Guide to Certification for Collision Repair Workshops

Guide to Certification for 

Collision Repair Workshops 

A Guide for the Person in Charge under the 

Hazardous Substances and New Organisms Act 1996 

June 2009

Published in June 2009 by 

ERMA New Zealand 

PO Box 131, Wellington 6140, New Zealand 

ER-EG-06-01 06/09

Contents 

Preface 5 

Introduction 6 

1. Interpretation of Terms 8 

2 Hazardous Substances 16 

3 Location Test Certificates 19 

4 Site Plans 23 

5 Approved Handlers 27 

6 Emergency Response Plan 31 

7 Fire Extinguishers 35 

8 Signage 37 

9 Secondary Containment Systems 41 

10 Storage of Flammable Liquids and Gases 43 

11 Building Types 44 

12 Controlled Zones 46 

13 Hazardous Atmosphere Zones 51 

14 Stationary Container System Used in Connection with Burners 54 

15 Test Certificate Information Requirements 57 

Appendix 1: Hazardous Substance Records 59 

Appendix 2: Location Test Certificate Records 63 

Appendix 3: Approved Handler Records and Test Certificates 65 

Appendix 4: Electrical Certification 67 

Appendix 5: Stationary Container System Records 69 

Appendix 6: Additional Information 73 

Guide to Certification for Collision Repair Workshops 3

Preface 

This document has been prepared to provide guidance to the person in charge of a 

collision repair workshop on their responsibilities for test certification under the 

Hazardous Substances and New Organisms Act 1996 (HSNO Act). 

The purpose of the HSNO Act is to protect the environment and the health and safety of 

people and communities by preventing or managing the adverse effects of hazardous 

substances. Collision repair workshops store and use significant quantities of hazardous 

substances, in particular flammable substances such as paints, thinners, methylated 

spirits, petrol, diesel, LPG and acetylene. It is imperative that these substances are 

stored and handled in compliance with the legislative requirements. 

ERMA New Zealand has developed this guidance document with the assistance of 

Quality Environmental Consulting Limited and the Department of Labour. 

The Collision Repair Association has been particularly supportive of this initiative. We 

would like to acknowledge the Association’s valuable support and the contribution of 

those who commented on drafts of this document. 

Rob Forlong 

Chief Executive 

ERMA New Zealand 


Introduction 

Collision 

repair 

workshops 

A collision repair workshop will generally comprise of a hazardous 

substance store, paint mixing room, spray booth and welding bay. 

Within these places a range of hazardous substances will be present 

which may include the following: 

• paints, including isocyanates; 

• thinners; 

• methylated spirits; 

• rust remover; 

• epoxy resins, fillers and hardeners; 

• flammable degreasers; 

• petrol and diesel; 

• flammable, oxidising, and non hazardous gases. 

Purpose of this 

publication 

This publication is to help you, the person in charge of a collision 

repair workshop, to obtain the test certificates required by the HSNO 

legislation. 

This document is a guide only. It is limited to an explanation of the 

test certificates likely to be required at a collision repair workshop. It 

does not explain all of the requirements of the HSNO Act, which you 

must still comply with. 

Purpose of the 

HSNO Act 

The purpose of the HSNO Act is to protect the environment and the 

health and safety of people and communities by preventing or 

managing the adverse effects of hazardous substances. 

Other 

legislation 

The requirements of the HSNO Act are in addition to other statutory 

requirements such as those in the Resource Management Act 1991, 

the Health and Safety in Employment Act 1992, the Electricity Act 

1992, and the Building Act 2004. 

ERMA New 

Zealand 

The Environmental Risk Management Authority (ERMA New 

Zealand) is the governing authority responsible for administering the 

HSNO legislation. 

To find out more about ERMA New Zealand visit the website at: 

www.ermanz.govt.nz. 

6 

Guide to Certification for Collision Repair Workshops

Enforcement 

The Department of Labour enforces the HSNO legislation in the 

workplace, which includes collision repair workshops. A Department 

of Labour enforcement officer has the right to enter a property for the 

purpose of inspection. 

An enforcement officer will help you to comply with the legislative 

requirements. 

Further 

information 

To read the HSNO Act or regulations referred to in this document 

visit New Zealand Legislation at http://www.legislation.govt.nz. 


1. Interpretation of Terms 

Interpretation 

of terms 

To help you understand this guide several of the terms used are 

explained in this section. 

Approved 

handler 

Flammable liquids, flammable gases, oxidising agents, organic 

peroxides (organic peroxides are used as curing agents and 

hardeners), toxic and corrosive substances must be under the control 

of an approved handler where threshold quantities are exceeded. 

Approved handlers must meet the requirements set out in the 

Hazardous Substances (Personnel Qualifications) Regulations. The 

approved handler must be available to provide advice if another 

person is handling the substance. If an approved handler is not 

available, hazardous substances that require an approved handler 

must be secured (that is, locked away) to prevent their unauthorised 

use. 

For more information, see section 5. 

Building design 

Buildings containing flammable substances must meet specific design 

requirements. 

The type of building that is required depends on: 

• the hazard class of each substance; 

• the aggregate quantity of each class of hazardous substance held; 

• whether the substance is in storage or being used. 

For more information, see section 10 and 11. 

Bund 

A type of secondary containment system that includes a compound 

with walls. 

Closed 

containers 

Containers that are unopened or securely closed by replacing the cap, 

or installing a tap, so that there is no release of the hazardous 

substance. 

8 


Controlled 

zones 

A controlled zone at a collision repair workshop is an area around the 

place where hazardous substances are used and stored. Within the 

zone, the adverse effects of the hazardous substance must be 

managed. 

The extent of a controlled zone depends on the: 

• hazard class of the substance; 

• quantity of the substance held. 

The public should be excluded from the areas of the workshop where 

flammable liquids and flammable gases are present. If the controlled 

zone extends into an area that the public may enter, this zone must be 

identified and have warning signs in place that prohibit people from 

bringing sources of ignition into the zone. 


Double 

skinned tank 

A means of providing secondary containment by building a tank 

within a tank, often referred to as a tank that has integral secondary 

containment. 

Emergency 

response 

plan 

Collision repair workshops must have an emergency response plan 

that covers every reasonably likely emergency that may occur such as 

fires, spillages or gas leakage. 

You must test each aspect of the emergency response plan at least 

once a year or within three months of a significant change of staff or 

procedures. Significant change in staff includes where key persons 

such as approved handlers or head building wardens have changed. 

Records of these tests must be kept for at least two years. 


Fire 

extinguishers 

Collision repair workshops must have fire extinguishers available 

onsite. These must be of the correct type and rating. 



Hazardous 

atmosphere 

zones 

Hazardous atmosphere zones are required to be identified, established 

and maintained where the hazardous atmosphere zone threshold 

quantities for flammable liquids and flammable gases are exceeded. 

The hazardous atmosphere zones are identified so that the correct type 

of electrical equipment for the zone can be installed. In addition, 

within the zone unintended ignition must be avoided. 

Three zones are identified: 

• Zone 0 An explosive air–gas mixture is continuously 

present; or present for long periods or frequently; 

• Zone 1 An explosive air–gas mixture is likely to occur 

during normal operation only occasionally; 

• Zone 2 An explosive air–gas mixture is not likely to occur in 

normal operation and, if it occurs, will persist for a 

short period only. 

Electrical equipment in hazardous atmosphere zones must be installed 

and maintained in accordance with the Electricity Regulations 1997. 

An electrical certificate of verification must be kept and this must 

include reports of periodic re-inspection by a competent electrical 

inspector. 


Hazardous 

substances 

inventory 

Collision repair workshops should maintain a record of all the 

hazardous substances onsite (separate from the stock reconciliation 

records). This is called a hazardous substances inventory. 


