Understanding Metalworking Fluids: Types, Risks, and Control Measures
Learn about the four categories of metalworking fluids, including their risks and control measures.
What are Metalworking Fluids?
Metalworking fluids (MWFs) refer to fluids used during grinding and machining and include four classes of MWFs: straight oil, soluble oil, semisynthetic, and synthetic MWFs. MWFs serve to prolong the life of the tool, carry away metal debris that results from cutting and grinding, protect the part being produced, and carry heat away from the ground or cut surface.
Occupational exposures to MWFs are a concern and need to be controlled. Repeated inhalation of MWF mists can cause respiratory illnesses and asthma, leading to non-reversible lung damage. Additionally, contact with skin can cause various skin diseases, most notably allergic dermatitis.
Types of MWFs
MWFs are grouped into four categories. The first category is “straight” oil (neat oil) MWFs. These oils are solvent-refined petroleum oils, animal, marine, vegetable oils, or synthetic oils that are not diluted with water. The straight oils may or may not contain additives that may include corrosion inhibitors, emulsifiers, buffers, and extreme pressure additives.
The next class are the soluble oils (emulsifiable oils), which are between 30 to 85 percent severely refined lubricant base oil with emulsifiers and may also contain additives. Soluble oils also contain a small percentage of water.
The semisynthetic class contains less of a percentage of the severely refined lubricant base oil (5-30%) and contains a higher percentage of emulsifiers and up to 50 percent water.
The final category is synthetic MWFs, which contain no petroleum oils and are diluted with 10-40 parts of water.
Occupational Exposure
Occupational exposures to MWFs occur either by inhaling mists and aerosols or from direct skin contact. Besides the MWF aerosols and the added additives or biocides, exposure risk can include metals and alloys from the parts ground or machined. Additionally, background contaminants in the work area and bacterial or fungal contamination in the water component of MWFs pose a risk.
The National Institute of Occupational Safety and Health (NIOSH) has established a Recommended Exposure Limit (REL) of 0.5 milligrams per cubic meter (mg/m3) for an eight-hour time-weighted average exposure. The REL applies to all categories of MWF. In addition to NIOSH, the Occupational Safety and Health Administration has established a Permissible Exposure Limit (PEL) of 5 mg/m3, which only applies to mineral oil-based MWFs. The NIOSH REL is based on regular and recent reviews of health hazard data and is the occupational exposure limit referred to for best practices.
During machining operations, the risk of Inhalation exposures is greater depending upon how close the worker is to the machine, whether there is an enclosure or splash guard, and whether the machine is operating at a high speed and making deep cuts. Other factors contributing to exposures during machining or grinding are whether there is exhaust ventilation installed to capture mists and aerosols near the point of generation and whether the exhaust system has been poorly designed or maintained. Additionally, improper machine maintenance can result in excessive fluid application or contamination of the oil with machine tramp oils.
In addition to inhalation, skin contact is a major concern with respect to exposure. Exposures occur when there are not enclosures or guards to protect from splashes during machine operation, and from handling parts, tools, or equipment without personal protective equipment (gloves and aprons), or prolonged contact with clothing contaminated with oil.
Health Effects
The NIOSH REL was established to address non-malignant respiratory disease. MWF concentrations above the REL in nine out of ten studies have been shown to cause respiratory conditions, including hypersensitivity pneumonitis (HP) which produces flu-like symptoms, acute airway irritation, chronic bronchitis, impaired lung function, and asthma. Cases of HP have been linked to water-based or diluted oils, and microbial contamination is believed to be the most likely cause. Three recent studies have shown that the risk of developing asthma is elevated and up to three times greater for workers exposed to synthetic MWFs than for workers who are not exposed.
A variety of skin diseases can result from direct skin contact with MWFs. The following factors contribute to the development of disease:
The MWF category and additives used
The duration of the skin contact
An existing skin abrasion or cut
Individual susceptibility
Inadequate or infrequent skin cleansing following contact
The use of irritating soaps or detergents
High or low humidity, hot or cold temperatures
Wearing MWF-soaked clothing or handling soaked rags.
The general cleanliness of the surrounding work area
Lack of controls i.e., machine enclosures, exhaust ventilation, personal protective equipment (gloves, sleeves, aprons)
The most reported skin diseases are irritant contact dermatitis or allergic contact dermatitis. The latter type of dermatitis is caused by an immune response to a substance that the body has become sensitized to. Dermatitis causes skin lesions and discomfort from burning and itching. Dermatitis is common with contact with soluble, semisynthetic, and synthetic MWFs.
Other skin diseases, including folliculitis (hair follicle infection), oil acne, and keratosis (rough, scaly skin patches), are linked to contact with straight oil MWFs.
Controlling Exposures to MWFs
The machine tool industry has undergone major changes in recent decades, leading to significant exposure reductions. The changes made have included the increased use of synthetic MWFs, which have increased tool and cut speeds which reduce machining time. Technological advances have also been made, leading to the development of machines with partial enclosures and the installation of local exhaust ventilation. During the 1970s and 80s, industries began installing air cleaners (mist collectors) and improving the recirculation of air and filtration.
Recommendations for Controlling Exposures
NIOSH recommends developing and implementing a comprehensive health and safety program to control exposures to MWFs. For programs to succeed, management must have a strong commitment and include worker involvement. The four main components recommended are safety and health training, worksite analysis, hazard prevention and control, and medical monitoring of exposed workers.
Worker training programs should teach workers to identify potential exposure hazards in their work areas and the adverse health effects of MWF exposure.
Worksite analysis refers to monitoring work practices and assessing personal exposures (air sampling) to assess the effectiveness of controls.
Hazard reduction can be achieved by the proper selection of MWF, i.e., using the most non-irritating, non-sensitizing fluids, regular fluid maintenance, isolation of the operation, and installation of exhaust ventilation.
With respect to PPE, workers should be trained in the proper use and care of protective equipment. If personal exposure assessment indicates that respiratory protection is needed, a respiratory protection program must be established in accordance with the OSHA Respiratory Protection standard (29 CFR 1910.134).
For more in-depth information about MWFs and controlling exposures, consult NIOSH publication 98-116, Occupational Exposure to Metalworking Fluids
Mary Dunlap is a Certified Industrial Hygienist and has been with Cornerstone Environmental, Health and Safety since 2016. When she is not working, you can find Mary enjoying the outdoors.
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Go Wild! The Benefits of Native Landscaping
Learn about the advantages of turning your yard into a space that supports native plants, animals, and habitats.
The summer heat has taken hold, and you’re probably struggling to keep that lawn at your home or business alive and green. What better time to learn about the advantages of turning all or a portion of that area back into a space that supports native plants, animals, and habitats? Traditional lawns require significant investments of time and resources while providing little in return.
Pollinators, for one, depend on native habitats for survival. According to the USDA, “Three-fourths of the world’s flowering plants and about 35 percent of the world’s food crops depend on animal pollinators to reproduce”. Native flowers in a former lawn space can support insect and bird pollinators with nectar and pollen as a much-needed food source, allowing them to complete their critical pollinating roles.
Once established, native habitats also require significantly less watering and eliminate the need for harsh chemicals and fertilizers. National Audubon Society experts estimate, “the traditional suburban lawn on average has ten times more chemical pesticides per acre than farmland”. Natural areas reduce groundwater penetrating chemicals and conserve our most precious resource, water.
