Organic solvents are used in the metal manufacturing industry for removing grease from metal objects. However, the inhalation of solvent vapours can pose health risks. Metallbau Wastler GmbH assessed the risks and replaced the harmful solvent by a watersoluble chemical in order to avoid skin allergies.

The task

Metallbau Wastler GmbH is a manufacturer of metal structures. The metal manufacturing industry uses toxic substances for the grease removal process. Grease removal is the process in which grease and adhesive material are removed from the surface of metal prior to painting and varnishing. One of the most widely practised types of grease removal carried out in the industry is grease removal using organic solvents. Solvents are particularly suitable for cleaning and for dissolving products that are not water-soluble, such as grease.

The risk

Repeated or prolonged skin contact with solvents can cause the skin's natural oils to disappear and can consequently produce rashes, drying and cracking of the skin, itching, etc. Furthermore, these solvents have a tendency to cause allergies, to irritate the lungs, the eyes and the respiratory tract, and to affect the blood count.

Besides this, there is a danger of fire or explosion if the solvent is used in enclosed spaces, and storage is difficult because of restrictions on quantities.

The solution and methodology

Metallbau Wastler is aware of the risks caused by the use of solvents and performed a risk assessment based on the procedure put forward by the Allgemeine Unfallversicherungsanstalt AUVA. AUVA together with trade unions, employers' organisations and R&D institutes developed a risk assessment procedure which is made available to all Austrian enterprises. The basic data are assessed with the help of safety data sheets, Risk-phrases and the matrix method. About 100 companies from Upper Austria participated in this sector project. About 1/3 of the participating companies could be motivated to substitute the dangerous substances.

The working procedure was analysed in the course of an environmental project through an external consultant. After assessment and evaluation of the chemical substance, the replacement of the organic solvent was suggested and the water soluble chemical "Tarco Super" was presented.

This chemical has the same grease removal qualities as the solvent but is harmless to health and the environment. In general, the working conditions have been improved.

The effectiveness of results

The substitution has proven extremely effective, since the risk of skin allergies and other health and safety problems is completely eliminated. The water soluble chemical has the same grease removal qualities as the organic solvent and is less dangerous for people's health and the environment.

The employee involvment

The employees participated in the assessment of the situation. Each employee received training on the use and the characteristics of the new substance.

The costs and benefits

It was not possibly to identify measurable results with regard to a reduction in the number of accidents. However, benefits could be observed concerning: the removal of the need for investment in a depot for dangerous substances; the prevention of illnesses for the employee; a reduction of the VOC-emissions (volatile organic compounds).

Entrepreneur’s testimony "Our enterprise will meet business management, quality, social, and environmental requirements. Our aims are: - to increase the satisfaction of our customers - to optimise quality - to increase the motivation of our employees - efficient and sustainable use of ressources - to respect existing rules and laws "