10 


Hazardous 

substance 

location 

A hazardous substance location is an area where flammable and 

oxidising substances are stored in excess of the threshold quantity set 

out in the legislation. 

Collision repair workshops are required to hold a location test 

certificate for the storage of flammable liquids, flammable gases and 

oxidisers, where threshold quantities are exceeded. Wherever 

practical you should maintain stocks below the threshold quantity and 

avoid the need for a test certificate. 

A location test certificate verifies that certain site features such as 

hazardous atmosphere zones, distances to neighbouring activities, 

signage, and emergency response plans are in place and being 

correctly managed. 


High 

intensity 

land use 

High intensity land use (HILU) is defined as: 

• an area of regular habitation; and 

• a structure made of or containing combustible materials that 

would sustain a significant fire; and 

• a high density traffic route; but 

• does not include a small office constructed of nonflammable 

materials associated with a hazardous substance 

location that is used by persons authorised to be at the 

location by the person in charge of that location. 

Low 

intensity 

land use 

Low intensity land use (LILU) is defined as: 

• an area where a person may be legally present occasionally; 

and 

• a public park or reserve; and 

• a traffic route of low or medium traffic density; but 

• does not include an area of regular habitation. 


Location test 

certificate 

Collision repair workshops are required to have location test 

certificates for the storage of flammable liquids, flammable gases and 

oxidisers where threshold quantities are exceeded. Wherever 

practical it is advisable to maintain stocks below the threshold 

quantity to reduce the fire loading of the building and to avoid the 

need for a test certificate. 

A location test certificate verifies that certain features such as 

hazardous atmosphere zones, distances to neighbouring properties, 

signage, and emergency management plans are in place and being 

correctly managed. 


Open 

containers 

Containers of hazardous substances that are open or are being used 

present a higher risk than containers that are closed. Consequently, 

the legislation sets a lower threshold quantity for a container that is 

open. 

If a single container is open and near a stock of closed containers, the 

total volume should be considered open as an incident with the open 

container could impact on the rest. 

If a single container is taken to a location remote from the closed 

containers and opened, this may be considered a separate hazardous 

substance location with only the single container considered open. 

Person in 

charge 

The person in charge of a collision repair workshop is the person with 

overall control of the workshop at any time. He or she may be the 

workshop’s owner, or occupier, or lessee, or manager, or supervisor in 

charge at the time. 

The person in charge is responsible for ensuring that: 

• the requirements of the HSNO Act are complied with; 

• all necessary test certificates are obtained. 

12 


Secondary 

containment 

systems 

Containers, including packages and stationary tanks used to store 

hazardous liquids, must have a means to contain any leakage. This is 

referred to as ‘secondary containment’ and may be in the form of a 

bund, compound or be of a double-skinned tank design. 

The secondary containment system must be capable of holding at 

least: 

• 110% of the contents of an above ground stationary tank; and 

• 100% of the contents of a below ground stationary tank. 

Stationary tanks that were constructed before 1 April 2004 and have a 

capacity of no more than 60,000 L that do not comply, may be 

managed using an ERMA New Zealand approved code of practice 1 . 

Flammable liquids that are open or being used inside a building 

should be provided with 100% secondary containment. 


Signage 

Signage must be provided at your workshop. This must detail: 

• the hazardous substances present; 

• the general type and degree of hazards; 

• steps that are necessary to prevent unintended ignition; 

• actions to be taken in an emergency. 


Site plan 

Your workshop must have a site plan (or plans) that show: 

• the site boundary; 

• the location of all hazardous substances present in relation to the 

site boundary; 

• any controlled zones associated with those hazardous substances; 

• any hazardous atmosphere zones associated with those hazardous 

substances. 


1 

Approved Code of Practice for the Management of Existing Stationary Container Systems up to 

60,000 Litre Capacity, see www.ermanz.govt.nz/hs/compliance/codesofpractice.html. 


Stationary 

container 

system test 

certificates 

You may need a stationary container system test certificate where 

diesel is used in connection with a burner, for example, a heated spray 

booth or drying room. It is unlikely that a collision repair workshop 

will use LPG from a bulk tank as the fuel for a spray booth because 

cylinders are generally used for this purpose. 

Stationary tanks that were constructed before 1 April 2004 may not 

comply with the requirements. If these stationary tanks have a 

capacity of no more than 60,000 L, you may manage them under an 

ERMA New Zealand approved code of practice 1 . 


Test 

certificates 

The Hazardous Substances and New Organisms Act 1996 (HSNO 

Act) may require a collision repair workshop to have test certificates 

to verify that certain legal requirements of the Act have been met. A 

test certificate is not a comprehensive compliance check. 

If your workshop holds quantities of hazardous substances that exceed 

the threshold levels you will need some or all of the following: 

• a location test certificate for flammable liquids, flammable gases 

and oxidisers; 

• an approved handler test certificate for people who handle these 

substances, including toxic paints; 

• stationary container test certificates for diesel systems associated 

with heating a spray booth. 

Test 

certifiers 

Test certificates are issued by test certifiers who are approved by 

ERMA New Zealand. A test certifier will issue a test certificate if 

compliance with specific controls is demonstrated. 

The test certifier will advise you of the specific controls that do not 

comply with those required by the test certificate so that shortcomings 

can be remedied. 

To find a test certifier, search the register of test certifiers on the 

ERMA New Zealand website see: 

http://ermanz.govt.nz/search/tc.html, or contact ERMA New Zealand 

directly. 

14 


Further 


For information on hazard substances compliance, see Industry Sector 

Information at http://www.ermanz.govt.nz/hs/industry/index.html, or 

call the Hazardous Substances Compliance Line (0800 376 234) or 

contact ERMA New Zealand or the Department of Labour. 

ERMA New Zealand, P O Box 131, Wellington 

Tel: 0800 376 234 

Email: hsinfo@ermanz.govt.nz 

Website: www.ermanz.govt.nz. 

Department of Labour, P O Box 3705, Wellington 

Tel: 0800 20 90 20 

Email: info@dol.govt.nz 

Website: www.dol.govt.nz 

For information on standards referenced in this publication, contact: 

Standards New Zealand, PO Box 2439, Wellington 

Tel: 04 498 5990 

Fax: 04 498 5994 

Email: snz@standards.co.nz 

Website www.standards.co.nz/default.htm 


2 Hazardous Substances 

Hazardous 

properties 

Your workshop will hold hazardous substances, in particular, 

flammable liquids such as paints, solvents, petrol and diesel, as well 

as gases such as LPG, oxygen and acetylene. Each substance is 

required to be managed in accordance with its hazardous properties. 

Hazard 

classifications 

The properties of hazardous substances are assessed against specific 

criteria 2 to establish the hazard classifications. A substance can have 

more than one hazard classification. 

Each class of substance is expressed in a similar format, for example, 

‘3.1A’, where: 

• ‘3’ is the class; 

• ‘1’ is the subclass; 

• ‘A’ is the level of hazard (with A being the most hazardous). 

A classification of ‘3.1A’ means a liquid that is flammable and a very 

high hazard. As the hazard classification progresses down the 

alphabet the less hazardous the substance becomes. Some substances 

have an additional subclass, for example, LPG is ‘2.1.1A’. The 

hazard classes are listed in Table 2.1. 

Table 2.1: Hazard classes 

Class Description 

1 Explosive 

2 Flammable gas 

3 Flammable liquid 

4 Flammable solid 

5 Oxidiser /organic peroxide 

6 Toxic to humans 

8 Corrosive to eyes, skin or metal 

9 Ecotoxic (toxic to the environment) 

2 

Hazardous Substances (Classification) Regulations 2001. 

16 


Substances 

at collision 

repair 

workshops 

Table 2.2 provides hazard classifications for substances commonly 

held at a collision repair workshop. 