Natural spaces also provide the reward of connecting on a personal level with the outdoors. Researchers at the Mental Health Foundation have observed that “people who are more connected with nature are happier and more likely to report feeling their lives worthwhile.” What better way to promote positive mental health than to create and enjoy a biodiverse area?
Lastly, we see more and more habitat loss and migration spaces being eliminated due to human sprawl and development. To put this in perspective, there are currently more than 63,000 square miles in the US of turfgrass. That’s larger than the state of Georgia (LawntoWildflowers.org). Rewilding even a portion of this massive space would provide much-needed resources for birds, insects, and other living creatures that depend on natural land.
Hopefully, these benefits have shown you why this summer could be the perfect time to convert your lawn into a native and rewarding landscape.
Resources:
Why Native Plants Matter | Audubon
Nature: How connecting with nature benefits our mental health | Mental Health Foundation
Bringing your lawn back to life by converting turfgrass to native wildflowers — Lawn to Wildflowers
Travis Clark is a Cornerstone Account Manager with a focus on business development. He manages corporate clients primarily in the industrial sector with a focus on manufacturing and logistics. He counsels clients in the areas of EPA and OSHA regulatory compliance management, quality certifications, and sustainability. He works closely with these operations to provide guidance on minimizing risk and implementation of cost-saving initiatives.
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Biochar for Environmental Remediation
For thousands of years, innovative farmers have added a charcoal-like substance—biochar—to the soil to improve crop productivity. But what is biochar?
For thousands of years, innovative farmers have added a charcoal-like substance—biochar—to the soil to improve crop productivity. Between 450 BCE and 950 CE, native farming communities of the Amazon basin successfully converted low-fertility, tropical soils to agricultural soils through the amendment of biochar, compost, manure, and other waste. Unknown to these farmers, the physical and chemical properties of the biochar in these terra preta soils (“black soil” in Portuguese) were helping to retain soil nutrients that otherwise would have been leached away during the tropical precipitation. In recent decades, interest in biochar has experienced a resurgence as insightful scientists have looked to those same properties that helped biochar mitigate nutrient leaching for utility in environmental remediation endeavors.
What is biochar? Analysis of the name likely draws up images of a burned forest, perhaps a biological experiment involving fire, or a new product riding today’s wave of environmental interest. In summary, when any carbon biomass (e.g., wood waste, plants, or even animal waste) is exposed to high heat in an oxygen-free environment, this biomass converts to a solid, charcoal-like product known as biochar. In this form, the carbon is resistant to decomposition and is chemically stable. Macroscopically, biochar appears as dusty, black charcoal pieces with grains of generally 0.1 centimeters or smaller. But it’s the microscopic properties of biochar that make it unique. Consider a cross-section of a plant under a microscope with all the plant’s xylem, stoma, cells, and other tissues shown in detail. Then, imagine removing all liquid components and leaving only this skeletal framework behind. This solid, carbon-based matrix makes up biochar and instills it with tremendous surface area. This surface area and its generally negative surface charge are the basis for biochar’s environmental applications.
The high surface area and negative surface charge of biochar enable it to adsorb various substances and chemicals. Within the terra preta soils, nitrogen and other nutrients from manure and other wastes would adhere to the biochar’s surface rather than be leached away during rainfall. This maintained nutrient availability to the crops grown by the Amazonian farmers. Similarly, pollutants (particularly those with a positive charge) cling to biochar and can include organic compounds and heavy metals. Pollutants adhering to biochar are immobilized and prevented from entering the water supply—much as a charcoal filter will screen particles from drinking water. Adding biochar has been shown to help stabilize heavy metals in soil and thus may make it a valuable tool in mine reclamation and the treatment of industrial spills.
In addition to stabilizing metals and chemicals, research suggests that the simultaneous adsorption of organic compounds and microorganisms to biochar facilitates metabolic interaction and expedites the degradation of these pollutants. Bioremediation, the use of microbes to clean up contaminated soil and groundwater, may be enhanced with biochar. One method of bioremediation—bioaugmentation—involves the introduction of a concentrated culture of microbes to the contaminated site. The physical application of these microbes requires mixing them with a carrier medium and amending the area of treatment with this mixture. A slurry containing biochar not only acts as an effective carrier but also provides a protective habitat for the microbes within the pores and rough surface of biochar. As aforementioned, biochar’s affinity for adsorbing organic pollutants helps to bring both the organic pollutants and the microbes into association, thus accelerating the breakdown of these toxins. One study found enhanced bioremediation of polycyclic aromatic hydrocarbons when using biochar as a carrier. Other studies have found similar success when using biochar in bioremediation.
Biochar may also be used to control ongoing pollution from agriculture and large-scale industrial processes. Wetlands and biofilters (engineered filtration systems composed of soil, sand, gravel, and plants) are often constructed to treat agriculture and industrial wastewater naturally. Biochar has demonstrated promise in augmenting contaminant removal of wetlands and biofilters when included among the substrates. Simply put, biochar's unique but consistent properties make it transferrable to various remediation methods.
Thousands of years ago, the Amazonian farmers understood little of biochar, except that adding it to soils improved the success of their harvests. Today, we know the properties of biochar and learn how it can be used in other applications. As our technology advances and our environmental standards improve, our environmental needs will evolve. Meeting these needs will require viewing old technology with a fresh perspective. There is no single solution to our environmental dilemmas. However, the investigation of novel ideas, such as biochar for remediation, can help us along the way.
Dan Smith is an Environmental Specialist for Cornerstone Environmental, Health and Safety out of our Zionsville office. His seven years in environmental consulting include experience in environmental compliance, site assessments, monitoring, remediation, and health and safety. When not at work, he can be found hiking, biking, or engaging in other outdoor activities.
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This Month in Environmental History: The Ozone Hole
In May 1985, a group of scientists from a British Antarctic Survey discovered a hole in the (Antarctic) Ozone. Learn more.
While my childhood is mostly gaps or memories created from thumbing through yearbooks or my dad’s slides, I do have solid memories of my first pair of high-top Air Jordans in the fifth grade and the time I peed my pants taking a standardized test in the first grade. I vaguely remember learning that littering was bad for the environment and, later, in middle school, understanding that my can of hairspray might also be bad somehow and looking for the ‘no CFCs*’ labels on bottles at the drugstore.
It was probably my middle school science class before a teacher mentioned the ozone layer and the subsequent havoc that the human population wreaked on the thin part of Earth’s atmosphere that absorbs a portion of the radiation from the sun.
In May 1985, a group of scientists from a British Antarctic Survey (Cambridge) published a ‘letter’ in the scientific journal Nature titled Large losses of total ozone in Antarctica reveal seasonal ClOx/NOx interaction. (Abstract below)
Translation: the discovery of the (Antarctic) Ozone Hole, thought to be one of the most striking indictors of ozone depletion. According to NASA, the depletion of the ozone layer is recognized as on the Earth’s most important environmental issues.
In October 1985, the area of the ozone hole was measured at 7.25 million square miles. Thirty-seven years later in October 2022, it measured 10.23 million square miles. For reference, the entire continent of North America is just over 9.5 million square miles.
