Operational Control Measures in Chemical Handling

Any chemical that can cause a harmful effect on human health, property or environment; due to their chemical properties, can be termed as a hazardous chemical. The risks associated with such chemicals include toxicity, flammability, reactivity and corrosiveness. As most of these chemicals find their place in manufacturing units, warehouses, laboratories and logistics facilities; special care shall be taken while handling such items, as per the existing dangerous goods/ hazardous materials safety protocols. The person who is handling these chemicals should be well-informed regarding the risks to health caused by exposure to these chemicals, necessary precautionary measures, hazard identification and control measures including the use of Personal Protective Equipment (PPE) and the emergency response procedures associated with each class of chemicals. Having mentioned that, the UN classification for hazardous chemicals, with nine classes of potentially dangerous goods, include the following:



As safety consultants, who provide expertise and guidance on managing risks associated with handling, storing, transporting, and disposing of chemicals in various industries; we come across numerous such incidents where lack of operational control measures leading to high-risk scenarios. During risk assessments, regulatory compliance audits/studies as well as safety trainings; we make sure to identify/communicate the hazards associated with operations such as storage, handling and transportation of chemicals, based on the international as well as local safety guidelines and regulations.

The key operational control measures commonly employed in chemical storage facilities include:  

  • Proper segregation of chemicals based on the UN compatibility chart (or any local guidelines, if necessary) to prevent chemical reactions leading to explosions, fires or release of toxic fumes.
  • · Correct labelling, including details such as name and class of the chemical, hazards associated, safety instructions for handling and emergency contact details, on individual containers.
  • · Inspections on a periodic basis, to check the integrity of containers. Also, prompt replacement of damaged containers is a necessary measure.
  • · If the chemical’s Material Safety Data Sheet (MSDS) demands specific conditions for storage room ventilation or temperature control; such conditions need to be met in order to prevent the buildup of hazardous vapours or gases in storage areas.
  • · During accidental spillages, proper spill containment measures including secondary containment basins should be in place to contain the contaminated water. Further treatment needs to be carried out to prevent the entry of effluent into common drain lines.
  • · Emergency response equipment including spill kits, eyewash stations, first aid kits and fire extinguishers should be provided within the storage facility at an easily accessible location.
  • · The operational control measures also include the use of appropriate PPEs, and personnel training on chemical handling and emergency preparedness.
During handling of potentially hazardous chemicals, it is advised to bring in safer design and installation practices such as totally enclosed process and handling systems; plants processes or work systems which minimize generation of, or suppress or contain, hazardous dust, fumes, etc., and which limit the area of contamination in the event of spills and leaks. Work systems and practices can also align accordingly to reduce the number of workers exposed and exclusion of non-essential access into the storage/process area.

For flammable or explosive chemicals, which are highly vulnerable to variations in ambient conditions should be provided with methods for elimination of sources of ignition and for the creation of an inert atmosphere for totally enclosed processes. Provisions such as fire detection alarms, means for detecting pressure variations, etc. can also be considered for the enhancement of safety measures.

The following control measures shall be adopted during the transport of chemicals:
  • · The criteria established by the competent authority shall be followed while transporting potentially hazardous chemicals.
  • · There will be limits on the quantity of chemicals that can be transported at any point of time, and this has to be strictly adhered to, in order to ensure safer conveyance of goods.
  • · The type and integrity of packaging materials used, the specifications of the vehicle used for carrying the freight and the routes that shall be taken are also major considerations when it comes to the safe transportation of chemicals.
  • · The transport workers need to undergo work-specific trainings to meet the safety criteria for loading and unloading of chemical goods.
Another important aspect of operational control is the proper disposal and treatment of chemicals, which include measures to eliminate/minimize the risk to safety and health and to the environment, in accordance with the local/international regulations.

Waste products need to be clearly identified as such, both based on their origins and their primary components, especially if known. The primary components should be discerned from the product's history. If there is uncertainty regarding the level of hazard posed by the waste, it should be classified according to the highest potential hazard. Containers that are empty but still contain traces of hazardous chemicals should be sealed and stored until disposal or reuse. They should be handled as if they still contain those hazardous chemicals. Additionally, these empty containers should maintain the same identification, markings, and labelling as they had for their previous contents. Effluent discharge, waste disposal and transportation, and emission of smoke and chemicals into the atmosphere must be conducted in a manner that prevents or minimizes risks to workers. Alternatively, they should align with national laws and practices aimed at safeguarding the general public and the environment.

EHS Consultants, with our 40 plus man-years of experience in supporting industries by providing solutions to health, safety and environmental risk-scenarios, followed by trainings on chemical handling as well as various emergency response/occupational safety; helps your business to reduce risks, ensure regulatory compliance, and create safer working environments for the employees.

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