Transforming Electroplating Safety: A Case Study in Mitigating Health Risks and Ensuring Compliance

In this case study, we explore a renowned industry leader that has been instrumental in the field of electroplating since 1979. Specializing in applying metal finishes to components for a diverse range of industries - from automotive and aerospace to electronics, medical and telecommunications - the company's broad-ranging expertise and unrivalled quality have made them a go-to partner for clients worldwide.

The organization operates from a purpose-built factory spanning over 2,100 square meters, where a dedicated team of electroplating specialists serves a global clientele. These clients value not only the technical prowess that the team brings to the table, but also their commitment to cost-effectiveness and waste minimization - key considerations in an industry where processes such as gold plating can be costly.

Exposure to electroplating chemicals presents several health risks that need to be carefully managed. Inhalation of acid aerosols and chemical fumes can lead to respiratory issues, including irritation of the nose, throat, and lungs. Prolonged exposure to these airborne contaminants can result in more severe respiratory conditions, such as bronchitis or chemical pneumonitis. Acid aerosols and irritating fumes can also cause eye and mucous membrane irritation, leading to discomfort, redness, and potential long-term damage if not properly protected against.
Chemical splashes and burns pose another significant risk in electroplating operations. The chemicals used in the process can be corrosive and caustic, causing severe burns to the skin upon contact. This can result in pain, tissue damage, and the potential for long-term scarring. Proper personal protective equipment, including chemical-resistant gloves and coveralls, is essential to minimize the risk of skin exposure and burns.

The skin is particularly vulnerable to the hazardous effects of electroplating chemicals. Direct contact with these substances can lead to dermatitis, allergic reactions, and chemical burns. Skin absorption of certain toxic metals, such as nickel or chromium, can also occur, which may have systemic health effects. Implementing effective skin protection measures, such as using appropriate gloves and regular hygiene practices, is crucial in preventing these adverse health outcomes.
By addressing these health risks associated with electroplating chemicals, companies can safeguard the well-being of their employees, reduce the incidence of occupational illnesses, and create a safer work environment overall.
 

Our Method

In our commitment to uphold the highest standards of health and safety, we designed our sampling methods to align with the guidance published by the Health and Safety Executive (HSE) in the UK. Our overall aim was to assess potential operative exposure to hazardous substances encountered during the electroplating process, which involves metals like gold, silver, copper, nickel, lead, palladium, and tin.

Our process involved the use of battery-powered pumps to draw known volumes of air through specific sample media. These pumps were attached to individuals working in the electroplating environment, positioned in their breathing zone to capture a realistic sample of the air they breathe during their shifts. For background measurements, the sample media were placed in static locations across the facility.
 
The sample media used in this case were Mixed Cellulose Ester (MCE) Filters held within IOM cassettes, a proven method for airborne particulate sampling. The sampling methodology followed the NIOSH 7300 method, a well-established approach recognized by the National Institute for Occupational Safety and Health in the United States. This method is specifically designed for the sampling and analysis of metal fumes and dusts in industrial environments.
 
Upon collection, the samples were analysed using Inductively Coupled Plasma Optical Emission Spectrometry (ICP-OES), a technique that provides accurate and reliable quantification of the metals in question. The analysis was subcontracted to Marchwood Scientific Services, a laboratory accredited with ISO 17025, a recognized international standard for testing and calibration laboratories.

By following these rigorous sampling and analysis procedures, we were able to provide a comprehensive assessment of the potential exposure risks faced by operatives in the electroplating industry. These findings then enabled us to recommend appropriate control measures and risk mitigation strategies, fulfilling our mandate to protect health and safety, while also helping the company to meet its legislative obligations under UK law.

Available guidance

There are number of publications available in the UK to health to manage the exposure risk during electroplating operations.

1. "Hexavalent Chromium in Electroplating: Prevention and Control of Chromic Acid Mist": A guide on how to prevent and control the emission of chromic acid mist in an electroplating setting, offering practical solutions to mitigate the risks associated with this hazardous substance.
 
2. "Hexavalent Chromium in Electroplating: Prevention and Control of Skin Exposure Risks": A guidance document highlighting methods to prevent and control the risk of skin exposure to hexavalent chromium, a common hazard in the electroplating industry.
 
3. "Hexavalent Chromium in Electroplating: Monitoring for Exposure": This document provides detailed guidance on how to monitor exposure to hexavalent chromium in an electroplating environment.
 
4. "Nickel and Nickel Alloy Plating Operations: Controlling the Inhalation Risk": This guide focuses on the prevention and control strategies for inhalation risks from nickel and its alloys during electroplating operations.
 
5. "Nickel and Nickel Alloy Plating Operations: Controlling the Risk of Skin Exposure": A comprehensive guidance on how to prevent and control the risk of skin exposure to nickel and its alloys in electroplating operations.
 
6. "Health Surveillance for Occupational Asthma": This guide outlines the steps employers can take to monitor and protect workers from occupational asthma, a potential risk in industries dealing with airborne chemical hazards.
 