Table 2.2: Hazard classifications of hazardous substances 

commonly held at collision repair workshop 

Hazardous substance 

Hazard classification 

Acetylene 

2.1.1A 

LPG 

2.1.1A 

Flammable aerosol spray 2.1.2A* 

cans 

Petrol 3.1A, 6.1E, 6.3B, 6.7B, 9.1B 

Paint - flammable 

3.1B, 9.1B* 

Thinners 

3.1B, 9.1B* 

Degreasers 

3.1B* 

Methylated spirits 

3.1B, 6.1E, 6.4A, 6.8B, 6.9A, 

9.1D 

Diesel 3.1D, 6.1E, 6.3B, 6.7B, 9.1B 

Oxygen 

5.1.2A 

* Note a substance may have several classifications and it is important 

to identify all of these. 

Hazardous 

substance 


A hazardous substance inventory is a list of all hazardous substances 

at your workshop, their classifications and maximum quantities held 

on site. Maintaining an inventory helps to facilitate the test certificate 

assessment processes. 

It is important to keep the list up to date, revising it whenever an 

additional or new substance is purchased or if the maximum quantity 

that you plan to hold changes significantly. 

Create an inventory of hazardous substances at your workshop using 

the template in Appendix 1. 


Safety data 

sheets 

A safety data sheet (SDS) tells you about the hazardous properties of 

a substance, how to handle or work with it safely, and what to do in 

an emergency. 

For each hazardous substance in the hazardous substances inventory, 

you must have an SDS. If you do not have an SDS, or your SDS is 

more than five years old, ask your supplier for a new one. When 

purchasing a hazardous substance for the first time, ask your supplier 

for a safety data sheet. 

Keep SDSs where staff can refer to them easily and quickly, at any 

time. Make sure staff know how to use them. They must be available 

within 10 minutes if you need to refer to them. 

File a copy of each SDS in Appendix 1, or store the copies elsewhere 

and record their location in section 15. 

Labelling of 

containers 

If a hazardous substance is repackaged on site or decanted into 

another container, those containers must also be labelled to identify 

the substance and its hazards. The container must be suitable for the 

substance and be able to retain the substance. 

Do not use disused food containers or drink bottles to hold hazardous 

substances. 

18 


3 Location Test Certificates 

Location test 

certificate 

A location test certificate verifies that certain site features such as 

hazardous atmosphere zones, distances to neighbouring activities, 

signage, and an emergency response plan are in place and being 

correctly managed, and that an approved handler (if required) has been 

appointed and is available. 

You will only need a location test certificate if you exceed the 

threshold quantity. 

It is best practice to keep a copy of the location test certificate on site. 

Person in 

charge 

Before commissioning the hazardous substance location you must 

advise the Department of Labour (the responsible enforcement 

agency) of its existence, including the address and maximum 

quantities of each flammable and oxidising substance that the location 

may hold. 

You are responsible for obtaining the required test certificates for your 

workshop. 

Location test certificates are usually valid for one year and must be 

re-issued by a test certifier. However, you may apply to ERMA New 

Zealand for an extension of up to three years. To be granted an 

extension you need to: 

• demonstrate a history of compliance; 

• have review and monitoring systems in place (for example, 

regular audits). 

Ask your test certifier or ERMA New Zealand about how to extend 

the duration of the test certificate 

Threshold 

quantities 

Substances with flammable or oxidising properties are required to 

have a location test certificate if threshold quantities are exceeded. 

Wherever practical it is advisable to maintain stocks below the 

threshold quantity and avoid the need for a test certificate. 

Table 3.1 lists the substances commonly present at collision repair 

workshops and the quantities above which a location test certificate is 

required. 


Table 3.1: Location test certificate threshold quantities 

Substance 

LPG 

Threshold quantity 

Closed container 

100 kg 

Acetylene 100 m 3* 

Oxygen 200 m 3** 

Petrol – class 

3.1A 

Flammable 

Liquids – 

class 3.1B 

Flammable 

Liquids – 

class 3.1C 

50 L *** 

100 L containers over 

5 L 

250 L containers up 

to 5 L 

500 L – containers over 

5 L 

1,500 L – containers up 

to 5 L 

Open container 

50 L 

250 L 

* Fourteen size G acetylene cylinders. 

** Twenty-three size G oxygen cylinders. 

*** This excludes any petrol contained in vehicle fuel tanks. 

Note 1: If a single container is opened near closed containers, the total 

volume is considered open. If a single container is taken to a 

location away from closed containers and opened, only the single 

container is considered open. 

Note 2: Class 3.1B, examples are acetone, thinners and methylated 

spirits. 

Note 3: Class 3.1C, examples are turpentine and kerosene. 

Note 4: Collision repair workshops that use or store a range of flammable 

gases such as acetylene and LPG should keep these gases 

separate from the flammable liquids and, ideally, in a separate 

hazardous substance location. If the quantity of gases that you 

hold exceeds the threshold quantity you will need a location test 

certificate. If a site holds: 

• three G size acetylene cylinders, class 2.1.1A (7.9 kg each); 

and 

• two G size LPG cylinders, class 2.1.1A (45 kg each); 

the total volume of class 2.1.1A gases is 113.7 kg and this 

exceeds the threshold of 100 kg. A location test certificate is 

therefore needed. 

Collision repair workshops are unlikely to have a quantity of: 

• flammable aerosols that exceeds the thresholds in Table 3.1; 

• oxygen that exceeds the thresholds in Table 3.1. 

Diesel does not require a location test certificate. 

20 


Quantity 

ratio 

You will need to take account of situations where you have 

substances with different hazard classifications, notably 3.1A, 3.1B 

and 3.1C. Individually these quantities may be below the threshold 

quantity, but collectively the total quantity stored may still require a 

location test certificate. In this situation you must calculate the 

quantity ratio. 

To determine this, sum the ratios of quantity stored and the threshold 

quantity for each hazard classification. If the sum is equal to or 

greater than 1, a location test certificate is required. 

Contact your test certifier or ERMA New Zealand for further 

guidance. 

Test 

certifiers 

issue 

location test 

certificates 

To obtain a location test certificate, contact a test certifier. The test 

certifier will need to visit and assess your site before he or she can 

issue a test certificate. 

A register of test certifiers is on the ERMA New Zealand website, see 

http://www.ermanz.govt.nz/search/tc.html. 

Items to be 

certified 

The test certifier who assesses your workshop will check: 

• that the person in charge has notified the Department of Labour; 

• site plans (see section 4); 

• approved handlers (see section 5); 

• emergency response plans, including evidence that they have been 

tested (see section 6); 

• fire extinguishers (see section 7); 

• signage (see section 8); 

• secondary containment systems (see section 9); 

• the design of buildings in which hazardous substances are stored 

(see section 11); 

• the location, extent, and management of controlled zones and 

segregation within the zones (see section 12); 

• hazardous atmosphere zones (see section 13). 

To be prepared for a location test certificate inspection, read the 

relevant sections and make sure you have the required documentation 

available. The documentation requirements are summarised in 

section 15. 


Test 

certificates 

to be 

available 

The location test certificate is an official document, and a copy should 

be kept at the collision repair workshop. If an enforcement officer 

asks to see the certificate, you should be able to show them a copy. 

File your 

location test 

certificates 

File a copy of your location test certificate in Appendix 2, or file it 

elsewhere and record its location in section 15. 

Further 


For information on location test certificates see the Quick Guide to 

Location Test Certificates in Appendix 6 or see 

http://www.ermanz.govt.nz/resources/publications/pdfs/ER-QG-23- 

1.pdf 

22 


4 Site Plans 

Site plan 

Your workshop must have a site plan (or plans). To avoid confusion 

separate hazardous atmosphere zones and controlled zone plans may 

be beneficial. 

Figures 1, 2 and 3 are typical examples of acceptable site plans. 

