Project Delivery

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I am working on an upfit to an existing warehouse building.  It is basically a Butler Building with some attached dependencies.

The facility will be using thermoset epoxies in injection molds to create sports equipment on a small scale.

I am working with the building official in a small municipality and want to ensure that I am classifying the building occupancy appropriately.

I received the following feedback from the client:

1) type of epoxy and mold process being used.
> I believe all our epoxy systems are bisphenol ambient cure thermosets.  90% of our molding is closed aluminum tooling. An injection machine takes the two components, mixes and injects them under low pressure.  The curing of the parts is accelerated by heating the mold to approx 170f thru the use of heat strips and a pid controller mounted to the mold.

> 2) type of paints being used.
Our paint usage is fairly limited.  Typically paint use is just urethane clearcoat and is limited to the" paint room"


> 3) respirators required by manufacturing personnel?
> yes, respirators and eye protection are required if any liquid or grinding is present or occurring

> 4) confirm that max of 12 people are expected to work per shift.
> we don't expect more than 12 people per shift in manufacturing.

I believe that the BOC should be H-4 for buildings which contain materials that are health hazards including corrosives, highly toxic materials, and toxic materials.  I believe that the thermoset epoxies qualify there.

I would appreciate any advice or feedback on this.

Thank you,

Tyler Smyth, AIA

Registered Architect in State of SC
LEED Accredited Professional


Tyler Armistead Smyth Architect
386-A Ashley Avenue
Charleston, SC 29403
843-425-0321

www.designsmyth.com
http://designsmyth.wordpress.com/

Tyler,

You may be correct about the H-4 classification for some parts of the facility.  It depends on the characteristics of the chemicals and their quantities.  There are also considerations about how they are handled (Open or closed systems) and how they are stored. Injection molding can, but does not necessarily present a closed system. The use of respirators is an initial flag, though some good industrial hygiene practices may not be a clear indication of an IBC H-4 occupancy.  Another caution flag is the level 3 health effect rating (Short exposure could cause serious temporary or moderate residual injury) on the NFPA Fire Diamond.  However, this is not part of the building code.

IBC Chapter 3 provides a good set of scientific definitions for hazardous materials.  Your client should have the resources to determine if the material falls within those definitions.  If so, then have your client determine what quantities of the materials will be present in the facility, both in use and stored.  With that information, you can consult the tables in Chapter 3 to determine if the H_4 Classification applies.

The hazardous classification will likely apply only to the production and storage areas. Other parts of the building are probably Factory and Business uses .  Be sure to weigh the costs vs benefits of both separated and non-separated mixed use occupancies.

This same analysis is necessary for any other potentially hazardous materials used in the facility.  Pay particular attention to the Paint Room and the paint materials.

Hazardous occupancies are complex code issues.  Seek expert advice if you are not highly confident in your own analysis.

Best Wishes,
Tom Donoghue

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Tom Donoghue, Principal
Donoghue Project Consulting, LLC
www.DonoghueProjectConsulting.com
Pittsburgh, PA

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