Large losses of total ozone in Antarctica reveal seasonal ClOx/NOx interaction
Abstract: Recent attempts1,2 to consolidate assessments of the effect of human activities on stratospheric ozone (O3) using one-dimensional models for 30° N have suggested that perturbations of total O3 will remain small for at least the next decade. Results from such models are often accepted by default as global estimates3. The inadequacy of this approach is here made evident by observations that the spring values of total O3 in Antarctica have now fallen considerably. The circulation in the lower stratosphere is apparently unchanged, and possible chemical causes must be considered. We suggest that the very low temperatures which prevail from midwinter until several weeks after the spring equinox make the Antarctic stratosphere uniquely sensitive to growth of inorganic chlorine, ClX, primarily by the effect of this growth on the NO2/NO ratio. This, with the height distribution of UV irradiation peculiar to the polar stratosphere, could account for the O3 losses observed.
For more information on Federal (Clean Air Act) and International (Montreal Protocol et al) actions to address Ozone Depletion, visit this site.
*chlorofluorocarbons and other Ozone-Depleting Substances (ODS)
Sources: Farman, J., Gardiner, B. & Shanklin, J. Large losses of total ozone in Antarctica reveal seasonal ClOx/NOx interaction. Nature 315, 207–210 (1985). https://doi.org/10.1038/315207a0
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Sustainability and the Increasing Demand for ESG Reporting in Business
A growing number of investment groups, businesses, employees, and other relevant stakeholders are starting to ask companies about their sustainability and ESG (Environmental Social Governance) metrics. Some companies are even receiving requests to disclose their sustainability performance through various ESG reporting frameworks. Many companies find themselves unprepared to respond to such questions.
To better understand this trend, it is important to understand what sustainability and ESG are. Why should companies care about these concepts? Why are stakeholders asking about sustainability programs and requesting ESG disclosures through reporting frameworks? What are these ESG reporting frameworks? All these questions and more will be answered here.
What is sustainability and ESG?
Sustainability is commonly defined as the ability to meet the needs of the present without jeopardizing the ability of the future to meet its own needs (United Nations Brundtland Commission). While sustainability is usually associated with the environment and topics such as climate change, renewable energy/energy use, and water use, this is only one-third of what makes up sustainability. The other two parts of sustainability consist of the economy and society. These three parts, often referred to as the three pillars or spheres of sustainability, are interconnected. Doing something in one sphere can affect (for better or worse) the other two spheres. The idea of sustainability is to affect all three areas in a positive way.
ESG falls under the umbrella of sustainability and is very similar. So much so that, for all intents and purposes, the terms could be used interchangeably. The difference, however, is that rather than looking at the economic side of things, ESG looks at the governance of an organization through scopes such as data management, anti-corruption, and other policies and procedures. ESG is mostly used in business settings and functions as a more quantifiable type of sustainability, with ESG metrics providing an easy way to measure and compare sustainability performance. ESG disclosure refers to the process of publicly reporting an organization’s sustainability and ESG performance. Organizations tend to either: 1) release a Corporate Social Responsibility report detailing their sustainability performance over the past year, or 2) disclose the relevant information in accordance with one or more ESG reporting frameworks.
Why should companies/organizations care about sustainability and ESG?
Aside from the benefits to the environment and society, sustainability can also benefit the business itself. Many sustainability and ESG-related initiatives are aligned with business goals, at the same time, just as many business-related initiatives can be aligned with sustainability and ESG. The difference lies in the intent behind the initiative. The following are real-world examples of initiatives that address both sustainability and business goals:
Reducing the number of natural resources needed (or wasted) to manufacture a certain product can benefit the environment by conserving those resources but it also benefits the company by reducing overall costs.
Diversity, Equity, and Inclusion initiatives address the governance side of ESG but can also benefit the company itself. As a result of such inclusivity, existing employees may decide to stay and prospective employees may decide to join, thus improving talent acquisition and retention.
Assisting the local community through a food drive or community service event addresses the social side of ESG while also benefiting the company through a positive brand image, possibly helping to cultivate beneficial community connections.
Many environmental regulations are aligned with sustainability to some degree. Therefore, by pursuing certain sustainability initiatives in these areas of regulation companies can be better prepared for any stricter regulations if they come. Furthermore, there is the potential for these companies to qualify for some financial or tax incentives based on different ESG metrics or for implementing different sustainability initiatives.
ESG metrics are important for any organization or business to consider. Various ESG metrics can help identify areas of improvement in a company as well as potential problems before they become serious. ESG metrics are also helpful for tracking progress in a company's sustainability performance. Disclosing ESG metrics and sustainability performance is important for improving transparency, something a greater number of stakeholder groups are looking for in a company.
Sustainability efforts and ESG can also trickle down (or, rather, up) from clients to companies, from companies to their suppliers, and vice versa. If a company or supplier can’t meet their clients’ needs for sustainability, they may lose those clients to another firm that can. Overall, businesses that disclose their ESG performance and/or make efforts to improve their sustainability gain an advantage over their competitors.
What are ESG reporting frameworks?
ESG reporting frameworks help stakeholder groups understand how sustainable a company is by providing measurable and quantitative metrics; thereby enabling comparisons to be made between similar companies as well as displaying measurable improvements to a company’s sustainability efforts.
There are several major ESG reporting frameworks currently being used: GRI Standards, SASB Standards, CDP, and TCFD. Although there are other reporting frameworks out there, those listed above are perhaps the most common.
GRI (Global Reporting Initiative) Standards were some of the first ESG reporting standards to be developed and GRI remains one of the most prevalent ESG frameworks. There are about 32 reporting standards from three sections: environment, economy, and people (though not all of these standards need to be addressed or reported on). Organizations that are reporting in accordance with the GRI standards need only prioritize reporting on their material topics; topics that represent an organization’s most significant impacts on the environment, the economy, and people and their human rights.
SASB (Sustainability Accounting Standards Board) Standards consist of 77 standards for various industries, all of which are focused on the ESG issues most relevant to the financial performance and enterprise value of an organization.
TCFD (Taskforce on Climate-related Financial Disclosures) does not have any standards but rather recommendations for climate-related disclosures around four key company areas: Governance, Strategy, Risk Management, and Metrics and Targets.
CDP (formerly known as Carbon Disclosure Project but now just CDP) consists of three questionnaires for ESG reporting: Climate Change, Water Security, and Forests. An organization can report through one questionnaire or all of them. When completed, organizations are provided a letter grade based on the quantity and quality of questions answered. CDP reporting is completed annually and, in order to qualify for a grade, must be submitted mid-year.
While many of these frameworks differ in the level of detail and information required, they also tend to overlap, working together to achieve their common goal of improved transparency. For example, the climate-change questionnaire for CDP actually addresses all the recommendations from TCFD. This allows organizations to report through CDP while also reporting in line with the TCFD recommendations.
Why are stakeholders asking about sustainability and requesting ESG disclosures through ESG reporting frameworks?
As sustainability has grown in demand, investors, businesses, and other stakeholder groups have started taking it into account when making business decisions. People are becoming more environmentally and socially conscious if only to protect their bottom line. As a result, companies and businesses unable to keep up may lose out on valuable investors, clients, or even employees to competitors that are more sustainable (or at least transparent with their ESG metrics). Companies wanting an extensive sustainability report may request relevant ESG metrics or a complete ESG report from each of their suppliers and distributors in order to determine the full extent of their environmental and social impact. Recently, major automotive companies have requested that their suppliers disclose annual greenhouse gas emissions through an ESG framework or other reporting forum.