What the 

site plan 

must show 

Your site plan(s) must show: 

• the position of all hazardous substance locations in relation to the 

site boundary; 

• the scale to which the plans have been drawn; 

• any controlled zones associated with the hazardous substances (for 

information about controlled zones, see section 12); 

• any hazardous atmosphere zones associated with the hazardous 

substances (for information about hazardous atmosphere zones, 

see section 13). 

Recommended 

items 

It is advisable to also show on your site plan(s): 

• buildings located within the site boundary; 

• openings into buildings within the site boundary; 

• the date the plan was drawn; 

• the location of emergency response equipment; 

• site identification, including the address of the site. 

Including this information will make the test certifier’s task simpler 

and potentially quicker. 

File your site 

plan 

File a copy of your site plan(s) in Appendix 2 of this document, or file 

the plan elsewhere and record its location in section 15. 


Figure 1 

24 


Figure 2 


Figure 3 

26 


5 Approved Handlers 

Approved 

handler 

Where flammable liquids, aerosols, oxidisers, LPG, acetylene and 

toxic substances exceed their threshold quantities, the substance must 

be under the personal control of an approved handler, or secured so 

that an unapproved person cannot gain access to the substance. 3 

The hazardous substance can be handled by other people who are not 

approved handlers when an approved handler has provided them with 

guidance and the approved handler is available to provide advice and 

assistance. 

It is best practice to keep a copy of the approved handler’s certificate 

on site. 

Person in 

charge 

You, as the person in charge, are responsible for making sure that 

approved handlers: 

• are certified; 

• remain competent in their responsibilities; 

• are available when required. 

Threshold 

quantities 

Table 5.1 lists the substances commonly held at a collision repair 

workshop and the quantities above which an approved handler is 

required. 

Your workshop may exceed these threshold quantities, in which case 

you must have an approved handler. 

Diesel does not require an approved handler. 

3 

Regulation 56 of the Hazardous Substances (Classes 1 to 5 Controls) Regulations 2001 and 

Regulation 9 of the Hazardous Substances (Classes 6,8 and 9 Controls) Regulations 2001. 


Table 5.1: 

Hazardous 

substance 

Approved handler threshold quantities 


Flammable 250 L if any containers are 5 L or bigger 

liquids 

Flammable 500 L if all containers are less than 5 L 

liquids 

Flammable 3,000 L 

aerosols 

Petrol 100 L * 

LPG/Acetylene 100 kg/100 m 3 

Oxygen 200 m 3 

Isocyanate 

paints 

Any quantity if class 6.1A, or B** 

10 L where class 6.7A 

* This excludes any petrol contained in vehicle fuel tanks. 

** Isocyanate paints will require an approved handler if they are class 

6.1A, 6.1B or 6.7A. 

Certification 

An approved handler may be approved for different types of 

hazardous substances, lifecycle stages (such as manufacture, storage, 

use or disposal) and handling activities, depending on their work 

experience and competence. 

However, the approval may also be limited to specific activities, such 

as use of the substances in a collision repair workshop. 

To be certified as an approved handler, they must have: 

• knowledge of the HSNO Act and regulations; 

• knowledge of the hazardous substances you are dealing with; 

• practical skills (competency) to safely handle and use the 

hazardous substances; 

• practical knowledge of the operating equipment involving the 

hazardous substance. 

The approved handler must be able to show they have experience 

handling the substance and can do so competently. The test certifier 

will need evidence, which could be a written record from a work 

supervisor or from the provider of an appropriate training course. 

28 


Availability 

and number 

When a substance is not secured and an approved handler is required, 

this person must: 

• “be available” when flammable or oxidising substances are 

present (hazard classes 2 to 5); or 

• “be available” and “at the place” when toxic, corrosive or ecotoxic 

substances are present (hazard classes 6, 8 or 9). 

You can come to a decision on the availability requirement by doing a 

risk assessment, or similar appraisal taking into account: 

• skills and competencies of staff ; 

• documented staff training and skills assessment; 

• store’s hours of operation; 

• types of hazardous substances on-site. 

You may decide to have an approved handler on-site at all times the 

workshop is open. This is the preferred approach. 

The number of approved handlers will also depend on your particular 

workshop needs and the following factors may have a bearing on the 

numbers: 

• the store’s hours of operation; 

• the number of staff; 

• cover required for leave, sickness, etc.; 

• staff turnover. 

Duration 

Approved handler test certificates are valid for five years. To renew a 

certificate, contact a test certifier. 

The approved handler will need to show the test certifier that you 

have kept up to date with any changes in work practices, the 

regulations made under the HSNO Act, and any relevant new or 

changed approved codes of practice since your certificate was issued. 

Test 

certifiers 

issue test 

certificates 

To obtain an approved handler test certificate, contact a test certifier. 

A register of test certifiers is available on the ERMA New Zealand 

website see: 



Test 

certificates 

to be 

available 

An approved handler test certificate is an official document, and a copy 

should be kept at the collision repair workshop. If an enforcement 

officer asks to see the certificate, you should be able to show them a 

copy. 

File your test 

certificates 

File copies of each approved handler test certificate in Appendix 3, or 

file certificates elsewhere and record their location in section 15. 

Further 


For information on approved handlers see the Quick Guide to 

Approved Handlers in Appendix 6 or see: 


2.pdf 

30 


6 Emergency Response Plan 

Emergency 

response 

plan 

Your workshop must have an emergency response plan. This must 

cover the response to every reasonably likely emergency that could 

happen involving each hazardous substance. 4 

Person in 

charge 

You, as the person in charge, must make sure the workshop has an 

emergency response plan and that the plan is tested and up to date. 

Threshold 

quantities 

Table 6.1 lists the substances commonly held at a collision repair 

workshop and the quantities above which an emergency response plan 

is required. 

Table 6.1: Emergency response plan threshold quantities 

Substance 


Flammable liquids 1,000 L 

(total volume class 

3.1B) 

LPG 

300 kg 

Flammable aerosols 3,000 L aggregate water capacity 

Acetylene 200 m 3 

Diesel 

1,000 L 

Petrol 100 L* 

Oxygen 100 m 3 

Compressed gas 1,500 kg 

* This excludes any petrol contained in vehicle fuel tanks. 

4 

Regulation 27 of the Hazardous Substances (Emergency Management) Regulations 2001. 


Contents of 

emergency 

response 

plan 

Your emergency response plan must: 

• cover every reasonably likely situation; 

• be available to the people and emergency service providers 

identified in the plan; 

• be site specific (that is, it must include all the reasonably likely 

occurrences and the responses for your particular site). 

Even if your workshop is below the threshold quantity for emergency 

management it is recommended that you have an emergency plan as 

you need to consider: 

• health and safety issues required by the Health and Safety in 

Employment Act 1992; 

• evacuation schemes required by the Fire Safety and Evacuation of 

Buildings Regulations 2006. 

Your plan does not need to specifically identify each of the situations 

outlined (see “Situations to consider”), but they must be covered by 

the principles underlying the plan. 

A template of an emergency response plan has been included inside 

the front cover of this folder. 

Situations to 

consider 

The emergency response plan should cover responses to situations 

such as: 

• flammable liquid spillages – small and large – for example: 

o a person spilling thinners; 

o a leak from a diesel tank; 

• flammable liquid and gas fires – small and large – for example: 

o a fire in the mixing room; 

o a fire in a building, including a building adjacent to your site; 

• emergency first aid, for example: 

o a person being splashed with paint; 

o a person sustaining burns. 

If your workshop stores LPG or acetylene, the emergency response 

plan should also cover: 

• a leak from a cylinder or fitting; 

• a fire adjacent to a cylinder; 

• a cylinder fire; 

• a fire at a burner. 

