Best Practices for Hazardous Materials Handling

Best Practices for Hazardous Materials Handling

Certain production and maintenance processes involve the use of hazardous materials, which, by definition, introduce workers and the worksite to the risk of exposure to harmful substances. Hazardous materials handling refers to the transport, use, and storage of these substances, which have the potential to cause harm to people and the environment.

There are various types of hazardous materials. The Globally Harmonized System (GHS) of Classification and Labelling of Chemicals classifies these materials as either physical hazards, health hazards, or environmental hazards. These include (but are not limited to) explosives, flammable substances, radioactive material, corrosives, biohazards and toxic substances, carcinogens, and those that damage the aquatic environment and ozone layer.

Hazardous material handling requires a commitment to occupational safety, health, and environmental (SH&E) practices to prevent exposure to these harmful substances.

 

Elimination and Substitution of Hazardous Materials

It is always important to emphasize that the most effective methods for controlling hazards at the top of the Hierarchy of Controls are elimination and substitution.

The best way to handle hazardous materials is to remove them from the workplace altogether. Elimination involves redesigning products or processes so hazardous substances are no longer required. For example, a product may be redesigned to eliminate component parts that require bonding, eliminating the use of toxic adhesives.

This step, while ideal, is not always feasible. For example, some manufacturing processes may require the use of substances that all have certain harmful properties but which are essential to production. When elimination isn’t possible, substituting a less harmful material is the next best option. In the example regarding use of adhesives, those with lesser toxicity should be used in place of those with greater toxicity.

Both elimination and substitution are preventive strategies that aim to reduce exposure and reliance on hazardous materials at the source, leading to a safer workplace and reducing the need for additional protective measures.

 

Engineering Controls

Following elimination and substitution, the risk of working with hazardous materials can best be mitigated by engineering controls.

The risk involved when working with hazardous materials is related to the potential for people or the environment to be exposed to the material’s harmful properties. Engineering controls modify the work process to minimize this exposure.

Hazardous material should be isolated from those not required to work with it by keeping the material in proper containers within a restricted area and removed from workers by both distance and secure containment.

When a hazardous material is required for work, potential exposure can be further limited by accessing the material remotely via robotics, piping the hazardous material from the isolated location, or by use of automated transfer lines and conveyors when transfer is required.

When hazardous materials are used at a workstation, isolation can be maintained through use of enclosed fume hoods, biosafety cabinets, or other means of separating workers from the substance. Local exhaust ventilation further captures any hazardous fumes, vapors, or dust at the source before they can spread into the workplace.

Finally, environmental monitoring and control systems ensure that hazardous materials, where they are stored or used, are properly vented, kept at a safe pressure when contained, and kept at safe temperatures.

 

Hazard Communication

Hazard communication is an important administrative control in the shipping, handling, or disposal of toxic or hazardous substances. Inadequate hazard communication is one of the Occupational Safety and Health Administration’s (OSHA’s) most cited areas requiring improvement in the United States, and its significance internationally spurred the creation of the GHS for the labeling of chemicals by the United Nations.

Proper labeling is important to ensure that everyone in the workplace is aware of potential hazards associated with materials. Each container holding a hazardous substance should have a clear label with the most pertinent information clearly displayed, including the substance’s name, hazard symbols, signal words (e.g., “Danger” or “Warning”), precautionary statements, and hazard statements.

The Globally Harmonized System of Classification and Labelling of Chemicals (GHS) should be used for these labels, further details on which can be found on the GHS website, OSHA’s Hazard Communication webpage, and the Canadian Centre for Occupational Health and Safety (CCOHS) page on Chemicals and Materials.

Safety Data Sheets (SDSs) with further details on the hazardous materials should be maintained for each, and include the substance’s properties, handling procedures, health risks, and emergency response recommendations.

The SDS documents should be readily accessible to all employees, either in physical binders or via an electronic database. OSHA’s Hazard Communication Standard requires employers to keep SDS documents for every hazardous material used on-site, ensuring that employees have access to safety information whenever needed.

Companies that manufacture hazardous materials are responsible for providing updated SDSs when new information about a substance’s hazards or its safe usage becomes available. As a secondary resource, OSHA maintains an Occupational Chemical Database for reference. Employers must maintain these updated records and promptly communicate any changes to employees.

 

Worker Training

Safe hazardous material handling requires employee training. Training programs should cover hazard identification, proper use of the hazardous substances, and emergency response.

First, employees must be trained to read and understand materials’ labels and SDSs. Workers must understand the GHS labels and know how to take the relevant precautions. They should also know where to locate SDSs and how to interpret sections covering handling, storage, disposal, and emergency protocols. Regularly scheduled training on the GHS labels and SDSs reinforces the importance of these as primary sources of information.

In addition to understanding the hazards associated with the materials with which they work, employees must receive training upon hire and periodically throughout employment that reinforces safe practices. Training topics should include safe handling and storage procedures, reporting hazards/near misses/incidents, how to use PPE, and emergency response.

Documenting each worker’s training history is essential to track compliance and ensure employees stay updated on safe handling practices. Note that, in many industries, workers must complete certifications before handling certain hazardous materials.

 

Personal Protective Equipment (PPE)

PPE is the last line of defense against exposure to hazardous materials and includes items such as gloves, goggles, respirators, and full-body suits. The choice of PPE depends on the type of hazard present.

PPE must be selected based on the material’s properties and the potential exposure. For instance, highly toxic or corrosive materials may require respiratory protection or chemical-resistant suits, while eye protection and gloves may suffice for less hazardous substances.

Workers need to know how to correctly use and maintain their PPE as well. Training should cover proper fitting, regular inspection, cleaning, and safe storage of PPE. Employers must provide PPE free of charge and replace it regularly to maintain effectiveness.

 

Emergency Preparedness

Even with stringent safety measures, accidents involving hazardous materials can still happen. Emergency preparedness ensures that workers and first responders know how to respond to spills, leaks, or other incidents.

Ensure your Emergency Action Plan (EAP) includes step-by-step actions for handling emergencies involving hazardous materials at your workplace. This plan should detail evacuation routes, communication procedures, spill containment strategies, and assigned responsibilities. All employees should be familiar with the EAP, and practice drills should be conducted regularly.

For larger facilities or those handling particularly dangerous materials, it’s important to coordinate with local emergency response teams, including fire departments and hazardous material (HAZMAT) units. Pre-planning with these groups can significantly improve response times and outcomes during an emergency.

The handling of hazardous materials requires a comprehensive SH&E program that includes the elimination or substitution of hazardous substances, engineering controls, effective communication, worker training, proper PPE, and emergency preparedness. By following these best practices, organizations can create a safer working environment that minimizes risk and ensures the safety and health of people and the environment.

 

Tags: Hazardous Materials PPE Emergency Preparedness Engineering Controls OSHA CCOHS

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