suffer such pains as headaches, tightness in the chest, nausea, vomiting, coughing, fever and fatigue when exposed to even minor amounts of isocyanates. Tom began to endure headaches each time he painted a car, and then these pains gave way to a more serious symptom: vomiting. The first time Tom's manager witnessed this, he promptly ended Tom's career. Even though he lost his job, Tom was fortunate. Other painters have lost their lives as a result of exposure to isocyanates long after they are sensitized.

While the occupational health problem that afflicted Tom is probably the most serious threat to industry professionals, collision repairers also must concern themselves with many additional workplace health and safety issues. Environmental conditions, unsafe work habits and failure to wear personal protective equipment can be as detrimental to one's health as isocyanates.

Shop owners must make prevention a top priority because employees who suffer from work-related illnesses or injuries are not the only ones affected. Losing key employees to easily avoidable incidents hurts staff morale and productivity. Ultimately, this could damage the health of the business--especially if poor health and workplace injuries are routine.

Committing to safety and health in the workplace should eliminate most hazards and prevent most injuries. Going above and beyond what compliance agencies, such as the Occupational Safety and Health Administration (OSHA), require can even prove profitable. An effective plan can lead to fewer worker compensation claims, a healthier staff, reduced absenteeism and lower insurance premiums. For example, the Vermont Occupational Safety and Health Administration (VOSHA) can choose to reduce fines by 25 percent for businesses with effective health and safety programs.

Getting Started

While vowing to focus on workplace safety is simple, organizing such an effort can seem unwieldy because of the scope of government regulations and the number of potential hazards in a collision repair facility. Fortunately, a number of organizations have undertaken the task of explaining the requirements in lay terms. OSHA, VOSHA and the National Institute for Occupational Safety and Health (NIOSH) address such topics as recordkeeping, spraying operations, fire protection, personal protective equipment and tools and equipment. The following checklist is a compilation of the work of these groups.

VOSHA promotes a four-point approach to developing a workplace safety and health program. The approach is divided into four categories:

* Management Commitment and Employee Involvement. Committed owners and managers are the foundation of a successful safety initiative. If they are apathetic, employees will follow suit.

* Worksite Analysis. Review all business operations to identify all potential hazards. Consider hiring an environmental consultant, and encourage employees to point out potential dangers.

* Hazard Prevention and Control. Create an action plan driven by priorities. Rank the items that need to be addressed according to the threat they pose to employees; the expenses required to eliminate the problem; and any need for more information if a control measure still needs to be determined. Assign an employee the task of periodically inspecting the workplace for hazards, verifying the use of protective equipment and monitoring the adherence to government requirements.

* Training for Management and Employees. Successful programs typically involve all levels of employees and managers. Seek help from employees in all departments, and form a committee that understands the safety and health issues, the prioritized plan and the major components of the company's plan. The committee should help to increase overall concern for the issues at hand.

Also keep these needs in mind:

* Select one person to coordinate and manage the safety and health program.

* Train employees to recognize tasks that might result in exposure to dangers; how to practice safe work habits and how to protect themselves from harm; how to obtain information on selecting and using personal protective equipment; and what to do if there is an emergency.

* Post the following: an OSHA workplace poster, emergency telephone numbers, a list of toxic substances or harmful physical agents, exit routes and signs prohibiting eating, drinking and smoking where necessary.

* Keep employees apprised of the efforts being put into the program as well as its accomplishments.

* Offer incentives for employees who excel in reducing injuries and accidents.

Recordkeeping

Paperwork rarely inspires even the most dedicated employee, but it's one of those "necessary evils" in the business. Complying with OSHA, EPA and other governmental laws also means maintaining paper files of your safety plans, employee health and injury records, Material Safety and Data Sheets (MSDS) and permits for your shop equipment.

Records primarily help you track safety efforts and prove to government officials that you're complying with the laws, but taking advantage of the information provided on the MSDS can also help to protect employees. Ensure that all employees who use hazardous chemicals understand the dangers and the precautions necessary to protect themselves. These measures also protect shop owners because they can be held liable for failing to inform employees. Additional recordkeeping requirements include:

* Tracking employee illnesses and injuries on OSHA form 101 or log 200.

* Maintaining employee medical and exposure records for such things as solvents, welding fumes, asbestos, benzene, ethylene glycol, noise and corrosives.

* Maintaining records on a long-term basis. Repairers are required to keep records for 30 years that indicate which chemicals their facilities used.

* Maintaining inspection logs for equipment grounding, equipment safety devices and fire extinguishers.

* Maintaining written plans for hazard communication, the shop's respiratory protection program, emergency medical procedures, bloodborne pathogens, fire prevention and exit routes, and exposure to toxic or physical agents.

