Industry-specific OHS solutions
OHS for chemical, plastics and rubber businesses in Bursa
An OHS service that manages the technical risks of chemical and polymer production, from the chemical inventory to the explosion protection document and from the injection molding machine to the raw material store.
- Hazard class
- Confirmed by the 6-digit NACE code
- Key document
- Chemical inventory and current SDSs
- Explosive atmospheres
- Explosion protection document
- Workplace exposure monitoring
- Laboratory authorized by the OHS Directorate General (İSGGM)
The foundation of OHS in chemical and polymer production: knowing your substances
The chemicals, plastics and rubber sector is a link in Bursa’s industry that is often invisible but present everywhere: injection molding and press shops making plastic and rubber parts for the automotive industry, plants supplying dyes and auxiliary chemicals to the textile industry, extrusion lines producing packaging and film, and manufacturers of paints, varnishes and adhesives all belong to this group.
The hazard class in this sector can vary over a wide range; basic chemical production and plastic parts manufacturing may not fall into the same class. Because the list was completely revised on 13 March 2025 in line with NACE Rev.2.1, we confirm the class of your activity one by one against the 6-digit code in your Social Security Institution (SGK) registration. If you are working with a classification based on the old 2012 codes, your obligations may have changed. A change in the main activity must be reported to the Ministry within 1 month; if the class changes, the necessary steps must be completed within 90 days.
Whatever the class, the foundation of OHS in this sector is knowing the substances in use. The most common gap we see on our first visits is the absence of an up-to-date chemical inventory and a current safety data sheet (SDS) for each substance. Without an inventory, exposure cannot be assessed, a monitoring plan cannot be drawn up, suitable personal protective equipment cannot be selected and the physician cannot determine the right tests.
The main risk groups in the sector are:
- Exposure to solvents, monomers, isocyanates, acids and bases by inhalation and skin contact
- Explosive atmospheres that can form from flammable liquid vapors and combustible dusts
- Entrapment and burns at injection, extrusion and calender machines and vulcanization presses
- Dust and fumes in rubber compound preparation
- Fire in warehouses and incompatible substances stored side by side
At these businesses, Bursa Sistemer OSGB starts with the chemical inventory and the process flow; we plan workplace exposure measurements with authorized laboratories and incorporate the results into the risk assessment.
The risks we encounter most often on site
Chemical exposure
Solvent vapors, monomers, isocyanates, acids and bases act through the respiratory tract, skin and eyes. Closed systems, local exhaust ventilation and the right choice of gloves are determined according to the SDS.
Explosive atmospheres
Transfer of flammable liquids, mixing tanks and powdered raw materials can create explosive atmospheres. Zone classification, control of static electricity and the selection of suitable equipment are required.
Injection and extrusion machines
Reaching into the mold closing area, burns at the screw and head, and heavy loads during mold changes are the main hazards. Safety gate interlocking and a written mold change procedure are critical.
Rubber mixing and vulcanization
Mixers and mill lines produce dust and entanglement hazards, while vulcanization presses involve hot surfaces and fumes. Regular testing of the mill’s emergency stop device is vital.
Storage and incompatible substances
Storing oxidizers next to flammables or acids next to bases, missing spill containment and excessive stock are common problems. A storage matrix and quantity limits must be clearly defined.
Work inside tanks and silos
Entering tanks, reactors and silos involves the hazard of oxygen deficiency and toxic gases. A confined space entry permit, gas testing and an attendant posted outside must be in place.
Health surveillance and medical testing plan
For jobs with chemical exposure, the test plan is derived from the chemical inventory, the SDSs and the workplace exposure measurement results. Periodic medical examinations are carried out at least every 5 years, every 3 years or every year depending on the class; the physician may shorten the interval.
Exposure-specific tests
Once it is established which employee is exposed to which chemical, the physician determines the necessary tests, including biological monitoring, and their frequency on a risk basis. The legislation sets no single uniform frequency for these tests.
Respiratory system
With exposure to isocyanates, solvents and dust, respiratory complaints and signs of sensitization are monitored. Employees working with powdered raw materials have chest X-rays taken in line with the ILO standard, at intervals set by the physician.
Noise
Where the upper exposure action value of 85 dB(A) is exceeded in granulator, extruder and compressor rooms, hearing tests are mandatory; above 80 dB(A) they may be carried out at the physician’s discretion.
Skin and eyes
Employees working with solvents, resins and hardeners are asked about contact dermatitis and eye irritation; the accessibility of emergency eyewash stations and safety showers is checked together with health surveillance.