Automotive manufacturers, however, aren’t the only ones requesting their suppliers conduct ESG audits. In November, the White House administration proposed a new rule that could roll out in 2023: the Federal Supplier Climate Risks and Resilience Rule. This rule would require federal contractors receiving more than $50 million dollars in annual contracts from the U.S. Federal Government to report their greenhouse gas emissions and assess their climate risks through CDP. Federal contractors with annual contracts between $7.5 and $50 million dollars would only be required to report on their scope 1 and 2 greenhouse gas emissions. On top of this, there is a proposed ruling from the U.S. Securities and Exchange Commission (SEC) about requiring ESG-related metrics in company disclosures.
In general, sustainability and ESG are likely something that companies and organizations will be seeing more of soon, regardless of regulations. Sustainability isn't just about social and environmental impacts, but also about bettering the economy and business as a whole.
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Occupational Exposure to Crystalline Silica: Possible Revisions
There are 2.3 million people in the U.S. alone that are exposed to silica at their workplace. Silica can be found in materials like sand, stone, concrete, and mortar which are in products such as glass, pottery, ceramics, brick, and artificial stone. High exposure to silica can result in diseases like Silicosis, lung cancer, chronic obstructive pulmonary disease, and kidney disease. The action level OSHA established is 25 µg/m3 and the permissible exposure limit is 50 µg/m3.
On March 25, 2016, OSHA made a final decision regarding occupational exposure to respirable crystalline silica. The standard established much needed action levels and permissible exposure limits which are calculated based on an eight-hour time-weighted average. The standard, however, did not establish a medical removal provision and only established medical surveillance provisions. Medical removal provisions are important for OSHA recordkeeping because if an employee meets or exceeds the limits during their medical surveillance, the employee must be removed from work. When an employee is removed from work for a medical condition or after surveillance, it is considered a recordable injury/illness due to an employee accumulating days away from work or restricted work. As of January 2023, there is not an established medical removal provision for crystalline silica, but there is a strong possibility this may change this year.
In the Spring of 2022, the U.S. Court of Appeals for the District of Columbia Circuit concluded that OSHA failed to explain why a medical removal provision was not included in the 2016 decision. As a result, a meeting to discuss further consideration was created and deliberation is currently scheduled for May 2023. If the change is made, it would have a major impact on industries across the country.
The importance of adding a medical removal provision, from an OSHA recordkeeping and employee health standpoint, is apparent but this doesn’t include a company’s financial and employee and employer relations point of view. Hypothetically, let’s assume that a company’s grinding operation exposes a dozen associates to a level where they are required to be medically removed from work. The grinding operation would need to be halted completely until certain controls have been made to reduce exposure for associates to continue working. Depending on the severity of the exposure, this could take months or even years to install equipment or create a respiratory protection program that reduces or eliminates exposure. This same company would also have to communicate this information to their employees, who may choose to leave due to unhealthy working conditions.
This potential change is one of many examples of why air sampling monitoring is vital to maintain a safe work environment. Silica monitoring should be completed at least on an annual basis or whenever there are process changes that may affect employees’ level of exposure to silica. In most cases, air sampling monitoring for silica can be completed in a single day with results coming back within the same month. Lastly, whether a medical removal provision is added or not in May 2023, there is a strong likelihood one will be established in the future, so getting a head start on monitoring and, if necessary, creating exposure controls will help long term.
Tyler Sandy is a Health and Safety Specialist and consults with clients in the area of worker safety. Tyler's experience includes industrial hygiene services, safety training, RCRA as well as OSHA and EPA compliance. His experience includes working with the packaging industry, railroad, welding, warehouse, food and medical waste, chemical manufacturing, and casting.
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Is Your Environmental Program Getting the Recognition It Deserves?
Companies have made significant strides over the past decades to achieve regulatory compliance. As of late, more and more businesses have been highlighted in the media for going above what is asked of them in an effort to become stewards for environmental consciousness. One of the most effective means to accomplish this goal is to implement an Environmental Management System (EMS). An EMS provides the framework to develop your system for maintaining compliance with environmental regulations by establishing a set of policies and procedures to follow. The EMS reduces the guesswork and unwanted actions that sometimes occur in daily operations which can lead to non-compliance issues.
Many state agencies promote regulatory compliance through voluntary programs that provide instruction on how to implement an EMS and encourage participation in a range of recognition programs. For example, Indiana sponsors the Environmental Stewardship Program (ESP) and a Governor’s Award for Pollution Prevention. These are separate programs, but both are intended to recognize regulated entities that go above and beyond current environmental regulations.
Applications for these programs can be tedious and time-consuming and can get lost in the shuffle of your other daily routines and responsibilities. Cornerstone’s team can assist in exploring these state-specific recognition programs and, after working with your team to determine which program best fits your needs, scoping the project to keep it manageable. Additionally, we can assist in completing and submitting the application for a recognition program in your state.
Our Division of Quality Management Services has decades of experience in every aspect of developing an ISO 14001 EMS as well as other comparable programs. In addition to full-service implementation consulting, we offer the following services:
Aspects and Impacts – Conduct onsite evaluations and written findings.
Policies and Procedures – Drafting and oversight of policies and procedures.
Application Submittal – Completing and submitting applications for approval.
Audits – Conducted at specified intervals for program compliance by a third party.
Projects – Sustainability projects with carbon footprints, energy audits, waste to energy, and solar.
Contact Cornerstone for support in meeting your Environmental Recognition Program and be the leader in your state.
Bill Hess is Cornerstone’s Manager of Business Development, Northern Midwest Region. He has been on a career path in Sustainability for more than 40 years and just celebrated 22 of those years with Cornerstone. He specializes in ensuring our clients have the resources they need for Environmental Management, Safety Culture Improvement, Loss Prevention, ISO Services, Safety Training, Industrial Hygiene Services, and SDS (MSDS) Management.
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Safety Signs 101: Understanding the Basics
Improper hazard communication including failure to properly follow safety sign regulations is one of the top 10 workplace violations cited by OSHA and contributes to thousands of workplace accidents each year. OSHA standard 1926.200 indicates that appropriate signage must be visible when performing work in at-risk areas. OSHA regulation 1910.145 tackles the specifications for accident prevention signs and tags. It discusses the different categories, colors, wording, and tags of signs.
Regularly checking the accuracy and visibility of safety signage at your facility is one of the easiest and most effective ways to prevent workplace injury. In fact, studies indicate that well-placed safety signs can minimize workplace accidents by up to 80%. This article will review standard 1910.145 to help you stay in compliance.
Categories and Colors
Danger Signs
Danger signs indicate immediate danger and that special precautions are necessary. The colors of the sign are red, black, and white. The image below is outside a construction site where there is a danger of falling objects. Therefore, as a safety precaution, hard hats must be worn in that area.
Caution Signs
Caution signs warn against potential hazards as well as against unsafe practices. The sign should be yellow with black lettering. The example below is of the wet floor sign we often see placed on freshly mopped floors of businesses.
