Safety Precautions Document

This document is concerned with safety in handling composite materials. This is a very broad subject and cannot be completely covered in this document. Given time constraints, I will continually update all of my information and make it available to anyone that wants it. Some background knowledge of composite construction and techniques will be helpful in understanding this information. I have two documents at this time that deal with fabrication: construc.htm and mold.htm.

Due to my high exposure of toxic resins and materials in the past, I am permanently disabled from working in the field again. I don't want you, the reader, to ever develop this sensitivity, hence the primary reason for compiling this document.

Most people can handle epoxy and urethane resins with no overt effects as long as they limit and control their exposure. Two forms of exposure are: inhalation and skin contact. Both are harmful but your sensitivity and tolerence depend on how long you're exposed.

Always provide good positive pressure ventilation. It's not necessary to wear a body suit, but you cannot work in an enclosed area without a constant circulation of fresh air. It's best to work outdoors if you can. Stay in the shade away from direct sunlight. If you are working indoors, buy yourself a good organic or fresh air mask to wear while you're working. Even with the mask, be sure there is a good positive air flow coming in and going out of the room you are working in, i.e.: a ducted fan blowing air into the room and one drawing air out of the room. You can buy organic and fresh air masks at most automotive paint stores. Several of the aircraft suppliers that I have listed in my mail.txt carry both styles. Fresh air masks are better, but require a greater investment.

Skin exposure is much worse than air exposure and the effects are more pronounced. Symptoms range from swollen eyes and running nose to skin cracking and draining. Be very sure that you work with latex or vinyl gloves and change your gloves frequently. Urethane and Epoxy resins are absorbed into the gloves and after a while you may as well not be wearing any. Watch out for poor quality gloves. A lot of cheap gloves contain pinholes or they are very porous. Gloves like these can be very dangerous. Most of the mail order suppliers I have listed, carry these gloves and they are a very cheap form of insurance.

Be sure and wear long sleaves and long pants when working with these materials. Also, make sure the material is thick enough to protect yourself. Thin shirts and pants absorb resins quickly and will hold them in contact with your skin.

If you do come into skin contact with the resin, wash the affected area immediately. Don't use a solvent to clean your skin; like acetone or laquer thinner. Solvents will cause your skin to absorb the resins much faster. Use a skin cleaner like Go Jo brand cleaner. These are available in most automotive parts houses. Get the waterless variety of cleaner. Clean the area thoroughly, then wash with soap and water.

Be careful of dripping resin on your shoes or clothes and while changing, getting it on your skin. I've done this frequently. I'll get some on my shoes or shirt, then while I'm changing, get it on my arms or hands. This type of exposure can go undetected very easily.

Generally it takes several years to become sensitized to epoxy and urethane resins with a fairly high exposure. I've noticed that people that are allergic to milk and insect bites cannot handle exposure. The symptoms are very similar to having a bad case of the flu. Your eyes become swollen, your nose runs and your chest becomes congested. This is because the allergies promote a hystamine reaction in your body. If these symptoms appear, take Benydril or some other strong anti-hystamine.

With skin contact allergies, your skin will crack and swell but heal very slowly. See a physician for these symptoms. Without proper care, it can take months to heal. It's very rare to have skin symptoms like these. Most of the time they are caused from cleaning the resin from your skin with solvents. The solvents remove the natural oils from your skin and the resin is then absorbed.

I've tried to cover all the basic points concerning safety with handling wet resins, but be warned, the catalyst or hardner used in these resins can stay on the surface of the cured part for several months. This is because the hardners are hygroscopic. They draw moisture out of the air and remain close to the surface of the cured part. Parts that are oven cured are safer than those that are cured at room temperature. Use gloves when handling even after they are cured. Always wash the parts thoroughly with soap and warm water to remove traces of the hardner that migrate to the surface.

Pay special attention to the detrimental effects of improper safety where dust is concerned. Your body cannot process glass and carbon dust out of your system. Whatever you inhale into your lungs, stays there forever. People that have been exposed to high concentrations of glass and carbon dust contract emphysema at a very early age.

Glass and carbon are also very irritating to your skin and long sleeves and gloves should always be worn when handling. As deceptive as glass microballoons and cabosyl are, take precautions and wear a particle mask when handling. These are glass products and will stay in your lungs forever.

Always wear a particle mask when grinding or sanding composites. The dust not only contains particles of the composite fabric, but also resin and hardner. Inhaling the cured dust can be as bad or worse than fumes from wet resin. Wash your skin thoroughly, change your clothes and take a shower. The dust goes everwhere and can be very irritating.

Always, always, shower after working with composites. The fumes and dust will coat the surface of your skin, only to be absorbed into it.

Any comments you want to add, or suggestions on improvement will be appreciated. Please send them as outlined at the beginning of this document.

Happy, safe flying!

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