7. "Health Surveillance for Occupational Dermatitis": This provides advice on health monitoring for workers at risk of developing occupational dermatitis, a skin condition caused by exposure to certain irritants or allergens at work.
 
8. "Biological Monitoring in the Workplace: A Guide to its Practical Application to Chemical Exposure - HSG167": This guide explains how to use biological monitoring, a method for assessing the absorption of chemicals into the body, to manage the risk of exposure to harmful chemicals.
 
9. "Managing Risks from Skin Exposure at Work - HSG262": This guidance document helps employers understand and manage risks associated with skin exposure to harmful substances at work.
 
10. "Chromium and You: Working with Chromium - Are You at Risk? INDG346": A guide aimed at workers who work with chromium, offering information on the risks and how to mitigate them.
 
11. "Nickel and You: Working with Nickel - Are You at Risk? INDG351": This guide is targeted towards individuals working with nickel, outlining potential risks and precautionary measures.
 
12. "INDG391 - Cadmium and You - Working with Cadmium - Are You at Risk?": This guide provides workers who deal with cadmium with information on potential hazards and safety measures.
 
13. "Preventing Contact Dermatitis and Urticaria at Work": A document outlining steps to prevent skin conditions like contact dermatitis and urticaria, which can be caused by exposure to certain substances at work.
 
14. "Selecting Protective Gloves for Work with Chemicals": This guide helps workers select the correct protective gloves when dealing with chemical substances, ensuring maximum protection.

Our observations and findings

In the various workshops, operating times for staff typically ran from 07:30 – 16:30 with a thirty-minute break. The setup of the workplaces involved multiple lines, where one operative would generally oversee the process per line, with machines running several chemical baths. Notably, these baths contained a variety of chemicals such as caustic cleaner, hydrochloric acid, gold plate, silver plate, copper sulphate, nickel plate, and others based on the specific machine.

Workplace observations showed that all baths were lidded and only opened for inspection purposes, with no visible airborne fumes or mists observed to be generated during production. Local exhaust ventilation (LEV) was fitted at the rear of each bath. There was also noticeable chemical residue on the extraction at the baths.

The use of personal protective equipment (PPE) varied among workers. Although respiratory protective equipment was not commonly worn, it was available along with chemical-resistant gloves. Some workers were observed to wear gloves such as Alphatec Ansell (Type A).

Our study also found that personal exposure to various metals including copper, nickel, tin, gold, and palladium was generally low and below the applicable Health and Safety Executive (HSE) Workplace Exposure Limits (WELs). Background airborne concentrations of these metals were also observed to be low. In Shop 3, exposure to lead in air was found to be below the Control of Lead at Work (CLAW) limit.

In conclusion, while the environment had control measures in place such as LEVs and availability of PPE, there is room for improvements, particularly regarding the usage of PPE and managing certain visible airborne fumes.
 

Recommendations

Based on our observations and findings, we recommend several immediate actions. It is crucial that personnel start using chemical-resistant gloves, particularly nitrile gloves that are 0.4mm thick, to reduce the risk of skin contact with isocyanates. These gloves should be replaced whenever they are damaged or according to the manufacturer's recommended frequency, or after each use.
Furthermore, all operatives should wear safety glasses while working in the main production areas to protect their eyes from potential chemical splashes. Similarly, wearing suitable overalls can help prevent skin contact with plating chemicals, which is a critical protective measure to be implemented.

As for the equipment and work environment, the slotted extraction points of the Local Exhaust Ventilation (LEV) system need to be regularly cleaned and maintained free of chemical residues. This is essential to ensure their maximum efficiency in controlling airborne concentrations of the chemicals.

Finally, for the process involving the gold pot, we recommend keeping the barrier screens lowered during processing whenever possible. This measure could substantially reduce the potential for airborne exposure to gold particles. These recommendations, if adhered to, can significantly improve the safety conditions for personnel involved in the electroplating process.

Value Delivered

The value we have delivered to our client is significant and multi-faceted. Our comprehensive occupational exposure monitoring and subsequent recommendations have provided the client with invaluable insights into the safety and health risks in their electroplating process. This has set the groundwork for a safer and healthier work environment, thus enhancing worker morale, productivity, and retention.

The strategies we suggested, such as the use of protective equipment and enhancements to the LEV system, can mitigate the risk of health issues arising from exposure to harmful chemicals. This will lead to a decrease in health-related absenteeism and associated costs, which will ultimately benefit the business’s bottom line.

Moreover, by following our recommendations, the client is demonstrating a commitment to worker health and safety, which can enhance their reputation among both employees and customers. In today's competitive industry, corporate responsibility and a strong safety record can serve as key differentiators.

Additionally, our assistance will also help the client remain compliant with the Health and Safety Executive (HSE) regulations, thereby avoiding potential penalties and legal issues. Our guidance provides a clear path for aligning their operational practices with the industry's best practices and legal requirements.
 
Our services, thus, present a holistic solution, ensuring the client's business is not only compliant with legislation but also efficiently optimizes its processes for a safer and healthier work environment. This assures the wellbeing of their most important asset: their employees. As a result, they can remain focused on their primary business goals, knowing their occupational health and safety responsibilities are being expertly managed.