Safety Instruction Signs
Safety instruction signs are used where there is a need for general instructions and suggestions relative to safety measures. The background should be white with a green panel and white letters. Any letters used on the white background should be black. You’ll often see the green signs around eyewash stations, safety showers, and exits.
Slow Moving Vehicles
If you have ever traveled in the Midwest during planting or harvest season, there is a good chance you have gotten stuck driving behind farming equipment. You might have noticed a triangle emblem on the back. Vehicles with a speed of 25 mph or less on public roads are considered slow-moving and are therefore required to display the triangle emblem. To make the sign visible both during the day and at night, the emblem is fluorescent yellow-orange with a dark red reflective border.
Wording
The wording of all signs follows the same general rules. If there is text, it must be clear, simple to read, and easily understood. The language must also be accurate and make a positive suggestion. The word "biological hazard" or "biohazard" must only be used to refer to infectious pathogens that are a danger or potential risk to human health.
Accident Prevention Tags
A tag is a label typically made of cardstock, paper, pasteboard, plastic, or other material that is used to classify a hazardous condition. Tags consist of a signal word and a major message. A signal word is intended to catch the pedestrian’s attention and should be able to be read from at least five feet away. Signal words include "Danger," "Caution," "Biological Hazard," "BIOHAZARD," or the biological hazard symbol (see below). You might also see “Warning” which can be used if the hazard level is between “Caution” and “Danger.” A major message identifies the hazardous condition or instruction for the employee and can be in the form of written text, pictographs, or both. Examples are “High Voltage” or “Do Not Use.” A pictograph uses pictures to represent a hazardous condition. With the help of tags, hazardous situations can be recognized and a warning to workers can be issued.
Conclusion
While this is not intended to be an exhaustive list of all the regulations relating to safety signs, it is a good basic introduction to the OSHA standards for signs. For more information, the ANSI standards Z53.1-1967 and Z535.1-2006 provide additional details on the regulations as referenced in the OSHA standard. If you would like to learn more about sign regulations, additional OSHA regulations regarding signs are referenced below.
1910.146 (c) – requiring signs for confined spaces
1910.335 (b) – electrical hazard signs
1910.37 (b) – signs for exits
1915.16 – employee comprehension of signs and labels
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Back and Neck Pain: Is Your Posture To Blame?
Is it not uncommon to hear someone complain about a sore back or a stiff neck. While many people experience these discomforts, very few give their posture much thought. Your posture, however, has an impact on your life both inside and outside of the office. As a matter of fact, the cause of your discomfort may very well be due to poor posture. Here are some questions to keep in mind throughout the day to help evaluate your posture.
While sitting, ask yourself:
Are your shoulders back?
Is your back straight?
Is your head in line with your back?
Are both your feet flat on the floor?
Are your knees at a 90-degree angle?
If using a keyboard or mouse, are your arms at a 90-degree angle with your wrists flat?
While standing, consider:
Are your shoulders back?
Is your back straight?
Is your head in line with your back and not titled to look at a screen?
Are your hips level?
Are your feet shoulder width apart?
Are you engaging your abdominal muscles?
If you answered no to any of those questions, that’s okay! Even I answered no to some questions. It does mean, though, that your posture could use some work.
Maintaining proper posture will help you avoid injuries and muscle pain that can prevent you from working or doing household chores. Your muscles work more efficiently with good posture.
Here are some tips to have better posture:
Take a wall test.
Stand with your heels roughly 4 – 6 inches from the wall with your shoulder blades and buttocks touching the wall. Measure the distance between your neck and the wall. Repeat with your lower back. Both measurements should be 2 inches or less.
If there is too much space between your back and the wall, engage your abdominal muscles a little more.
If there is not enough space or you have no space between you and the wall, arch your back enough so that you could fit your hand comfortably in the gap.
Create mental reminders to check your posture.
Every time you are stopped at a red light, think about your posture.
Put a sticky note on your monitor at work to remind you to sit correctly.
When you enter a new room, think about your standing posture.
On your phone or favorite device, add a daily digital reminder to correct your posture.
Replace standard equipment with products that have an ergonomic design.
Keyboards, computer mice, desks, footrests, gardening tools, and even snow shovels have an ergonomic option. Next time you go to purchase an object, see if there is an ergonomic option.
Strengthen your muscles
Do some yoga or Pilates to help strengthen your muscles and improve your posture.
It is never too late to improve your posture. It takes work and dedication to continually have good posture. Just taking a few minutes each day to remind yourself about your posture could make a big difference in your neck and back pain.
Recent Posts
Risk Assessment: The Starting Point of Health and Safety Management Systems
Starting at the Beginning
Over the past couple of years, the focus on a systematic approach to worker health and safety has never been greater. Whether due to unprecedented illness records due to the pandemic or a greater focus on how their workers’ health impacts a company’s sustainability, it is something that is gaining momentum. A key first step in creating the basis for an occupational health and safety management system is to assess the risks that a company faces. This assessment is the starting point to controlling risks and keeping workers healthy and safe.
Tackle the Most Important Things First
One of the key advantages of a risk-based approach is that the most important and risky things are worked on first. Every organization has a limit to their available resources. Allocation of these resources is critical. Traditional job hazard analysis does not provide as distinct of a list of priorities as using a risk-based approach. Hazards are simply identified for control with little or no explicit ranking of needed action. Incorporating risk analysis into job hazard analysis is the key to prioritizing controls to best utilize resources.
Take Advantage of Worker Participation
Cornerstone begins the task of evaluating worker health and safety hazards and their risks with a risk-based workplace hazard assessment. This is a cooperative practice with the workers who face the hazards. Along with HSE managers and supervisors in the work areas, each job and its tasks are assessed to determine the hazards present. The team then determines the risk of negative outcomes from each task by judging the severity and probability of the negative outcome. They assign a numerical score to each risk and the product of those gives us a risk level for each hazard.
Control the Risks
We determine an acceptable risk level with the team and anything that exceeds that level requires action. Our staff will then determine required or recommended controls for each hazard. We use the US OSHA (Occupational Safety and Health Administration) Hierarchy of Controls to guide this part of the assessment. In the end, Cornerstone Health and Safety evaluators produce a prioritized list of needed controls. Those hazards with a higher risk level demand more urgent action. This action is designed to reduce the risk level. Either through eliminating the hazard, minimizing the severity, or decreasing the probability, the list of hazards and their risk level shifts as controls are implemented. This automatically shuffles the priorities so that, again, the highest risks are controlled first.
Whether done to conform to an ISO Standard, for ESG (Environmental, Social and Governance) efforts, or simply to improve as a corporate citizen, the development of a formal occupational health and safety management system is more and more commonplace. Nearly all formal standards rely on a risk-based analysis of hazards as a starting point for the system. These analyses help organizations identify all the hazards, determine the level of risk they present, and prioritize them for action. Talk to Cornerstone more about how we can help you in your efforts to continually improve your occupational health and safety management system.
Recent Posts
Environmental History: DOCUMERICA
From what I’ve been told, I’m right on the cusp of being either a Gen Xer or a Millennial -- a Xennial as it were (that weird micro generation born between 1977 and 1985). I tell you this because it’s important to note that cell phones weren’t in existence during my youth and disposable cameras didn’t become widely affordable until my teens. My dad took his ‘good’ Nikon everywhere and fancied himself an amateur photographer. He was good at it too (still is), especially outdoor photography. He’d have the film developed on slides which filled countless carousels. Then, he would pull out a wall-sized, retractable screen to entertain viewers with family slideshows.
