How to Work Safely with Flammable Substances

• Employers must assess and control the risks associated with flammable substances in line with the Dangerous Substances and Explosive Atmospheres Regulations.
• Risks can be reduced through the implementation of control, mitigation and general safety measures.
• Control measures prevent incidents from happening. Examples include eliminating or substituting flammable substances, ensuring proper containment and maintaining good ventilation.
• Mitigation measures reduce the impact of an incident. Examples include providing appropriate PPE and establishing clear emergency procedures.
• General safety measures include keeping work areas tidy, designing facilities to minimise risks and inspecting and maintaining equipment.

There are strict legal requirements for handling flammable substances at work. The main regulations you need to know are the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) 2002 and the Regulatory Reform (Fire Safety) Order 2005.

• DSEAR: Requires employers to assess and control the risks of dangerous substances that could cause fires or explosions. It covers everything from risk assessments to providing training.
• Regulatory Reform (Fire Safety) Order 2005: Focuses on fire safety, including the need to have proper fire precautions and emergency plans.

Employers are legally responsible for ensuring flammable substances are stored, handled and used safely. Ignoring these duties puts your people and property at risk and leaves you exposed to legal action, including fines and even imprisonment in extreme circumstances.

Understanding what substances are flammable in your workplace is the first step to working safely. There are different types of flammable substances, and they’re not always obvious. They include:

• Liquids: Petrol, paint thinners and cleaning solvents are common examples.
• Gases: Propane, butane and certain welding gases can ignite easily.
• Solids: Some packaging materials, plastic foams and textiles can catch fire quickly.
• Dusts and Powders: Fine dust from woodworking can be highly flammable when dispersed in the air. Flour or sugar carry similar risks.

These substances are often classified by their flashpoint – the lowest temperature at which they produce vapours that can ignite. The lower the flashpoint, the more flammable the substance is.

The Health and Safety Executive (HSE) offers guidance on working safely with flammable substances in HSG140: Safe use and handling of flammable liquids. This document outlines essential steps to control risks and adds to the more comprehensive DSEAR Approved Code of Practice.

Here’s how you can apply these principles in your workplace:

You must have a thorough risk assessment in place before working with any flammable substances.

It should follow the same structure as a general workplace risk assessment:

1. Identify the Hazards: Start by listing all flammable substances in your workplace.
2. Decide Who Might Be Harmed and How: Identify everyone (employees, contractors, visitors, etc.) who might be exposed to these substances. Think about how they might be harmed during handling, storage or disposal.
3. Evaluate the Risks and Implement Precautions: Assess how likely it is that a fire or explosion could occur. Look at potential sources of ignition then decide on safety measures.
4. Record Your Findings: Document the hazards you’ve identified, the risks they pose and the control measures you’re implementing.
5. Review and Update the Assessment Regularly: Review your assessment at regular intervals and whenever you introduce new substances, change processes or after an incident.

No quantity of flammable liquid is considered automatically safe. A risk assessment is always necessary, even if flammable substances are used sparingly in your workplace.

Control measures should prevent an incident from happening. They’re ranked under DSEAR, with the elimination of flammable substances as the most preferred option and ventilation the least.

• Elimination: Eliminate the use of flammable substances wherever possible.
• Substitution: If elimination isn’t practical, check if there are safer alternatives with higher flashpoints.
• Reduction: If substitution isn’t practical, reduce the quantity of the flammable substance as much as possible.
• Containment: Use proper containers designed for flammable substances. Make sure containers are tightly sealed when not in use, and use bunding or spill trays to prevent spills from spreading. Regularly inspect containers for damage or leaks.
• Ventilation: Ensure that areas where flammable substances are used or stored are well-ventilated. This helps disperse vapours and reduces the risk of ignition. Mechanical ventilation may be necessary for enclosed spaces.

Mitigation measures limit the impact of an incident if it does happen:

• Separation: Store and use flammable substances away from other processes or storage areas. Use fire-resistant partitions or barriers to separate these substances from potential ignition sources.
• Personal Protective Equipment (PPE): Provide employees with appropriate PPE, such as flame-resistant clothing and anti-static footwear. PPE can’t be the first line of defence but should help reduce risks after implementing other safety measures.
• Emergency Procedures: Have clear emergency procedures in place for dealing with incidents involving flammable substances. Ensure that all workers are trained on these procedures and keep appropriate firefighting equipment easily accessible.

General safety measures cover efforts to make workplaces and processes as safe as possible:

• Design and Construction: Facilities where flammable substances are handled should be designed and built to minimise risks. Use materials that are compatible with the substances and maintain adequate containment to prevent spills.
• Maintenance and Modifications: Regularly inspect and maintain equipment used to handle flammable substances. Ensure that maintenance activities are carefully planned and controlled, especially when they involve hot work or could introduce ignition sources.
• Housekeeping: Maintain high housekeeping standards to minimise fire risks. Clean up spills immediately using appropriate absorbent materials, and dispose of waste safely. Keep work areas tidy, and ensure that exits and escape routes are always clear.

Training is a crucial part of keeping everyone safe when working with flammable substances. It ensures that all employees understand how to handle them safely and reduce risks. Here’s why training matters:

• Understanding Hazards: Training helps workers recognise flammable substance hazards, such as how vapours can ignite or how certain actions can create sparks. This awareness is the first step in preventing accidents.
• Correct Handling and Storage: Employees learn the proper methods for handling, storing and disposing of flammable substances. This knowledge reduces the risk of spills, leaks or fires.
• Emergency Preparedness: In the event of an accident, trained workers respond quickly and effectively. They’re familiar with emergency procedures, know where firefighting equipment is located and understand how to use it.

While not specific to handling flammable substances, Fire Awareness Training is a vital part of any workplace’s overall fire safety strategy.

Our online Fire Awareness Training course helps employees understand their role in fire prevention, safe evacuation procedures and how to handle firefighting equipment in critical situations.

This training helps reinforce fire safety knowledge and ensures everyone is prepared in case of an emergency.