Solvent-Based Epoxy in a Basement Plant Room
A two-person crew is applying a solvent-based epoxy floor coating in a 6 m by 4 m basement plant room with a 2.4 m ceiling. The room has a mechanical extract fan but it is switched off because the power circuit is being used for temporary lighting. The product is decanted into an unlabelled plastic bottle. The workers wear nitrile gloves and safety boots, but no eye protection or respirator. After 40 minutes, one worker complains of headache, dizziness and nausea and his face is flushed; he says he just needs a short break. The other worker has epoxy on his forearms. The SDS is in the site office, not at the workplace. There is a strong solvent smell. A hot work permit is not in place, but an angle grinder is being used 5 m away outside the room. The nearest welfare facilities are 150 m away and the workers have been taking breaks in the plant room.
1. What should be done immediately for the affected worker and the work area?
Read the worked answer
Stop work and evacuate the plant room. Move the affected worker to fresh air, sit him down, loosen tight clothing, and monitor breathing and consciousness. Call the site first aider and, if symptoms persist or he becomes drowsy, call emergency services. Do not let him 'rest' in the same room. Remove contaminated gloves and wash epoxy from the other worker's forearms with soap and water; flush eyes for 15 minutes if there is any eye contact. Isolate the room, switch off the grinder outside, remove ignition sources, and prevent re-entry until the atmosphere is tested and the ventilation is working. Treat the headache, dizziness and nausea as possible solvent exposure, not as malingering.
2. Should the job restart, and what controls would make it acceptable?
Read the worked answer
The job should not restart until controls are in place: mechanical ventilation running and verified; atmospheric monitoring for solvent vapour and oxygen; SDS available at the point of use; product transferred to a labelled container; suitable respirator with the correct cartridge and face fit; chemical goggles and gloves; fire extinguisher and no hot work nearby; training and health surveillance; and a welfare area away from the plant room. The control hierarchy says ventilate and substitute first. The current method relies on gloves alone, which is inadequate. If ventilation cannot be achieved, use supplied air or respiratory protection and limit exposure time.
3. What reporting, health and welfare actions follow?
Read the worked answer
Report the incident internally, record the symptoms and exposure time, and arrange medical assessment. The safety officer should investigate and review the COSHH or HIRARC assessment. The worker should not return to the task until medically cleared. Breaks should be taken in a clean area, not the plant room, and washing facilities should be close enough that workers use them.