Gas shortage 6/1973
As you might guess, imagery and the art of photography became ingrained on me. I have always adored old photographs. Black and white, sepia, vintage, full color…I just love it. I think “Why? Why this shot?” “What compelled the photographer to shoot this?” “Did this scene or these people mean something to them?” “What was it?” And, photos of people are even more intriguing to me! Just the same, when I came across the DOCUMERICA Project, I was absorbed! (and, I think you will be too…
For the DOCUMERICA Project (1971-1977), the Environmental Protection Agency (EPA) hired (at $150/day + film and expenses) freelance photographers to “photographically document subjects of environmental concern”, EPA activities, and everyday life across the United States in the 1970s.
The collection reports over 22,000 photographs in the U.S. National Archives and they’ve digitized more than 15,000 photographs from the series Documerica (Local ID 412-DA) and included them in an online catalog.
I encourage you to visit the catalog linked above. It’s an addictive time capsule of imagery. The visuals are haunting, beautiful, and compelling.
Recent Posts
Make Sure Your EHS Recordkeeping is "Turnover-Proof"
It happens all the time... an inspector from EPA or OSHA goes to a facility and asks for copies of required documentation and compliance records.
What happens if you are new to your position and are asked to produce those documents?
You're certain that the previous EHS Manager kept them ‘somewhere’, but you don’t know where. You fumble around at an unfamiliar desk, rifle through a couple of file cabinets, and frantically click files in your company’s shared hard drive. While you are doing that, the regulator is getting annoyed, looking around, and thinking of other questions he or she is now going to ask you.
If the information had been readily available, you could have had them out the door already but, instead, you’re scrambling to locate anyone who might know where the information is stored.
As the economy continues to return to normal and a demand for higher wages increases in many sectors, employee turnover has become one of the biggest issues manufacturing companies must address. It isn’t only hourly employees leaving for greener pastures. EHS personnel are finding new opportunities as well.
So, what happens when they leave and take all their knowledge with them?
Develop a Team to Manage EHS Recordkeeping
EHS recordkeeping requirements don’t stop just because you lose the expertise you’ve come to depend on. If your facility is still operating, you must continue to keep records as required by federal, state, and local regulations. One of the issues that I run into as an onsite environmental auditor is facility personnel not knowing where the records are kept. When longtime EHS personnel leave, many times you don’t know what you don’t know. So, you don’t know what to ask. In other words, when that employee is gone, so are years of institutional knowledge about who submits Tier II reports, who collects used oil bills of lading, who completes stormwater sampling, etc.
One way to prevent this is to create an internal storage system controlled by one person but accessible by many. Have your EHS Manager train two or three people on how to access information in your system. Have those two or three people assess the system and make changes based on their suggestions. One person controlling a recordkeeping system will almost always lead to confusion when someone else tries to use it. Use plain language in file descriptions and group things by media (air, water, hazardous waste, SDSs, HazCom, etc.) and by year.
Have your IT team create a file structure to store those records that is accessible by authorized personnel and regularly backed up to prevent file loss. Make sure that everyone who receives documents (EHS, purchasing, maintenance, quality) knows where those documents are stored. You could even use an outside vendor like Cornerstone and our electronic file cabinet system to help you maintain your documentation. Whatever method you choose to manage this information, ensure it is secure, regularly backed up and that multiple people understand how to access the system.
Turnover is inevitable but you don’t have to be caught scrambling when it happens. Plan for the future by creating redundancy and putting in place a system that can be handed down to the next person.
Recent Posts
Winter Weather Driving Safety Tips
The onset of winter weather brings to mind the obvious hazard of cold stress; however, workers also can be exposed to weather-related hazards while driving.
Winter Driving
Employers should encourage workers to implement safe driving behaviors. The first step should always be to assess the risk of driving in winter weather conditions. Crashes can be avoided if workers recognize the hazards of driving on snow-and ice-covered roads and train to drive safely in slick conditions. Employers should establish driver safety policies; monitor drivers’ safety performance; and enforce driving rules.
To ensure safety, employers must implement an effective maintenance program for all vehicles and equipment operated. A vehicle inspection to determine proper functioning should include:
Brakes: Brakes should provide even and balanced braking. Also check that brake fluid is at the proper level.
Gas Tank: keep the tank at least 1/2 full.
Cooling System: Ensure vehicle cooling systems have the proper level and mixture of antifreeze and water.
Electrical System: Check the ignition, battery, and alternator belt.
Engine: Inspect all engine systems.
Exhaust System: Check exhaust for leaks.
Tires: Check tread depth, signs of damage or uneven wear, proper tire inflation.
Oil: Check oil level.
Visibility Systems: Inspect all exterior lights, defrosters, and wipers. Install winter windshield wipers.
Work Zone Traffic Safety
Workers can be struck by vehicles or mobile equipment in work zones. This leads to many injuries and fatalities annually. During snow and ice events, vehicles can skid causing drivers to lose control. It is important to properly set up work zones with traffic controls identified by signs, cones, barrels, and barriers, to protect workers. Workers also need to wear proper PPE such as high visibility vests, jackets, and pants when entering work zones.
Stranded in a Vehicle
If you are stranded in a vehicle, stay in the vehicle. Call for emergency assistance if needed, but be aware that due to severe weather, response time may be slow. You should also call someone, such as a family member or your employer, and notify them of your situation. Do not leave the vehicle to search for assistance unless help is visible within 100 yards. Signal distress by hanging a brightly colored cloth on the vehicle’s radio antenna and raising the hood.
To help keep warm, turn on the vehicle's engine for about 10 minutes each hour and run the heat. Also, turn on the vehicle's interior lights when the vehicle is running as an additional distress signal. However, you should beware of carbon monoxide poisoning. Keep the exhaust pipe clear of snow and open a downwind window slightly for ventilation.
Watch for signs of frostbite and hypothermia and maintain good blood circulation by doing minor exercises, such as clapping your hands and moving your arms and legs occasionally. Try not to stay in one position for too long. Staying awake is vital so that you will be less vulnerable to cold-related health problems. Use blankets, newspapers, maps, and even the removable car mats for added insulation. However, you should avoid overexertion since cold weather puts an added strain on the heart. Unaccustomed exercise such as shoveling snow or pushing a vehicle can bring on a heart attack or make other medical conditions worse.
Cornerstone's safety experts are ready to help you develop a world-class safety program and train your workers in the latest safety information. Contact us at info@corner-enviro.com for more information or view our website at www.corner-enviro.com
Recent Posts
Health and Safety Sustainability: Does Your Operation Go "Above Compliance"?
Earlier this year, I wrote an article entitled “Where the S in ESG intersects with HS in EHS.” While I stand behind the tenor of that piece, there is one thing I said that gives me some pause. I wrote “Today, compliance with Environmental, Health, and Safety (EHS) regulations is a given. Employers must go beyond compliance.” That statement is true when viewed through the ESG and sustainability lens. But my history with clients, including recent work, has shown that sometimes even the most sophisticated of our clients still falls down when it comes to compliance with OSHA regulations. At times, companies within the regulated community have difficulty remaining in compliance with applicable regulations. So, how can they go beyond compliance to sustainability?