32 


Register of 

emergency 

equipment 

You must compile a register of the equipment identified in the 

emergency response plan, including the purpose and location of each 

piece of equipment. You may wish to identify the location of this 

equipment on your site plan. Refer to section 4. 

Training of 

personnel 

Every person responsible for executing some part of the emergency 

response plan should be trained in what to do in that part of the 

emergency. You should keep records of this training. 

Training should include: 

• how to select and wear the correct personal protective equipment 

and clothing; 

• how to use the spill kit or containment material; 

• how to use the first aid kit; 

• warden duties; 

• person in charge responsibility; 

• clean up and disposal. 

Your staff must know what to do in the event of an emergency. 

Testing 

Each aspect of the emergency response plan must be tested at least 

once a year and within three months of a significant change of staff or 

procedures. Testing must demonstrate that every procedure or action 

in the plan is workable and effective. 

You must keep records of these tests for at least two years. Your test 

certifier must sight the records before they can issue a test certificate. 

File records in Appendix 2, or elsewhere with the location recorded in 

section 15. Make changes to the plan if problems are encountered 

during the tests or an enforcement officer has requested this. 

Updating of 

plans 

You should review your plans after each test or when staff change or 

procedures change. Make sure: 

• all procedures are still relevant and up to date; 

• the persons responsible are correctly identified; 

• telephone numbers other than emergency 111 are checked for 

currency in the phone book; 

• all relevant changes in process and procedures are recorded. 


File 

File a copy of your emergency response plan inside the front cover of 

this folder, or file the copy elsewhere and record its location in section 

15. 

Further 


For information on emergency management see the Quick Guide to 

Emergency Management in Appendix 6 or see: 


1.pdf 

34 


7 Fire Extinguishers 

Fire 

extinguishers 

Your workshop must have fire extinguishers available if the threshold 

quantity is exceeded. 5 

This requirement does not negate the requirements of other statutes 

such as the Building Act 2004. 

Person in 

charge 

You, as the person in charge, must make sure the workshop has the 

necessary fire extinguishers and that they are of the right type, 

correctly located and in working order. 

Threshold 

quantities 

Table 7.1 lists the substances commonly present at a collision repair 

workshop and the quantities above which a fire extinguisher must be 

provided. 

Table 7.1: 

Fire extinguisher threshold quantities 

Classification Threshold quantity Number of 

fire 

extinguishers 

required 

Acetylene 30 m 3 1 

LPG 50 kg 1 

Flammable 

aerosols 

Petrol (other than 

in fuel tanks of 

vehicles) 

Flammable 

liquids 

3,000 L aggregate 

water capacity 

50 L 

200 L 

1 

1 

2 

250 L 2 

Diesel 500 L 2 

Oxygen 10 m 3 1 

Oxygen 50 m 3 2 

The number of fire extinguishers is not cumulative. That is, if your 

workshop has more than 50 L of petrol and 250 L of flammable liquids it 

must have at least two extinguishers. 

Notwithstanding this, you should review your site’s risks. Your workshop 

may need more extinguishers than the HSNO Act requires. 

5 

Regulation 21 of the Hazardous Substances (Emergency Management) Regulations 2001. 


Location of 

fire 

extinguishers 

Sufficient extinguishers must be available so that there is at least one 

located and accessible within 30 m of each hazardous substance. 

Size of fire 

extinguisher 

The fire extinguishers must have a minimum 30B rating. (The rating 

is on the label on the extinguisher.) 

Servicing 

Make sure each fire extinguisher is serviced at regular intervals. 

36 


8 Signage 

Signage 

Your workshop will require signs to be erected if you exceed the 

threshold quantity for signage. 6 

Threshold 

quantities 

Table 8.1 lists the threshold quantities for substances commonly held 

at collision repair workshops. 

Table 8.1: Signage threshold quantities 

Substance 


Flammable liquids (class 3.1B) more than 250 L 

LPG/Acetylene more than 250 kg/100 m 3 

Diesel 

more than 1,000 L 

Toxic substances (6.1A) more than 50 kg/50 L 

Information 

required on 

signs 

You must have signage that provides the following information: 

• that hazardous substances are present; 

o the signs do not have to mention the specific substances, 

but it is recommended that you include this information; 

• the general type and degree of hazard; 

o the signs must depict the type of hazards associated with 

the substance; 

• steps to prevent unintended ignition; 

o if the workshop exceeds the threshold quantity of a 

flammable substance, signs must explain how to avoid any 

unintended ignition; 

• the action to be taken in an emergency. 

6 

Regulations 29 and 52 of the Hazardous Substances (Identification) Regulations 2001 and regulation 

42 of the Hazardous Substances (Emergency Management) Regulations 2001. 


Location 

and visibility 

Where hazardous substances are stored outdoors, signs must be 

displayed near the substance. For example near to or on the diesel 

tank or the LPG or acetylene cylinder or the store. 

Signs must be easy to read and understand from a distance of 10 m. 

The exact nature (for example, size, colour, or wording) of signs is 

not prescribed in the regulations. You can have signs that best suit 

your needs. The ERMA New Zealand approved code of practice for 

signage 7 provides examples. 

Above 

ground 

stationary 

tanks 

Above ground stationary tanks that exceed the threshold quantities 

will require signage. For most workshops, this is applicable to diesel 

stationary tanks holding more than 1,000 L. 

Example - 

flammable 

gas 

If you hold an aggregate quantity of more than 250 kg of LPG and 

acetylene on your site, display the following sign on every vehicular 

and pedestrian entrance to the building. You will also need to put a 

duplicate sign on your front gate or entrance. An example of the 

signage is as follows: 

7 

Approved Code of Practice Signage for Premises Storing Hazardous Substances and Dangerous 

Goods, September 2004, available from NZCIC, see www.nzcic.org.nz. 

38 


Example - 

flammable 

liquid 

If you hold more than 250 L of flammable liquids in a building on 

your site, display the following sign on every vehicular and pedestrian 

entrance to the building. You will also need to put a duplicate sign on 

your front gate or entrance. An example of the signage is below: 

Example - 

diesel fuel 

tank 

If you have a diesel tank on your site, greater than 1,000 L and less 

than 10,000 L capacity, display the following sign on or near the tank. 

Diesel 

If the tank is over 10,000 L capacity, the sign must also include a 

class 3 pictogram. 


Combined 

sign 

If you have both flammable gas and flammable liquid on site inside a 

building your site entrance sign may be as follows: 

Customer 

areas 

To manage hazardous atmosphere zones and controlled zones, the 

following signage may be appropriate: 

40 


9 Secondary Containment Systems 

Secondary 

containment 

system 

Your workshop must have a secondary containment system if the 

quantity of liquid hazardous substances present exceeds the threshold 

quantity for emergency management. Gases do not require secondary 

containment. 

The secondary containment system must retain liquids, should they 

escape from the container in which they are stored. The system must 

be able to: 

• retain any the escaped liquids; 

• allow the liquid to be recovered; and 

• withstand reasonably foreseeable events, such as a fire. 

A common form of secondary containment for packages is a 

compound, such as an impermeable concrete floor and bund walls. 

Threshold 

quantities 

Table 9.1 gives examples of some substances typically held at a 

workshop, and the quantities above which a secondary containment 

system is required. This is applicable irrespective of whether the 

substances are stored in packages or other forms of containers such as 

stationary tanks. 

Table 9.1: Secondary containment system threshold quantities 

Relevant hazard classification Threshold quantity 

Flammable liquids (class 3.1B) 

1,000 L 

Diesel* 

1,000 L 

if supplying a burner 

60 L 

if supplying an internal combustion engine 500 L 

* Diesel has several hazard classifications and each classification needs to 

be evaluated. Use the hazard classification that has the lowest threshold 

quantity when evaluating the level of secondary containment. 


