On this episode of the WorkSAFE Podcast, we sit down with Rhonda Kauffman, Safety and Risk Specialist and Industrial Hygiene Team Lead, to learn how employers can address hidden health hazards with industrial hygiene best practices.
When you think of workplace safety, you might picture hard hats and safety glasses. But some of the most serious risks on the job are the ones you can’t see. Airborne chemicals. Excessive noise. Poor ventilation. These exposures can go unnoticed until an employee develops a long-term health condition. By then, it may be too late to prevent permanent damage or disability.
Listen to this episode of the WorkSAFE Podcast, or read the show notes below.
What is industrial hygiene and why should you care?
According to Kauffman, industrial hygiene is “the process of anticipating, recognizing, evaluating, and controlling workplace health hazards in an effort to protect worker health and well-being.”
Classifying workplace health hazards
Knowing what to look for is the first step in protecting your workforce from serious long-term health problems. Industrial hygiene hazards fall into four main categories:
- Physical hazards like noise, dust, and radiation
- Chemical hazards including solvents and welding fumes
- Biological agents such as mold or bacteria
- Ergonomic issues from repetitive motions or awkward positions
Unlike a wet floor or an unguarded machine, industrial hygiene hazards are often invisible. You can’t see welding fumes accumulating in someone’s lungs or hear the gradual hearing damage that excessive noise causes.
The hidden cost of occupational diseases
“There can be a latency period for an occupational disease to develop and manifest symptoms,” Kaufman noted. This delay can make it tricky to connect the symptoms with the exposure. Once symptoms do appear, the employee may already have an irreversible condition like hearing loss.
➡️ The bottom line: These conditions often result in expensive work comp claims that impact your business for years. Prevention costs a fraction of the healthcare and productivity costs associated with occupational diseases.
Most common industrial hygiene hazards in the workplace
Certain hazards appear across many different industries and work environments. Recognizing these common risks can help you identify potential problems in your own workplace.
Excessive noise exposure
“One of the most common inadequately controlled workplace exposures we find is excessive noise levels,” Kaufman said. Noise hazards exist across many industries, including manufacturing and construction, where machines create constant sound or impact noises.
Here’s a simple test: If you’re within arm’s length of someone and you have to yell to be heard, you probably need professional hearing protection.
Chemical exposures
Chemical hazards are common in manufacturing environments where potentially hazardous substances are used in production processes. Fumes from carbon steel torching, plasma cutting, and MIG welding can expose employees to dangerous particles. Even seemingly safe products can pose risks. For example, some welding anti-spatter products contain methylene chloride, which is a suspected carcinogen with strict OSHA compliance requirements.
Sometimes, simply replacing these chemicals with safer alternatives can eliminate the risk without disrupting production processes.
Dangerous dust particles
Exposure to respirable dust is a concern in industries like granite and quartz countertop fabrication, where workers are exposed to crystalline silica dust, and in construction during concrete cutting and sandblasting operations. Dust exposure in these fields frequently exceeds OSHA limits.
How it works: MEM’s industrial hygiene evaluation
Led by Kauffman, MEM’s industrial hygiene team takes a systematic approach to identifying and addressing health hazards. We focus on uncovering actionable information and making impactful recommendations.
The evaluation process
We start by talking through the policyholder’s specific concerns and then scheduling an on-site evaluation if necessary. The process involves specialized equipment, such as decibel meters to measure sound levels and air sampling pumps for silica.
“We try to capture as much of the workday as we can, to get good data,” Kauffman explained. After testing, the team provides a detailed report with findings and recommendations. If lab results show elevated levels, they call the policyholder ASAP to discuss the findings before the formal report arrives.”
Focus on prevention, not just compliance
At MEM, we value OSHA compliance standards. Our approach to safety evaluations differs from typical compliance monitoring – rather than simply meeting regulatory requirements; our focus is on identifying problems and providing data for decision-making. Our preventive approach helps policyholders act on risks before they turn into serious problems.
Real-world success stories
Kauffman shared two real success stories that demonstrate how proactive industrial hygiene assessment can protect employee health while improving workplace conditions and productivity.