Periodic inspections to keep track of
- Steam boilers and hot water boilers: at least once a year; for steam boilers, by an accredited inspection body from 01.01.2027
- Compressors, air and gas receivers: once a year at operating pressure, at least every 3 years at test pressure
- LPG tanks and installations: by an accredited inspection body
- Local exhaust and general ventilation systems: at least once a year
- Molding and vulcanization presses: at least once a year
- Overhead cranes and mold handling equipment: at least once a year
- Forklifts and pallet trucks (raw material and product warehouses): at least once a year
- Indoor electrical installations, earthing and lightning protection: at least once a year
- Fire detection, sprinkler and extinguishing systems: at least once a year
- Industrial racking and doors: at least once a year
Industry-specific training topics
- Reading chemical labels and SDSs
- Selecting gloves and respiratory protection
- Explosive atmospheres and static electricity
- Chemical spill response
- Mold changes and injection molding safety
- Work in confined spaces and gas testing
- Storage of incompatible substances
- Eyewash stations and first aid for chemical burns
How we apply our services in this industry
Documents you should have ready for an inspection
- Current hazard class determination (according to the 2025 list)
- Chemical inventory and a current SDS for each substance
- Risk assessment and explosion protection document
- Chemical and dust exposure measurement reports (laboratory authorized by İSGGM)
- Exposure-based test results and Annex 2 (EK-2) examination forms
- Inspection reports for pressure vessels, LPG, ventilation and lifting equipment
- Confined space entry and hot work permit records
- Emergency plan, spill response procedure and drill form
- PPE selection rationale and issue records
- Training records and exam results
- Inspection records for earthing and static electricity measures
Areas where this industry is concentrated
Frequently asked questions
Which hazard class is our plastic injection molding shop in?
The class is determined by the 6-digit NACE code in your Social Security Institution (SGK) registration and the main activity carried out at the workplace. Because the list was completely revised on 13 March 2025 in line with NACE Rev.2.1, information based on the old codes may be misleading. Plastic parts manufacturing, chemical production and rubber processing may fall under different codes and different classes. Send us your code; we will confirm it against the annex of the current communiqué and work out your obligations together with the calculator.
Which businesses need an explosion protection document?
At workplaces where flammable gases, vapors, mists or dusts can form an explosive atmosphere, the employer is obliged to assess explosion risks, divide areas into zones and document this in an explosion protection document. Paint and adhesive manufacturers using solvents, facilities storing flammable liquids and businesses processing powdered raw materials are typical examples. The document can be prepared as part of the risk assessment and is updated whenever the facility changes.
Who carries out chemical exposure measurements?
Measurements must be carried out by a laboratory holding a competence or pre-competence certificate from the Directorate General of Occupational Health and Safety (İSGGM); certain parameters also require accreditation by the Turkish Accreditation Agency (TÜRKAK). The laboratory notifies İSG-KATİP (the Ministry’s OHS registration system) of the measurement at least 3 days in advance; results from an uncertified laboratory are invalid. The results determine whether engineering controls are adequate, which respiratory protection to select and which test the physician applies to which employee. We plan measurements with authorized laboratories and incorporate the results into the risk assessment.
Our SDSs are in a foreign language and out of date; is that a problem?
The safety data sheet is the key document setting out a chemical’s hazards, exposure limits, personal protective equipment and first aid information. It must be up to date and in a language the employee can understand; a current SDS in Turkish should be requested from the supplier. We match your chemical inventory with the SDSs, list missing or outdated sheets and check that labels and sheets are consistent. This matching is also the starting point for the measurement plan.
What is the most critical safeguard on rubber mills?
Entanglement accidents on open mills have very serious consequences. There must be an emergency stop device that can be reached from both sides of the mill and activated with the body; its operation and the stopping distance must be tested regularly. For manual feeding of the compound, a safe working distance and feeding aids must be specified in work instructions. Our OHS specialist checks the records of these tests during visits and enters any shortcomings into the risk assessment.
How can mold changes on injection molding machines be done safely?
A mold change brings together risks that are not present during production: moving a heavy mold by crane or forklift, a hot mold and hydraulic lines, and unexpected movement. A safe change requires a written procedure, energy lockout/tagout (LOTO), suitable lifting accessories and securing of the mold. The annual periodic inspection of cranes and slings is also part of this process. We prepare the procedure together with you, tailored to your machines.