Capacity of the 

secondary 

containment 

system 

Where hazardous substances are stored in packages, the capacity of 

the secondary containment system is dependent upon the sizes of the 

packages and the hazard classes. 

An above ground stationary tank must have a secondary containment 

system with a capacity at least 110% of the capacity of the tank. A 

below ground stationary tank must have a secondary containment 

system with a capacity at least as large as the capacity of the tank. 

Flammable liquids in use (for example in the workshop) must have 

100% secondary containment. 

A stationary container holding diesel must have a secondary 

containment system capable of holding 110% of the tank’s volume if 

the tank is more than 500 L. 

42 


10 Storage of Flammable Liquids and Gases 

Storage in 

cabinets 

Up to 250 L of flammable liquids may be stored in a storage cabinet 

(for example, methylated spirits stored in a workshop) that is 

compliant with Australian Standard AS1940. 8 The capacity of each 

container must be no greater than 20 L. 

An AS1940-compliant cabinet is: 

• constructed of metal; 

• double skinned; 

• has a secondary containment system; 

• has self-closing doors; 

• has signage. 

A nameplate or certificate should show the cabinet is compliant. 

Storage and 

use in a 

building 

Flammable liquids must be stored in a building of a certain type and 

there are limitations on the quantity that may be stored. In a similar 

way, rules apply to substances being used or held in open containers. 

The types of store rooms and work rooms are set out in section 11. 

Flammable liquids may be kept in a store inside a building provided 

they are stored: 

• in a room with the walls and ceiling constructed with a 

60/60/60 fire resistance rating and the maximum quantity is 

450 L and no container size exceeds 20 L; or 

• in a room with the walls and ceiling constructed of reinforced 

concrete or equivalent with a 120/120/120 fire resistance rating 

and the maximum quantity is 2,000 L and one container only 

holds a maximum of 250 L with the remainder 60 L or less; or 

• in a building made of brick, block concrete or reinforced 

concrete that has a 240/240/240 fire resistance rating and is 

part of a secondary containment system, with no openings into 

the interior of the building except for a door that is self closing 

in the event of a fire which opens into a type 1, 2, or 3 building 

(refer section 11). 

Examples of 

fire resistant 

rating (FRR) 

120/120/120 minutes - a reinforced concrete wall 100 mm thick. 

240/240/240 minutes - a reinforced concrete wall 150 mm thick. 

8 

AS1940:2004 The Storage and Handling of Flammable and Combustible Liquids. 


11 Building Types 

Building 

design 

Buildings containing flammable liquids must be of a specific design. 

The type of building that is required depends on: 

• the hazard class of each substance; 

• the volume of each substance held; 

• whether the substance is in storage or in an open container; and 

• the proximity of neighbouring properties and activities. 

Buildings must be provided with secondary containment. 

Person in 

charge 

The person in charge of the workshop must ensure that the quantity of 

hazardous substances held at the place is consistent with the building 

type and its distance from neighbouring activities (see section 12). 

Using a 

substance 

When you are working with a substance in an open container the 

activity should be carried out in a workroom of the following type: 

• a Type 1 building, which may hold a class 3 hazardous substance: 

o in a container that is no more than 20 L capacity; and 

o the aggregate quantity is no more than 450 L. 

• a Type 2 or 3 building, which may hold: 

o class 3.1A and 3.1B substances with a combined quantity of 

no more than 7,500 L; or 

o a class 3.1C if no more than 10,000 L. 

Despite the provisions for type 1, 2 and 3 buildings, substances may 

be used in a building of any type if the quantity is no more than 60 L 

of a class 3.1A and 3.1B substance or no more than 250 L of a class 

3.1C substance provided that: 

• the building is occupied by the same organisation that is storing 

the substance; and 

• the building is constructed of fire resistant materials at least 6 

metres in all directions from where the substances is being used; 

and 

• if a class 3.1A or 3.1B substance and the quantity is more than 

30 L there is no source of ignition within 15 m of where the 

substance is being used. 

44 


Alternative 

building 

type 

The legislation allows for a flammable liquid to be used in a paint 

mixing room that complies with AS/NZS 4114 Spray Painting Booths, 

Designated Spray Painting Areas and Paint Mixing Rooms. 

Storage of 

packages 

If you are storing flammable liquids but not in a cabinet, they must be 

held in a building designed to the following requirements: 

• Type A buildings, defined as: 

o constructed to provide a platform on which one or more 

containers are located; 

o secured to prevent unauthorised access; 

o part of a secondary containment system; 

o the platform and shelter are made of non-combustible 

materials. 

• Type B buildings, defined as: 

o a framed building; 

o has non combustible cladding; 

o is part of a secondary containment system. 

• Type C buildings, defined as: 

o made of brick, block concrete, or reinforced concrete that has 

a fire rating of 120/120/120 minutes; 

o has a roof made of wood and iron or equivalent products; 


• Type D buildings, defined as: 

o made of brick, block concrete or reinforced concrete that has a 

fire resistance rating of 240/240/240 minutes; 


Identifying 

the building 

type 

Determining the fire resistance rating of your building is not always 

straightforward. You may be able to go back to the local authority 

and check the original design to confirm the standard to which it was 

built. Alternatively, you may seek advice from a building or fire 

engineer or your test certifier. 


12 Controlled Zones 

Description 

of a 

controlled 

zone 

A controlled zone is an area established to protect people and adjacent 

facilities from the risks posed by flammable and oxidising substances 

should anything go wrong. Outside the controlled zone, the public 

will be provided with reasonable protection. 

Within the controlled zone, the potential for adverse events, such as 

unintended ignition must be reduced or prevented. 

At a collision repair workshop a controlled zone is necessary around 

any above ground stationary tanks (for example, diesel tanks), LPG, 

flammable liquids, acetylene and oxygen. 

Extent of the 

zone 

If you are building a workshop or planning to use an existing 

building, the controlled zone should be identified before you commit 

to the building. If you later find that the controlled zone is not 

correctly defined, you could find yourself looking for other premises! 

The extent of the controlled zone is set out in the Hazardous 

Substances (Dangerous Goods and Scheduled Toxic Substances) 

Transfer Notice 9 : The controlled zone depends on: 

• the nature of the neighbouring activities: 

o for a controlled zone separating hazardous substances from 

areas of high-intensity land use (HILU), the location of the 

hazardous substances must meet minimum distances from 

facilities where people are frequently present (for example, 

buildings, and high-density traffic routes); 

o for a controlled zone separating hazardous substances from 

areas of low-intensity land use (LILU), the location of the 

hazardous substances must meet minimum distances from 

facilities or activities where people are present only 

occasionally (for example, public reserves or low- to mediumdensity 

traffic routes); 

• the hazard classifications of the substance, which means the 

controlled zones for flammable liquids and gases are different; 

• the quantity of the substance held; 

• the building type. 

9 

Schedule 10 to the Hazardous Substances (Dangerous Goods and Scheduled Toxic Substances) 

Transfer Notice 2004, see http://www.ermanz.govt.nz/hs/transfer/docs.html. 

46 


Flammable 

packages in 

use 

Any Type 1, Type 2, or Type 3 building (described in section 11) in 

which flammable liquids are used must have a controlled zone 

established around it. 