Case study: Dust control solution
A policyholder contacted MEM about elevated dust levels in their facility. Kauffman’s team conducted air testing, which confirmed the problem. The solution was two-step:
- First, the policyholder immediately implemented an interim respirator program to ensure employee safety while planning permanent improvements.
- Next, they applied for and received an MEM safety grant to help fund improved ventilation throughout the facility.
After the new system was installed, follow-up testing showed significant improvement. Kauffman described the mood in the building: “The other great thing here was that the employees were so happy.” Employees reported a dramatic boost in comfort and their ability to perform daily tasks.
MEM’s safety grant program helps fund dozens of projects like this one every year. Here’s how policyholders can apply.
Case study: Solving the mystery of workplace headaches
Another case involved a more complex investigation. The policyholder’s employees were experiencing unexplained headaches at work. Initially, they suspected that the new LED lighting might be too strong.
Through systematic testing, however, MEM discovered the real culprit: carbon monoxide from two separate sources. Propane forklifts were operating in a space that was too small, and a damaged heat exchanger in the HVAC system was also contributing to the problem.
The solution addressed both sources by:
- Limiting the number of forklifts that could operate in the area
- Repairing the HVAC system
- Ultimately, replacing the forklift fleet with newer, cleaner-running equipment
Follow-up testing confirmed levels were well below OSHA limits, and the headache problem was resolved. This story highlights how proper air quality management can solve health problems that might otherwise go undiagnosed.
Cost-effective ways to get started
You don’t need a huge budget to begin addressing industrial hygiene hazards. Several free and low-cost resources can help you identify potential problems and take steps toward protecting your employees.
Free and low-cost resources
Start with what you already have. If you have chemicals in your facility, review the safety data sheets for all products you use. “Every workplace using chemicals should have a hazard communication program,” Kauffman advised. “If you’ve got chemicals in your facility, take a look at the safety data sheets for those products.”
Look for the word Danger on labels, which indicates products containing substances requiring special attention. Icons and pictograms can provide additional warnings about specific hazards like respiratory risks.
Check with your state’s Department of Labor for free consultation programs for smaller employers. These programs provide professional assessments at no cost, and the only requirement is that you address the hazards they identify.
Simple improvements can make a big difference
Good ventilation is fundamental to industrial hygiene and clean air in the workplace. Simple changes like adding fans or improving air circulation can significantly reduce exposure to airborne hazards.
“Having good air quality is key to keeping people breathing easier on the job,” Kauffman emphasized. While ventilation improvements require investment, they’re often highly effective and can provide immediate benefits.
When to call in the experts
While there’s a lot you can do to improve industrial hygiene, it’s also crucial to recognize when you need professional help. Some situations require specialized knowledge and equipment that only trained industrial hygienists can provide.
Red flags that require professional assessment
Some situations call for bringing in the experts:
- Employees reporting unexplained symptoms like headaches, respiratory issues, or fatigue
- Work processes involving known hazardous materials
- High-dust or high-noise environments
- Recent OSHA visits or citations
“Many times, these things don’t produce pain. It’s not like a laceration where you immediately know that there’s an injury,” Kauffman explained. Because these hazards are often silent, it’s important to stay vigilant and take concerns seriously.
How your insurance carrier can help
Specialized work comp carriers like MEM may provide industrial hygiene services at no charge to policyholders. At MEM, we also offer safety grants to help fund safety improvements and customized safety training.
Your insurance carrier shares your goal of identifying concerns before they turn into long-term problems and costly claims. Be sure to take advantage of any resources they offer to protect your employees.
Protecting your most valuable asset
The keys to successful industrial hygiene are awareness and proactive assessment. “Know your workplace,” Kauffman advised, “and know what could be a potential hazard that could result in someone becoming ill on the job.”
Your employees are your most valuable asset. Protecting them from long-term health risks isn’t just good business; it’s the right thing to do.
Ready to take the next step? MEM policyholders can contact Safety and Risk Services for an industrial hygiene assessment. For safety checklists, posters and more, check out our comprehensive resource library.