I’ll be the first to admit that compliance with governmental regulations doesn’t always equate to a healthy and safe workforce. Unfortunately, it doesn’t always work that way; however, when regulators discover violations and take enforcement action, investors, competitors, and employees will take notice. You simply cannot have strong ESG performance without a good compliance record.
Take the Hazard Communication Standard (HazCom) for example. Failing to properly label chemicals or not keeping an updated chemical list and corresponding Safety Data Sheets (SDSs) is always one of the Top 10 Most Frequently Cited Standards. In 2020, it was #2 on the list. HazCom has been around since the beginning of my career. You can do some research and see that is a very long time — over 30 years! What that means is that in three decades, many facilities still struggle with basic aspects of labeling and documentation. A recent project at a very large corporate client demonstrated this, when we discovered almost 99% of their chemical list was outdated or missing SDSs.
Another frequently cited Standard is Energy Control (a.k.a. Lockout/Tagout). It was #6 in 2020. We do dozens of projects each year with very large clients, and it is unanimous that if OSHA took even a cursory look at their procedures and training, violations could follow. Conducting lockout, training employees, writing procedures for each piece of equipment, and inspecting the procedures each year is required.
One reason more enforcement doesn’t occur is that OSHA is a very small agency. Inspections fell drastically in 2020 due to the pandemic. In 2019, over 33,000 inspections were conducted. This dropped to under 22,000 in 2020. In early 2021, the Department of Labor Office of Inspector General called OSHA out on this reduction, and everyone agreed that more and deeper inspections were needed. In short, expect more inspections and investigations.
Additionally, in October, Douglas Parker was confirmed as OSHA’s new leader. It bears mentioning that he is a past chief of California’s Division of Occupational Safety and Health (Cal/OSHA). Anyone with experience in California knows the approach taken there to worker health and safety. It is a much more enforcement-focused regulatory scheme. It is likely that some of that scheme will follow Mr. Parker to the Federal OSHA he now leads.
So, the question is, are you ready to go beyond compliance? If you do not have a good feeling about your compliance program, the answer may be “no.” And, if that is the case, what are you risking beyond the health and safety of your workers? If sustainability and ESG performance are what you aspire to, you may be risking investment, growth, and the long-term outlook of your business.
Further Information
As ESG reporting becomes more vital and more publicly transparent, Cornerstone’s industrial health and safety experts can help ensure that your programs and data are ready for the spotlight. Contact us at info@corner-enviro.com or visit our website for more information regarding our ESG services.
Recent Posts
Air Quality Modeling: What Is It?
Frequently, a manufacturing plant or industrial operation may have processes that emit air pollutants into the atmosphere. In most cases, the operation will be required to calculate the potential, and sometimes actual, emissions and present the findings to their State’s environmental agency. Then, the type of emission sources and the potential and/or actual emissions rate will be used to determine if an air permit is required. The State will also review the sources and emissions and apply specific regulations to the plant to allow those emissions to be released into the environment. This information will typically be summarized and included in an air permit. Additionally, depending upon the amount or nature of the emissions, the permit may include requirements for controls or limits on emissions.
In some cases, a regulatory agency may ask an operation to present information beyond the amount of calculated air emissions released into the atmosphere. The plant may have to determine what the impact of their emissions is on the surrounding community. When an operation has the potential to release chemicals that, in high concentrations, could cause unhealthy conditions, State regulatory agencies may require an estimate of downwind effects of air pollution emissions. This is accomplished by using air quality modeling.
How do you calculate downwind air pollutant concentration?
Calculating the volume of pollutants being emitted from a stack is relatively straightforward, however, using air quality modeling to determine the concentration of pollutants downwind of the facility is a more complex process. Air quality modeling uses computer programs to calculate the release of a pollutant into the atmosphere and determine how it disperses as it travels downwind. The program will then calculate the eventual concentration of that pollutant at a certain location.
The U.S. EPA has developed many different air quality models to calculate downwind air pollutant concentrations, and these models vary in size and complexity. Simple air quality models, known as Screening Models, can quickly determine concentrations and require limited information about the emissions and the emission points. Screening Models are relatively quick to prepare, do not require a lot of site-specific information, and will provide general estimates of downwind concentrations.
Other more sophisticated models, known as Refined Models, require more detailed information to generate results. These models use site-specific information, such as local weather data, terrain elevation around the site, and other specifics about the emission sources. Due to the complexity and amount of information required, Refined Models require significantly more set-up time and effort to obtain proper results.
You may ask, “If the Screening Model is so easy to use, why would anyone want to use the Refined Model?” The simple answer is that Screening Models are not as accurate as Refined Models. Usually, Screening Models tend to estimate concentrations on the high end to prevent underestimating the downwind impacts. Screening Models are also very general and are not designed to estimate emissions from complex scenarios. Refined Models are able to model complex situations and are site-specific.
Which model should you use — Screening or Refined?
In most cases, Screening Models are used as a “first step” and, since they tend to overestimate emissions, provide a conservative estimate of concentrations from a source. If the calculated concentrations from a Screening Model show no adverse health effects, then one can assume the emission source will not adversely affect the surrounding environment. If, however, a Screening Model shows concentrations higher than allowable values, all is not lost. A Refined Model can be used to provide more accurate and often lower concentrations, possibly showing that the emission source would not have detrimental effects on the downwind area.
Further Information
Cornerstone can help you determine whether air quality modeling is necessary for your facility. Our team of experts has provided clients with both Screening and Refined Modeling analyses to assist them with State agency modeling requirements and other studies. For more information about our air quality services, please visit our website or contact us to discuss your specific needs.
John Nuckels, Sr. Environmental Engineer
John helps clients with the preparation of air permits and supports them in responding to inquiries by State permitting agency personnel. His expertise in air quality monitoring, stack tests, recordkeeping, and reporting assists clients in achieving and maintaining air quality compliance. Industry experience includes aerospace, aluminum, motor vehicle / automotive parts, government, plastics, military, and other manufacturing clients in both public and private sectors.
Recent Posts
The Value of Ergonomics for your Business
By Mary Dunlap, CIH Ergonomics, defined simply, is fitting a job to a person to reduce the risk of strains and injury to muscles, tendons, and ligaments, also known as musculoskeletal disorders (MSDs). The human costs are the best reason for preventing MSDs, but the financial burden to businesses cannot be underestimated. A 2018 survey of days away from work from the U.S. Bureau of Labor Statistics determined that 30 percent of cases were due to MSDs and that MSD cases require 38 percent more lost time days than typical injuries and illnesses. The direct costs associated with a sprain, strain, or hernia type injury can cost a business between $28,000 and $32,000 for medical treatment to resolve the injury. However, the medical costs are only part of the story and do not include indirect costs such as work stoppage, overtime, training of new employees, legal costs, and increased insurance premiums.
What are the benefits of ergonomics programs?