The controlled zone depends on the construction and fire rating of the 

building and the activities undertaken in neighbouring properties. For 

the quantities likely to be present at a collision repair workshop the 

distances are given in Table 12.1: 

Table 12.1 

Open packages controlled zones 

Quantity 

Class 3.1A and 3.1B 

(L) 

Area of HILU 

Type 2 Building Type 3 Building 

Separation distance (m) 

Up to 1,750 0 0 

3,000 5 0 

7,500 8 5 

Class 3.1C (L) 

Up to 2,500 0 0 

4,000 5 0 

10,000 8 5 

Closed 

packages in 

storage 

Any building storing packages of flammable liquids must be 

separated from an area of high intensity land use (HILU) by the 

distance specified in Table 12.2: 

Table 12.2 

Aggregate Quantity of 

Class 3.1A or 3.1B, or 3.1C 

(L) 

Building Type 

Distance to 

area of HILU 

(m) 

Container size 

A or B C D less than 60 L more than 60 L 

250 1,000 20,000 0 0 

500 1 2 

750 2,000 2 3 

2,000 50,000 3 4 

100,000 4 6 


Flammable 

gas cylinders 

Class 2.1.1 gases may trigger a controlled zone. Any cylinder or 

cylinders located at a hazardous substance location must be separated 

from HILU and LILU. The extent of the separation and the limits of 

the controlled zone shall not be less than the distances set out in the 

Table 12.3. 

All cylinders should be securely restrained in the upright position. 

Managing 

controlled 

zones 

The controlled zone must be managed to prevent risks to the public 

and the environment. Options include: 

• restricting access to the controlled zone (for example, using 

signage or fences); 

• erecting signs indicating the conditions of entry into the controlled 

zone (for example, signs saying ‘no smoking’ and ‘no sources of 

ignition’); 

• correct segregation of substances. For example, oxidisers should 

not be stored with flammable liquids. Further information on 

hazardous substance segregation can be found in the Approved 

Code of Practice Incompatible Hazardous Substances Separation- 

Locations 10 . 

Boundaries 

The controlled zone must not extend over your property boundary. 

However, if it does, you may: 

• ask the neighbouring property owner to give you permission (in 

writing) to allow the controlled zone to extend into their property; 

• the neighbour must agree to manage the controlled zone and 

ensure that there are no unauthorised people present and that 

within the zone any potential problems are reduced or managed; or 

• apply to ERMA New Zealand for a variation to reduce the extent 

of the controlled zone. Any variation may require you to take 

some mitigating action, such as an intervening wall. 

Buildings 

If the controlled zone encompasses another building on your property, 

you may apply to ERMA New Zealand for a variation to reduce the 

extent of the controlled zone. This may require you to install, for 

example, an intervening wall. 

10 

HSNOCOP28-1 Approved Code of Practice for Incompatible Hazardous Substances Separation- 

Locations see: http://www.ermanz.govt.nz/resources/publications/pdfs/HNSOCOP%2028-1_IS.pdf 

48 


Table 12.3 Flammable gas controlled zones 

Quantity 

Up to 100 kg 100 kg to 300 kg 300 kg to 1,000 kg Above 1,000 kg 

No location test certificate required. Location test certificate required. 

No approved handler required. Approved handler required; or the system must be secure. 

Separation distance from 

buildings may be zero. 

There must be no openings in any 

building within 1 metre of the 

cylinder(s): 

• below the top of the cylinder; 

• within 1 metre either side of 

the cylinder. 

No building must be within 2 metres; or if within 2 metres the wall 

of the building or any intervening wall must be: 

• constructed of a material 

that is fire resisting 11 ; and 

• the fire resisting material 

must extend for a distance 

of at least 2 metres either 

side of the end cylinders. 

• vapour tight; and 

• constructed of material with 

a fire resistance rating 12 of 

60/60/60; and 

• the fire resistance rated 

material must extend for a 

distance of at least 2 metres 

either side of the end 

cylinders. 

Any building within 2 metres of the cylinder(s) must not have an 

opening: 

• below the top of the cylinder; 

• within 2 metres either side of the cylinder. 

Installations in excess of 

1,000 kg must be separated 

by a specified distance not 

only from buildings but also 

neighbouring properties. 

The extent of the separation 

depends on the quantity of 

flammable gas and the way 

in which the building or 

property is being used. 

If you are installing a 

system of more than 

1,000 kg, involve a test 

certifier at an early stage in 

the planning. Some local 

authorities may also require 

a resource consent. 

11 

12 

Fire resisting means the material is difficult to burn. 

Fire resistance rating refers to the grading periods in minutes of the materials’ Structural adequacy –the ability to maintain stability and adequate load bearing capacity, 

Integrity – the ability to resist the passage of flames and hot gases and Insulation –the ability to maintain a temperature on the surface not exposed to the fire below a specified 

limit. 


Mark on site 

plans 

You must mark the controlled zone on your site plan (see section 4). 

File a copy of your site plan in Appendix 2, or file the copy elsewhere 

and record its location in section 15. 

50 


13 Hazardous Atmosphere Zones 

Description 

of a 

hazardous 

atmosphere 

zone 

A hazardous atmosphere zone is a space in which an explosive or 

flammable atmosphere is present, or may be expected to be present, 

and requires precautions to exclude potential ignition sources. 

At collision repair workshops, hazardous atmosphere zones typically 

exist where you find flammable liquids, LPG and acetylene. Parts 

wash vessels, if using flammable liquids, will also generate a 

hazardous atmosphere zone. 

Diesel and oxygen do not require a hazardous atmosphere zone. 

Types 

Hazardous atmosphere zones are categorised as one of three types, 

based on their likelihood and persistence (see Table 13.1). Areas 

classified into these zones must be protected from sources of ignition. 

When defining the extent of hazardous atmosphere zones you should 

seek professional advice. 

Table 13.1: Types of hazardous atmosphere zones 

Zone 

category 

Zone 0 

Zone 1 

Zone 2 

Description of zone 

An explosive air–gas mixture is continuously 

present or is present for long periods or 

frequently. 

An explosive air–gas mixture is likely to occur 

during normal operation only occasionally. 

An explosive air–gas mixture is not likely to 

occur in normal operation and, if it occurs, will 

persist for a short period only. 

Potential 

ignition 

sources 

Potential ignition sources include electrical equipment, naked flames 

(e.g. smoking), sparks from grinding and welding operations, and hot 

surfaces. 


Threshold 

quantities 

Hazardous atmosphere zones must be established and documented 

when the thresholds in Table 13.2 are exceeded. 

Table 13.2: Hazardous atmosphere zone threshold quantities 

Substance Threshold quantity 

Acetylene* 30 m 3 

LPG 

100 kg 

Flammable 

liquids 

100 L if in a closed container 

25 L when decanting 

5 L if the container is opened occasionally for 

a short period 

1 L if in an open container for continuous use 

Note: Hazardous atmospheres can still exist at lower volumes. 

* Four size G acetylene cylinders. 

Examples of 

hazardous 

atmosphere 

zones 

At collision repair workshops, hazardous atmosphere zones typically 

exist at: 

• spray booths; 

• mixing rooms; 

• tinting operations; 

• vents of spray booths; 

• LPG cylinder areas; 

• parts wash vessels. 

Typical examples of hazardous atmosphere zones are shown on the 

site plans included in section 4. 

Extent of 

hazardous 

atmosphere 

zones 

Typical hazardous atmosphere zones for collision repair workshops 

have been established and are recognised in Australian/New Zealand 

Standards. 13 

Relevant standards for defining a hazardous atmosphere zone are: 

• AS/NZS 2430.3.3:2004, Classification of hazardous areas – 

part 3.3 examples of area classification - flammable liquids; 

• AS/NZS 2430.3.9:2004, Classification of hazardous areas – 

part 3.9 examples of area classifications – miscellaneous. 

13 

AS/NZS 2430.3 Classification of Hazardous Areas: Examples of area classification. 

52 


Mark on site 

plans 

You must show hazardous atmosphere zones on site plans (see 

section 4). 

Managing 

hazardous 

atmosphere 

zones 

Hazardous atmosphere zones must be managed to prevent the risk of 

ignition or explosion. 14 

The Electricity Regulations 1997 require any electrical device or 

instrument installed in a hazardous atmosphere zone to be correctly 

rated for the zone. 

