Write a safe work procedure for working with hazardous chemicals

A safe work procedure for hazardous chemicals should start with a chemical inventory and task-based risk assessment. Identify each chemical, confirm its intended use, review the SDS and label, determine the hazards involved, evaluate how workers may be exposed by inhalation, skin or eye contact, ingestion, fire, explosion, or environmental release, and assess the quantity used, physical form, and conditions of use. Workplaces should maintain an accurate inventory, use SDS information and other technical data to identify hazardous properties, and conduct a risk assessment that considers the amount of a potential spill and the severity of harm to workers, the workplace, and the environment. Employers should then implement controls using the hierarchy of controls: eliminate or substitute where possible, then engineering controls, administrative controls, and PPE. [2] [2] [5]

Hazard identification must include the product identity, supplier, physical and health hazards, emergency hazards, incompatibilities, and exposure limits. Under WHMIS and OSHA HazCom, the SDS is a core hazard communication document. Workers should verify that the product name on the container matches the SDS, review Section 1 for identification, Section 2 for hazards, Section 7 for handling and storage, and Sections 4, 5, and 6 for emergency response. SDS Section 8 provides exposure limits, engineering controls, and PPE requirements. Because SDSs may not specify every workplace-specific control, the employer must translate SDS information into site-specific safe work procedures. [1] [1] [4]

SDS requirements: Ensure an SDS is readily available for every hazardous chemical, current for the product in use, and reviewed before work begins. The SDS should be used to identify first-aid measures, firefighting measures, accidental release procedures, handling and storage precautions, exposure controls, and PPE. OSHA HazCom SDS sections 4 through 7 specifically cover first aid, firefighting, accidental release, and handling/storage. During inventories and routine operations, confirm SDS availability and that workers know how to access and use them. [6] [6] [6] [15]

Labeling: Every hazardous chemical container should be clearly labeled with the product identifier and hazard information, and workplace containers should never be left unidentified. The label must match the SDS and support segregation and emergency response. For waste and spill residues, use labeled disposal containers made of compatible material and identify the spilled chemical. Good storage practice also includes selecting cabinets and storage systems based on the chemical hazard class and segregating incompatible chemicals. [1] [7] [11]

PPE selection must be chemical-specific and task-specific. Select gloves, eye/face protection, protective clothing, footwear, and respiratory protection based on the chemical, route of exposure, concentration, physical form, and duration of work. There is no single glove or clothing material that protects against all chemicals. Typical PPE may include chemical goggles or safety glasses with side shields, face shields, impervious gloves, aprons or suits, boots, and respirators where inhalation hazards exist. Respirator use must follow applicable respiratory protection requirements and should be based on exposure assessment and SDS guidance. [5] [8] [9]

Safe handling and storage procedures should require workers to avoid skin and eye contact, avoid breathing vapors, mists, or dusts, keep containers closed, use chemicals only as intended, prohibit eating, drinking, and smoking in work areas, wash thoroughly after handling, and remove contaminated clothing for cleaning before reuse. Storage areas should be dry, cool, well ventilated, secured as needed, and arranged to keep incompatible materials apart. Flammables must be kept away from heat, sparks, flames, and static discharge, and may require flammables cabinets or explosion-proof storage arrangements depending on the hazard. [6] [13] [14]

Exposure controls should follow the hierarchy of controls. Prefer elimination or substitution first. Where chemicals remain in use, apply engineering controls such as closed systems, local exhaust ventilation, process enclosure, chemical fume hoods, explosion-proof ventilation or electrical equipment where needed, and readily accessible eyewash stations and safety showers. Administrative controls should include limiting exposure time, restricting access, written procedures, hygiene rules, and health surveillance where appropriate. PPE is the last line of defense, not the primary control. [5] [9] [12]

