Health and Safety in Hazardous Material Handling: Essential Safety Measures

Understanding health and safety when handling hazardous materials can help prevent injuries, protect employees and reduce the risk of serious workplace incidents.

Hazardous substances are used across a wide range of industries, including manufacturing, logistics, healthcare, laboratories, construction and engineering. While many of these materials are essential to everyday operations, they can present significant risks if they are stored, handled, used or transported incorrectly.

Hazards may include exposure to toxic substances, chemical burns, fire, explosion, dangerous reactions and environmental contamination.

For UK businesses, managing these risks means understanding the substances being used, carrying out suitable risk assessments, implementing effective control measures and ensuring employees receive appropriate training.

A key source of information is the Safety Data Sheet (SDS) supplied with hazardous chemical products. An SDS provides important information about a substance’s hazards, handling, storage, emergency procedures, exposure controls, disposal and transport considerations.

You can learn more in our guide to why Safety Data Sheets are important.

It is important to remember that an SDS is not a risk assessment in itself. The Health and Safety Executive’s guidance on Safety Data Sheets explains that the information within the SDS should be used to help employers assess and control workplace risks.

1. Carry Out a Risk Assessment

Before employees begin working with hazardous materials, the risks associated with the activity should be properly assessed.

Under the Control of Substances Hazardous to Health Regulations (COSHH), employers must assess the risks created by substances hazardous to health and determine how exposure will be prevented or adequately controlled.

A hazardous-substance risk assessment should consider factors such as:

• The hazardous properties of the substance
• The quantity being used or stored
• How employees could be exposed
• The frequency and duration of exposure
• The physical form of the material, such as a solid, liquid, dust, vapour or gas
• Potential chemical reactions
• Storage and handling conditions
• Existing control measures
• Emergency arrangements

Product labels and Safety Data Sheets should form an important part of this assessment.

Useful SDS sections include:

• Section 2 – Hazard identification
• Section 7 – Handling and storage
• Section 8 – Exposure controls and personal protection
• Section 10 – Stability and reactivity
• Section 11 – Toxicological information
• Section 12 – Ecological information

The HSE provides detailed guidance on how to carry out a COSHH risk assessment.

For transport-related risks, you can also read our Dangerous Goods Risk Assessment guide.

2. Provide Appropriate Training

Employees cannot work safely with hazardous materials if they do not understand the hazards involved.

Training should be appropriate to the employee’s responsibilities and the substances or activities they encounter. Depending on the workplace, training may cover:

• Hazard identification
• Safe handling procedures
• Storage requirements
• Use of control measures
• PPE and respiratory protective equipment
• Spill response
• Fire and emergency procedures
• Waste disposal
• Dangerous Goods Regulations

Training should also be reviewed when working practices, materials or relevant regulations change.

Where a product may be classified as dangerous for transport, Section 14 of the Safety Data Sheet provides transport-related information. This can include the UN number, Proper Shipping Name, transport hazard class and packing group where applicable.

However, Section 14 should not be treated as a substitute for checking the applicable Dangerous Goods Regulations.

The UK Government provides guidance on the rules for transporting dangerous goods by road, air and sea.

If your employees are involved in preparing, handling or transporting dangerous goods, explore our Dangerous Goods Training Courses.

3. Use the Correct Personal Protective Equipment

Personal Protective Equipment (PPE) can provide an important additional layer of protection when employees are working with hazardous substances.

Depending on the substance and activity, PPE may include:

• Chemical-resistant gloves
• Safety glasses or goggles
• Face protection
• Protective clothing
• Safety footwear
• Respiratory Protective Equipment (RPE)

Section 8 of the Safety Data Sheet should be reviewed for information about exposure controls and recommended personal protection.

However, PPE should not automatically be treated as the primary means of controlling exposure. Employers should first consider whether the hazard can be eliminated, substituted or controlled through engineering measures and safer working methods.

The HSE provides further guidance on using Personal Protective Equipment to control risks at work.

4. Store Hazardous Materials Safely

Correct storage is essential for reducing the likelihood of leaks, spills, fires and dangerous chemical reactions.

Hazardous materials should be stored in suitable containers and in designated areas appropriate to their properties.

Storage arrangements may need to consider:

• Ventilation
• Temperature
• Ignition sources
• Spill containment
• Security
• Container compatibility
• Separation of incompatible substances
• Maximum storage quantities
• Emergency access

For example, flammable substances may need to be separated from oxidising materials or other substances that could increase the severity of a fire.

Section 7 of the SDS provides handling and storage information, while Section 10 provides information about stability, reactivity and incompatible materials.

Businesses handling flammable liquids, gases, combustible dusts or other dangerous substances should also consider their responsibilities under the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR).

Read the HSE’s official DSEAR guidance for more information.

For practical advice, see our guides to Safe Chemical Storage and Hazmat Storage Requirements.

5. Establish Safe Handling Procedures

Safe systems of work should be established for employees who use, transfer, load, unload or otherwise handle hazardous materials.

Procedures should reflect both the substance involved and the task being performed.

Measures may include:

• Using suitable pumps, containers and transfer equipment
• Keeping containers closed when not in use
• Preventing uncontrolled releases
• Avoiding incompatible materials
• Controlling ignition sources
• Maintaining good housekeeping
• Following correct decanting procedures
• Inspecting containers and equipment for damage

Employees should understand these procedures and know what to do if something goes wrong.

Always review Section 7 of the Safety Data Sheet for product-specific handling and storage requirements.

6. Prepare for Spills and Emergencies

Even with effective prevention measures, organisations should be prepared for emergencies.