The Electricity Regulations 1997 also require a verification dossier to 

be kept for the electrical equipment. The dossier must include 

periodic re-inspection reports from the four-yearly inspections by a 

licensed electrical inspector. 

The periodic re-inspection reports must be available for review as part 

of the location test certificate assessment. 

File the verification dossier and reports in Appendix 4, or file them 

elsewhere and record their location in section 15 of this document. 

Further 


For more information about the requirements of the Electricity 

Regulations 1997, contact Energy Safety at the Ministry of Economic 

Development, see: 

http://www.energysafety.govt.nz/. 

14 

Regulations 59 to 70 of the Hazardous Substances (Classes 1 to 5 Controls) Regulations 2001. 


14 Stationary Container System Used in Connection with 

Burners 

Description of 

a stationary 

container 

system 

A stationary container system means a stationary tank and its 

associated equipment, pipe work, and fittings including burners. 

A test certificate will be required for a heated spray drying booth 

where diesel fuel is used. The test certification process for stationary 

container systems verifies that the system has been designed and 

installed and is operated in accordance with accepted engineering 

principles. 

Person in 

charge is 

responsible 

You, as the person in charge, are responsible for ensuring the 

stationary container system test certificate is obtained, even if the 

workshop owner does not own the stationary container system. 

Threshold 

quantities 

If your diesel tank is attached to a burner, and holds more than 60 L 

then you need a stationary container test certificate. 

If you have a diesel tank that is not attached to a burner, then the tank 

needs a stationary container system test certificate if the capacity is 

more than 500 L and it supplies an internal combustion engine. 

Otherwise the threshold is 5,000 L or more. 

Maintain 

records 

Keep a record of the standards to which all components of your 

stationary container system were designed and installed. These 

records may be in the form of drawings, a test certifier’s report, or a 

design report. 

Also maintain records of any routine servicing or maintenance work. 

An equipment register, as included in Appendix 5, will help you to 

maintain up-to-date records. 

File these records in Appendix 5, or file them elsewhere and record 

their location in section 15. 

54 


Burners 

Stationary 

container 

system 

certification 

All burners must be of a type that is approved. Your test certifier will 

check this. ERMA New Zealand maintains a register of approved 

types of burners, see: 

http://www.ermanz.govt.nz/search/index.html#other. 

For a stationary container system to be certified, a test certifier will 

assess (as applicable) and verify: 15 

• the system’s design, construction and installation; 

• the pressure management and emergency pressure management 

system; 

• level indicators; 

• lightning protection (above ground stationary tanks); 

• the distances between stationary containers, tank wagons and 

transfer points; 

• fire-fighting systems (above ground stationary tanks); 

• secondary containment systems; 

• markings; 

• maintenance carried out; 

• pipe work and fittings; 

• burners. 

Existing 

stationary 

container 

systems 

A stationary container system constructed before 1 April 2004 may 

not comply with the requirements. If you have a tank installed before 

this date and the capacity is less than 60,000 L, you may deal with it 

using an ERMA New Zealand approved code of practice. 16 

Test 

certifiers 

issue test 

certificates 

To obtain a stationary container system test certificate, contact a test 

certifier. The test certifier will need to visit your workshop and assess 

the stationary container system before he or she can issue a test 

certificate. 

A register of test certifiers is on the ERMA New Zealand website at: 


File copies of the stationary container system test certificate in 

Appendix 5, or file them elsewhere and record their location in 

section 15. 

15 

16 

Schedule 8 of the Hazardous Substances (Dangerous Goods and Scheduled Toxic Substances) 

Transfer Notice 2004, see http://www.ermanz.govt.nz/hs/transfer/docs.html. 

Approved Code of Practice for the Management of Existing Stationary Container Systems up to 

60,000 Litre Capacity, see http://www.ermanz.govt.nz/hs/compliance/codesofpractice.html. 


Compliance 

plans for 

existing 

stationary 

container 

systems 

If a stationary container system was constructed before 1 April 2004 

and requires a compliance plan to be submitted the records of this 

compliance plan must be retained. 

File your compliance plan and the letter of approval from ERMA New 

Zealand in Appendix 5, or file the plan and letter elsewhere and record 

their location in section 15. 

56 


15 Test Certificate Information Requirements 

Records 

You may file your records in this folder or you may file them 

elsewhere. For ready reference record their location in Table 15.1. 

If any record is not applicable to your workshop, write ‘Not 

applicable’ in the location column. 

Table 15.1: Location of records 

Use * Record Location 

Hazardous substances 


Safety data sheets 

Location test certificates 

1, 2 Site plans 

1 Approved handler test 

certificate(s) 

1 Emergency response plan 

1 Emergency response plan 

practice records 

1 Electrical certificates 

Stationary container 

system test certificate(s) 

2 Stationary container 

system design and 

installation records 

2 Compliance plan(s) 

2 Stationary container 

system service records 

Equipment register 

1, 2 Stock reconciliation 

records 

* 1 = make available for location test certificate 

2 = make available for stationary container test certificate 


58 


Appendix 1: Hazardous Substance Records 

Hazardous 

substance 


Complete the following sample hazardous substances inventory or 

replace it with your own inventory. 

Safety data 

sheets 

File copies of your safety data sheets after the hazardous substance 

inventory. 


60 


Hazardous Substances Inventory 

Trade or common 

name 

Acetylene 

Classification 

2.1.1A 

LPG 2.1.1A 

Container 

size 

(L or kg) 

Maximum 

quantity held 

(L or kg) 

Areas where stored and used 

Gas store 

Vehicle repair workshop 

Petrol 3.1A, 6.1E, 6.3B, 6.7B, 9.1B 

Methylated spirits 3.1B, 6.1E, 6.4A, 6.8B, 6.9A, 9.1D 

Diesel 3.1D, 6.1E, 6.3B, 6.7B, 9.1B 

Oxygen 5.1.2A 


62 


Appendix 2: Location Test Certificate Records 

Location test 

certificates 

File copies of your location test certificates after this page. 

Site plans 

File copies of your site plans after your copies of location test 

certificates. 


64 


Appendix 3: Approved Handler Records and Test 

Certificates 

Approved 

handler test 

certificates 

File copies of your approved handler test certificates behind this 

page. 


66 


Appendix 4: Electrical Certification 

Electrical 

certification 

File copies of your electrical certification records after this page. 

Electrical 

dossier 

File records of your electrical equipment after the electrical 

certification records. 


68 


Appendix 5: Stationary Container System Records 

Stationary 

container system 

test certificates 

File copies of stationary container system test certificates behind 

this page. 

Stationary 


design and 

installation 

verification 

records 

File copies of stationary container system design and 

installation verification records after the copies of stationary 

container system test certificates. 

Stationary 


compliance 

plans 

File copies of your compliance plans and approval letters after the 

copies of stationary container system design and installation 

verification records. 

Stationary 


service records 

File copies of your stationary container service records after the 

copies of your compliance plans and approval letters. 

Stationary 


equipment 

register 

File a copy of your completed stationary container system 

equipment register after the copies of your stationary container 

service records. 

Secondary 

containment 

system 

compliance plan 

File copies of your compliance plans and approval letters after the 

copy of the completed stationary container system equipment 

register. 


70 


Stationary Container System Equipment Register 

Stationary container 

system 

Component Registration number Manufacturer Design standard 


72 


Appendix 6: Additional Information 

Quick Guides 

File the following Quick Guides here: 

• Person in Charge 

• Approved handler 

• Group standards 

• Location test certificates 

• Emergency management 

ERMA Transfer 

Documents 

LPG 

Acetylene 

Oxygen 

Petrol 

Diesel 

Surface 

Coatings Group 

Standards 

Surface Coatings and Colourants (Flammable) Group Standard 

2006. 

Other group standards may be applicable to your flammable 

paints, check with your supplier. 


74

Guide to Certification for Collision Repair Workshops

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