In addition to keeping workers healthy, there are many added benefits to implementing an ergonomics program that ultimately can make a business more profitable and attractive to potential business partners, highly qualified new employees, and outside investors, including:
Reduced costs associated with treating MSDs
Reduction in lost workdays and the length of long-term absences
Lower employee turnover and costs associated with replacing an employee
Higher employee engagement and focus on work quality
Increased productivity and efficiency
Reduced costs for correcting defects
Creating a safety record that is attractive to lenders and outside investors
When ergonomics is regarded as an important part of the operational process, employee engagement is enhanced, as is productivity and work quality. When an employer places value on the ability to perform the job comfortably and efficiently, employees feel respected. From this respect, workers are much more likely to be engaged in their work. With this engagement, comes regard for the quality of work they produce and a willingness to participate in improving processes and performing the work more efficiently. It has been estimated that even a simple improvement can result in a one-percent increase in quality and a five-percent increase in productivity. As attention to detail increases, the defect rate goes down and, with that, the costs for correcting the defects. Safety and sustainability have become very important aspects of how companies operate and are key environmental, social, and governance (ESG) indicators that lenders and investors consider when assessing business performance, assigning corporate credit ratings, and considering new investment opportunities. It is common practice for investors and lenders to request disclosure of injury rates. The top 29 companies that have earned safety culture awards have been found to consistently outperform the S&P 500 stock index.
What are the risks of workplace injuries?
The major risk factors for musculoskeletal disorders are:
forceful exertions involving with lifting, lowering, carrying, pushing, and pulling
repetitive movements, encountered when job cycles are less than 30 seconds long and when the cycle is repeated two or more times in a minute
awkward postures that result from poor equipment or the workspace design, not having the right tool to perform a job, and lack of worker awareness of how to properly move and position their body when performing a task.
Of these factors, the Occupational Safety and Health Administration (OSHA) has estimated that 25 percent of non-fatal occupational injuries result from forceful exertions primarily associated with material handling. The costs associated with treating MSDs can be significant when an injury occurs. Such injuries often result in multiple trips to a doctor or clinic, physical therapy appointments, and even surgery. In addition to treating the injury, lost workdays and sometimes long-term absences create staffing issues which increase overtime costs and losses in production. Additionally, job duties sometimes require modification to accommodate an employee who has been injured. When job tasks remain at risk for injury, there are not only lost workdays directly related to injuries but often there is also an increase in “casual absenteeism”. When strains or injuries are common, workers simply do not want to do the job. As dissatisfaction increases, so does the rate of employee turnover and the costs for replacing an employee. On average, it costs a business 20-50 percent of an employee’s salary to find and train a new employee replacement.
What is included in an ergonomics program?
Ergonomics programs and tools can make a big difference in the comfort, safety, and well-being of workers as well as add money to your bottom line? Actions can range from the simple to the complex and may include:
Implementing a daily stretching program for employees
Frequently rotating workers that perform repetitive jobs during a shift
Providing work surfaces that are the right height for the job
Reducing reach distances for parts or tools
Providing the right tools and equipment such as lift assist devices
Designing new workstations and equipment to best fit workers and their job tasks.
Coach and train employees how to properly position their bodies when lifting and performing tasks to avoid strains and injuries.
Further information
Cornerstone’s Health and Safety department can perform a Worksite Analysis to observe operations, job tasks, and work practices for ergonomic safety. As a Certified Industrial Hygienist, I can provide reports of risks, prioritize areas for changes, and recommend control measures. Contact Cornerstone at info@corner-enviro.com or on our website for more information. Mary Dunlap, CIH, is a Senior Industrial Health and Safety Specialist and Certified Industrial Hygienist. She works with Cornerstone’s clients to develop exposure assessment strategies tailored for their work environments. She regularly performs ergonomic assessments using a variety of OSHA and NIOSH tools to rate severity of risk for work related to musculoskeletal disorders.
Recent Posts
Where the S in ESG Intersects with the HS in EHS
By John Scifres Environmental, Social, and Governance (ESG) rating is all about the long game. Industry has learned if they are to stay in business and thrive in today’s world, they must be sustainable in all facets of their culture. For our Health and Safety Division, the “social” portion means offering our client’s the best tools to take care of their workers. Today, compliance with Environmental, Health and Safety (EHS) regulations is a given and employers are expected to go beyond compliance in their worker safety efforts. The links between employee health and safety, morale, loyalty, and retention are undeniable. Healthy, happy, loyal, and experienced workers make for a sustainable business. Today’s investors know this and demand it from the companies they want to back. Cornerstone helps to improve ESG metrics by maximizing worker health and safety with a stepwise approach from assessment to training.
Assessment
The first step in our Health and Safety Management System services is a baseline assessment of Compliance to get the feel for where a company is in the spectrum from Compliance to Sustainability. It is a Gap Analysis of sorts, but it gives our experienced evaluators a feel for what they have to work with. We present our clients with a detailed report of regulatory applicability including a finding of compliance or non-compliance for each element. For those areas that need work, a Findings and Corrective Actions Summary becomes a compliance punch list that can be attacked quickly and systematically to bring the site into compliance. We can couple a Compliance Assessment with a Culture Assessment to dive even further into needed actions to improve the “S” in ESG. Either along with or as a result of the assessment, Cornerstone then begins the task of evaluating worker health and safety hazards and their risks with a Risk-Based Workplace Hazard Assessment. The goal of this is to assess each job and its component tasks to determine the hazards present. Our evaluators determine the risk of negative outcomes from each task by judging the Severity and Probability of the negative outcome. They assign a numerical score to each and the product of those gives us a Risk Level for each hazard. Of special note is our Ergonomic focus. A critical part of workers’ health and safety is how they feel and move while accomplishing their jobs. Using the risk assessment data our ergonomics team monitors employees in each workstation to ensure a practical solution to complex ergonomic issues.
Control
Generally, we determine an acceptable risk level with the client and anything exceeding that level requires action. Our staff then determines required or recommended controls for each hazard. We use the U.S. OSHA Hierarchy of Controls to guide this part of the assessment. In the end, Cornerstone Health and Safety Evaluators produce a prioritized list of necessary controls. Those hazards with a higher risk level demand more urgent action. Controls often include the development of administrative policies, procedures, and programs. Cornerstone works hard to develop these along with stakeholders at every level of the company. The information gathered during previous steps guides this process. It can range from something as simple as protective gloves to Injury and Illness Prevention Plans and the establishment and facilitation of Health and Safety Committees. Worker Health and Safety training and coaching are integral to making these Administrative Controls come to life.
ESG Reporting
While the methods to arrive at an ESG rating differ, they all have the same end goal in mind; to identify those companies that consider their human resources as a long-term investment in their success. Data from government reports of compliance, worker injury audits, and worker experience of every sort regarding compliance and culture all play into ratings. Everything we do helps our clients prove to the world through ESG score that they are a sustainable business. This is never more evident than in our approach to worker health and safety. We carefully determine compliance gaps, rate the risk of everything done at a client’s operation, and then work closely with all levels of employees at the facility to ensure that compliance obligations are met, hazards are controlled, and workers go home at the end of their workday in the same condition that they arrived. And, we do this over time with the overall goal to continually improve all factors that play into an ESG rating.
Further Information
As ESG reporting becomes more vital and more publicly transparent, Cornerstone’s industrial health and safety experts can help ensure that your programs and data are ready for the spotlight. Contact us at info@corner-enviro.com or through our website.