Emergency arrangements should reflect the materials present and the potential consequences of an incident.

Depending on the workplace, plans may need to cover:

• Chemical spills
• Leaks
• Fires
• Employee exposure
• Accidental releases
• Evacuation
• First aid
• Environmental contamination

Relevant Safety Data Sheet sections include:

• Section 4 – First-aid measures
• Section 5 – Firefighting measures
• Section 6 – Accidental release measures

Emergency equipment such as suitable spill kits, eyewash facilities, safety showers and fire extinguishing equipment should be available where identified by the risk assessment.

Importantly, the appropriate response can vary considerably between substances. Water, for example, may be unsuitable for particular reactive materials.

For more information on preparing for incidents, read our guide on how to create an Emergency Spill Response Plan.

7. Communicate Hazards Clearly

Clear hazard communication helps employees, contractors, transport operators and emergency responders understand what they are dealing with.

Containers should retain the appropriate product labels and hazard information. Employees should also have access to relevant Safety Data Sheets and workplace procedures.

For dangerous goods being transported, additional transport classification, marking, labelling and documentation requirements can apply.

Dangerous goods are divided into nine hazard classes, covering substances and articles ranging from explosives and gases to corrosives and miscellaneous dangerous goods.

Read our guide to the 9 Dangerous Goods Hazard Classes for an overview.

You can also explore our individual guides, including:

• Class 2 Dangerous Goods – Gases
• Class 3 Dangerous Goods – Flammable Liquids
• Class 4 Dangerous Goods – Flammable Solids, Spontaneously Combustible and Dangerous When Wet

8. Maintain Regulatory Compliance

Hazardous material management can involve several different areas of UK legislation depending on what the substance is and what the organisation is doing with it.

These can include requirements relating to:

• COSHH
• Chemical classification and labelling
• DSEAR
• PPE
• Dangerous goods transport
• Hazardous waste
• Environmental protection

It is important to recognise that hazardous substances in the workplace and dangerous goods for transport are not necessarily the same thing.

A product may be subject to workplace chemical controls while having different requirements when it is offered for transport. Businesses should therefore check both workplace safety obligations and the relevant transport regulations.

For businesses moving dangerous goods, the UK Government’s guidance on moving dangerous goods provides an overview of the requirements for road, rail, air and sea transport.

For a more detailed overview, read our UK Dangerous Goods Regulations guide.

9. Provide Suitable Ventilation and Exposure Controls

Ventilation can play an important role in controlling exposure to hazardous gases, vapours, fumes, mists and dusts.

Depending on the activity, general workplace ventilation may be appropriate, or a properly designed Local Exhaust Ventilation (LEV) system may be required to capture contaminants close to the point where they are generated.

Ventilation should form part of an overall exposure-control strategy rather than being considered in isolation.

The HSE provides guidance on ventilation in the workplace and COSHH control measures.

Where occupational exposure limits apply, employers should ensure exposure is appropriately controlled and monitored.

10. Dispose of Hazardous Waste Correctly

Hazardous materials do not stop presenting a risk simply because they are no longer required.

Waste chemicals, contaminated packaging, oils, solvents, batteries and other materials may be classified as hazardous waste and require controlled storage, collection and disposal.

Section 13 of the Safety Data Sheet provides disposal considerations for the substance or mixture.

Businesses should ensure hazardous waste is:

• Correctly identified and classified
• Separated from incompatible waste
• Stored safely
• Collected by appropriately authorised organisations
• Accompanied by the required documentation
• Sent to authorised facilities

For businesses in England, GOV.UK provides official guidance on hazardous waste responsibilities for producers and holders.

11. Monitor and Review Your Controls

Health and safety management should be an ongoing process.

Employers should regularly review whether their control measures remain effective. This could involve:

• Workplace inspections
• Checking storage areas
• Reviewing Safety Data Sheets
• Examining PPE
• Maintaining ventilation and LEV systems
• Monitoring workplace exposure where necessary
• Investigating spills, near misses and incidents
• Reviewing employee training
• Updating risk assessments

Reviews are particularly important when new substances are introduced, processes change, an incident occurs or new information about a hazard becomes available.

Continuous monitoring helps organisations identify weaknesses before they result in an accident or exposure.

The Importance of Safety Data Sheets

Throughout hazardous-material management, the Safety Data Sheet is one of the most useful sources of product-specific safety information.

A standard SDS contains 16 sections covering areas including hazards, first aid, firefighting, accidental release, storage, exposure controls, stability, toxicology, disposal and transport.

The HSE provides further information on Safety Data Sheets and UK chemical requirements.

You can also read Logicom Hub’s guide: Safety Data Sheets Explained: Why Every Business Handling Hazardous Materials Needs Them.

Conclusion

Handling hazardous materials safely requires more than simply wearing PPE or keeping a Safety Data Sheet on file.

Organisations need a structured approach that includes risk assessment, employee training, appropriate controls, safe storage, emergency planning, clear communication and regular review.

When hazardous materials are also classified as dangerous goods for transport, businesses must consider the additional requirements that apply when shipping them by road, air, sea or rail.

Investing in appropriate training helps employees understand these responsibilities and gives them the confidence to recognise hazards and follow the correct procedures.

Need Dangerous Goods Training?

Logicom Hub is a leading provider of Dangerous Goods Training Courses (HAZMAT), supporting businesses and individuals who handle, prepare and transport dangerous goods.

We provide interactive training designed to build confidence, improve knowledge and help organisations maintain compliance across different modes of transport.

Explore our Dangerous Goods Training Courses or contact our team to discuss the most appropriate training for your organisation.

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