An explosion at a Houston manufacturing facility in January 2020 killed two employees when a spark ignited a propylene gas tank leak. In July 2021, three chemical operators at an Alabama manufacturing facility suffered respiratory failure due to the unexpected release of the toxin fluorocarbon during routine maintenance. Incidents from unexpected chemical leaks can be reduced or eliminated when companies follow the Occupational Safety and Health Administration’s (OSHA) strict guidelines on handling, using, moving, storing, and manufacturing highly hazardous chemicals (HHCs).
These tips can help companies prevent HHCs from being mishandled or released:
1 Make sure workers know the hazards associated with all workplace chemicals.
The “Right-to-Know” law requires employers to have a written Hazardous Communication (HAZCOM) Program that includes:
- a list of all hazardous chemicals known to be in the workplace;
- Safety Data Sheets (SDS) for each hazardous chemical;
- a training plan to communicate hazard information to employees; and
- a warning label on each container of a hazardous chemical.
2 Create a written Respiratory Protection Program.
OSHA requires employers to have a written Respiratory Protection Program when permissible exposure limits (PELs) of airborne contaminants are exceeded, or when the employer requires employees to use respirators.
3 Perform initial and periodic tests for chemical exposures.
OSHA sets limits on chemical exposure in the workplace. Three tables on the OSHA website show the exposure limits of different types of contaminants allowed over an eight-hour workday. OSHA expects employers to sample the air quality, assess chemical exposure, and keep within the PELs.
4 Ensure workers use appropriate personal protective equipment (PPE).
PPE incorporated into work practices when coming into contact with HHCs may include chemical-resistant gloves, safety glasses, safety shoes, earplugs or muffs, hard hats, respirators, coveralls, vests, or full bodysuits. Companies must have a PPE Program (see 29 CFR 1910 Subpart I) if PPE is used. Employers must train each worker on:
- when PPE is necessary;
- what type of PPE is necessary;
- how to properly put on and take off PPE;
- the limits of the equipment; and
- the proper care, maintenance, service life, and disposal of PPE.
5 Follow OSHA’s Process Safety Management of Highly Hazardous Chemicals standard.
This standard contains fourteen requirements for safely using, storing, manufacturing, handling, or moving HHCs onsite. Its objective is to help employers prevent unwanted releases of toxic, reactive, flammable, or explosive chemicals in locations that could expose employees and the community to serious hazards.
OSHA encourages employers to take these steps to identify, reduce, and prevent hazards from unexpected chemical releases. The Texas Occupational Safety and Health Consultation (OSHCON) Program is available to provide employers free on-site assistance in developing HAZCOM, respiratory protection, PPE, and Process Management Safety programs, or to ensure companies are following OSHA standards. OSHCON consultants are available at OSHCON@tdi.texas.gov or 800-242-8031, option 2. For more information, download or stream any of DWC’s free chemical safety publications or workplace safety videos.