Spraying Operations

Painters face dangers from isocyanates, volatile organic compounds (VOCs) and metals, such as lead and chromium. These dangerous substances enter the body through the eyes, mouth and skin, and prolonged exposure can cause nervous disorders, skin and eye irritation, respiratory sensitization, asthma and reduced lung function. But refinish technicians can help protect themselves by minimizing their exposure to these chemicals as much as possible. There are a variety of ways to do this, such as using high-volume, low-pressure (HVLP) sprayguns, a ventilated spraybooth and personal protective equipment such as full-face, air-fed respirators. Here's how these methods can help:

* Spraying with high-volume, low-pressure (HVLP) sprayguns offers advantages over conventional guns because these guns reduce paint overspray by about 50 percent. HVLP guns also transfer paint more efficiently, thereby reducing waste.

* NIOSH recommends using a downdraft booth for refinishing vehicles. Because of their air flow design, downdraft ventilation booths produce lower concentrations of paint overspray. The movement of air from top to bottom carries overspray away from the paint technician.

* Even the best downdraft booths and HVLP sprayguns do not eliminate paint overspray. Implement a respiratory protection program, and establish written replacement schedules for canister and cartridge filters if the filter-type respirators used are not equipped with end-of-life service indicators.

* Provide adequate ventilation.

* Never spray within 20 feet of flames, sparks, operating electrical motors or other sources of ignition.

* Illuminate spray areas with explosion-proof lighting. Portable lights are not allowed in the spray area.

Sanding Operations

When technicians perform sanding operations, dusts are released that may contain hazardous substances, such as lead and chromium. These metals can damage the lungs and nervous system. Dust concentrations in the shop may also exceed OSHA standards.

But ventilated, or vacuum, sanders are effective at controlling worker exposure to sanding dusts. Rotary/orbital and straight line/reciprocating sanders equipped with high-velocity, low-volume exhaust ventilation reduce dust concentrations when sanding body-filling compounds. They are also designed to reduce the total dust level to one-tenth of that produced by unventilated sanders.

Work Environment

Slips, trips and falls account for the majority of industry accidents. They cause 15 percent of all accidental deaths--ranking only second to car accidents as a cause of fatalities. OSHA requirements designed to prevent such catastrophes include:

* Keeping work areas orderly, sanitary and well lit. Implement a documented, effective housekeeping system.

* Storing stacked, piled or racked materials in a way that eliminates falling, rolling and other hazards.

* Containing and cleaning up spills and leaks immediately.

* Keeping all walking surfaces clean and slip-resistant. Mark all directional changes in aisleways.

* Providing restroom facilities and cleaning them regularly.

* Covering all pits and floor openings. This includes grates over floor drains.

* Marking all doors with their purpose--for example, "Exit," "Storeroom" and "No Exit."

* Arranging aisles and walkways around machinery or welding operations.

Protective Equipment

In addition to shopwide protection and safety policies, employees should protect themselves from eye, face, skin and foot injuries--allowing eyeglasses to double for protective goggles is unacceptable. Employees must have personal protection equipment available, and the equipment must fit. Consider these points when determining how to protect your employees:

* Require eye protection when necessary (check your MSDS), including when there is a danger of flying particles or corrosive materials or when there is a risk of punctures, abrasions and burns.

* Require face shield protection for operations involving welding, cutting, grinding, abrasive wheels or hand tools.

* Require approved protective clothing, such as aprons, gloves and shields, when an employee may be exposed to cuts, burns, caustics or skin-absorbed toxins.

* Clean and sanitize all safety equipment regularly.

* Make sure a dual eye flush system is available in areas where toxic or corrosive compounds are used. Keep eating and drinking areas separate from areas of potential exposure.

* If noise levels exceed 85 decibels in eight hours, provide noise protection or engineering controls.

* Require employees to use approved protective equipment to clean spills and leaks of toxic and hazardous substances.

Tools and Equipment

Tools are so prevalent in our lives that it's sometimes hard to remember that unsafe or improper use can lead to injuries. Using a screwdriver as a chisel, for example, can break the tip of the tool and send it hurtling toward a coworker. And even though technicians typically supply their own tools, employers are responsible for ensuring that the tools are in good condition. When examining the safety of your shop, keep these needs in mind:

* Use only hand tools that are in good condition. Replace or recondition tools such as chisels and punches that develop mushroomed heads during use.

* Use the right tool for each job.

* Replace broken or cracked handles on hammers and similar equipment.

* Ensure that abrasive wheels or grinders are permanently mounted, grounded with metallic conduit wiring and equipped with individual on-off switches. They must also have ample side guards, splash guards and dust collection, if necessary.

* Inspect all equipment regularly.

* Machines should not be able to start up automatically in power-outage situations, and low-level current surges should not be able to start the machine.

* All welding, brazing and cutting equipment should be of an appropriate type. Handle all cylinders in a manner that will prevent the release of compressed gas and damage to the cylinder.

* Separate stored acetylene and oxygen tanks with a fire-rated wall or sufficient distance, unless they are on a cart for use.