Exposure limits from SDS Section 8 and applicable occupational exposure standards must be incorporated into the assessment and controls. For example, SDSs may list OSHA PELs, ACGIH TLVs, or other limits that determine whether ventilation, enclosure, monitoring, or respiratory protection is required. Where a chemical has a skin notation or can be absorbed dermally, skin protection and contamination control are especially important. Under COSHH, this aligns with assessing exposure, preventing or adequately controlling exposure, maintaining controls, monitoring where needed, and providing health surveillance when appropriate. [4] [9] [13]

Spill response must be planned in advance. Maintain a chemical inventory, develop a spill control procedure, define small versus large spills, identify who responds, and stock spill kits near the work area with compatible absorbents, neutralizers, PPE, tools, waste containers, labels, caution tape, and communication devices. Only trained personnel with the correct equipment should clean spills. If the spill is beyond the worker's training or control, evacuate, isolate the area, and call for help. Prevent entry to drains, control ignition sources for flammables, ventilate the area, and use containment and cleanup methods compatible with the chemical and its physical form. [2] [10] [3]

• Sound the alarm and isolate or evacuate the area as needed.
• Put on appropriate PPE, including respiratory protection if there is an inhalation hazard.
• If safe, stop the leak and control ignition sources.
• Contain liquids with compatible absorbents or diking materials; for solids, avoid dry sweeping fine powders unless confirmed safe and use suitable vacuum methods where required.
• Do not allow chemicals to enter drains or sewers.
• Place waste and contaminated absorbents in compatible, labeled disposal containers.
• Decontaminate or dispose of PPE and report the spill and any near miss according to procedure.

[7] [7] [7] Emergency procedures should cover first aid, fire, evacuation, spill escalation, rescue limitations, emergency contacts, and reporting. Workers must know when to use eyewash stations and safety showers, how long to flush exposed eyes or skin based on the SDS, when to pull the fire alarm, and when to evacuate rather than intervene. Emergency equipment should be located near the work area and workers must be trained in its use. For fires or highly toxic, reactive, or flammable releases, only properly equipped responders should intervene. [3] [3] [15]

Training and competency are essential. Workers must be trained on chemical hazards, WHMIS/HazCom labeling and SDS use, task-specific safe work procedures, PPE selection and limitations, hygiene practices, spill response, emergency equipment, and reporting requirements. Training should be refreshed when new chemicals, processes, or hazards are introduced. Supervisors should ensure workers know who to contact when instructions are unclear and that only competent, trained personnel perform higher-risk chemical tasks. [2] [5] [5]

For regulatory compliance, align the procedure with the common core requirements of WHMIS, OSHA Hazard Communication, and COSHH. In practice, this means: maintain a chemical inventory; ensure containers are labeled; keep current SDSs accessible; assess hazards and exposure before work; implement controls using the hierarchy of controls; provide suitable PPE and respiratory protection where needed; establish spill and emergency procedures; train workers; maintain eyewash/showers and other emergency equipment; and document inspections, incidents, and corrective actions. COSHH additionally emphasizes assessing substances hazardous to health, preventing or adequately controlling exposure, maintaining and examining controls, monitoring exposure where necessary, health surveillance where appropriate, and providing information, instruction, and training. [1] [6] [10]

1. Create and maintain a complete chemical inventory.
2. Obtain and review the current SDS before use; verify the container label matches the SDS.
3. Perform a task-specific risk assessment covering health, physical, and environmental hazards.
4. Identify exposure routes, quantities, physical form, incompatibilities, and worst-case spill/fire scenarios.
5. Apply the hierarchy of controls: eliminate, substitute, engineer, administratively control, then PPE.
6. Define required PPE and hygiene rules for each task.
7. Specify safe handling, transfer, decanting, and storage requirements, including segregation of incompatibles.
8. Set exposure control requirements such as ventilation, fume hoods, monitoring, and eyewash/shower availability.
9. Establish spill response and emergency procedures, including escalation criteria and reporting.
10. Train workers initially and periodically, and verify competency through supervision and review.

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