* Remove combustibles when welding, cutting or brazing.

* Allow only trained staffers to operate welding, cutting or brazing equipment.

* Measure welding fumes to ensure that health standards are met and determine if ventilation is required.

* Use welding shields at all times.

* Post signs that warn of air compressors' automatic start-up feature.

* Do not use compressed air to clean clothes or your body.

* Check pneumatic and hydraulic hoses periodically for deterioration.

* Ensure that hoist ratings are appropriate for the task at hand. All hoists must be capable of holding 125 percent of their rated load.

* Use the locking mechanism any time someone is under a lift. Secure lifts that lack built-in step locking mechanisms with a jack capable of supporting three times the lift's rated capacity.

Fire Protection

* Notify the local fire department of any fire hazards at your facility.

* Maintain certification of the fire alarm system and frequently inspect and test sprinkler systems.

* Make fire extinguishers available and regularly inspect, service, recharge and tag them. Appropriate fire extinguishers should be mounted within 75 feet of outside areas containing flammable liquids and within 10 feet of any inside storage area for such materials.

* Store combustible scrap and waste materials in covered metal receptacles and remove them regularly. Store all flammable liquids in approved, closed metal containers when not in use.

* Install explosion-proof lighting in rooms where flammable materials are stored or used.

* Vacuum whenever possible instead of blowing or sweeping combustible dust.

* Select fire extinguishers based on the types of materials on which they are designed to be used: Class A extinguishers are for combustible material fires; Class B are for liquid, gas or grease fires; Class C are for energized-electrical equipment fires; and Class D are for metal fires. Combination extinguishers are available.

* "No Smoking" signs should be prominently posted in areas where flammable materials are used or stored.

* Ensure that storage rooms, cabinets and containers are designed for the materials they will hold. Ventilation may be required for some types of materials.

* Direct sprinkler heads so that water will not spray electrical switchboards or equipment if the system is activated.

First Aid

* Pre-employment physicals are recommended for some employees and are required for those employees who will use respirators. Physicals help to identify pre-existing conditions.

* A hospital or clinic must be located within four minutes of the facility or an employee must be trained in first aid.

* Equip the shop with first aid kits, which should be regularly inspected and restocked.

Electrical

* Ground all electrical equipment.

* Inspect all machinery, equipment and cords prior to energizing.

* Ensure that all contract work is OSHA-compliant.

* Prohibit multiple-plug adapters.

* Use extension cords that have grounding conductors.

* Secure flexible cords or cables at plugs, receptacles, tools and equipment.

* Ensure that electrical tools and equipment used in wet or damp locations are suitable for use in such environments.

* Label all disconnecting switches and circuit breakers to indicate their use or the equipment served.

Why Bother?

Establishing or expanding a workplace safety program requires a massive effort on the part of collision facility owners and their employees. Such an endeavor is time-consuming, requires attention to details and lacks any amount of glamour.

But it's the law, and employees deserve to be informed and protected--just ask Tom and other fellow technicians who will forever associate their health conditions with their careers.

Put It in Writing

OSHA regulations mandate that collision repairers develop and maintain a number of written safety and health plans. Although the requirement can be viewed as tedious paperwork, the plans provide a plethora of information essential to employers and employees. The plans include:

Hazard Communication

* List and describe all hazards, ways in which individuals can be exposed, procedures for preventing exposure, the availability of Material Safety Data Sheets (MSDS) and procedures for responding to each type of exposure.

* Train employees who could be exposed to hazards. The training must describe the hazard communication standard and communicate all aspects of the written plan detailed above.

* Ensure that all containers are labeled with each chemical's trade name, the danger each poses and the effect on organs targeted by the chemical.

Emergency Medical Procedures

* Decide if first aid will be provided on site. If a medical facility is not within four minutes of the shop, first aid must be offered. The designated first aid employees must be trained.

* Provide written procedures and training that describes how to determine if a situation requires first aid or emergency medical treatment.

* Provide the name and telephone number of, as well as directions to, the closest medical response facility.

Fire Prevention and Exiting

* Train employees in the availability and use of fire extinguishers, alarm systems and automatic fire suppression systems. Explain safety procedures, responsibilities and exit routes during fire emergencies. Be sure to document this training.

Exposure to Toxic or Physical Agents

* Create a document for each toxic or physical agent that explains the following: the hazardous effect, routes of exposure or entry, signs of overexposure, use and availability of personal protective equipment or controls, and ways to handle overexposure.

Respiratory Protection Program

* If employers can't prevent hazardous dust, fumes, sprays, gas and vapors from entering the work environment, they must provide employees with respirators.

* All employees who use respirators must be medically evaluated.

* Write down the criteria that will be used for selecting respirators, procedures for proper use and maintenance of respirators, ways employees will be informed of the hazards to which they are exposed, and procedures for evaluating the program's success.