Hazardous Materials In The Warehouse

In warehouses around the world, there are always some industries that store large amounts of hazardous materials in their warehouses. So how do we, as warehouse managers, store these hazardous materials in the safest way possible?

So next, let’s discuss the topic of how to manage and store hazardous materials with you!

What are the Hazardous Materials in a Warehouse?

There are many common hazardous materials stored in warehouses. In this article, I will provide examples based on their physical and chemical properties:

Flammable Liquids

Typical Scenarios: Logistics warehouses, chemical warehouses, retail warehouses.

• Common Materials:
  • Gasoline (used for industrial equipment or vehicles).
  • Ethanol (a component of cleaning agents or disinfectants).
  • Acetone (paint thinner).
  • Diesel fuel (backup generator fuel).

Flammable Gases

Typical Scenarios: Industrial gas warehouses, warehouses attached to production plants.

• Common Materials:
  • Propane (used for forklift fuel).
  • Hydrogen (for manufacturing or laboratory use).
  • Liquefied petroleum gas (industrial fuel).

Corrosive Materials

Typical Scenarios: Chemical warehouses, storage of cleaning supplies.

• Common Materials:
  • Hydrochloric acid (for cleaning or industrial use).
  • Sodium hydroxide (for cleaning or pharmaceutical use).
  • Sulfuric acid (used for battery storage).

Toxic Substances

Typical Scenarios: Agricultural product warehouses, chemical warehouses.

• Common Materials:
  • Pesticides (pesticide storage).
  • Chlorine gas (for water treatment).
  • Benzene (solvent).

Compressed Gases

Typical Scenarios: Industrial gas warehouses, warehouses attached to production facilities.

• Common Materials:
  • Oxygen cylinders (for medical or welding use).
  • Carbon dioxide cylinders (for the food and beverage industry, for cooling or carbonation).
  • Argon gas (for welding).

Lubricants and Petroleum Products

Typical Scenarios: Mechanical equipment maintenance warehouses, logistics centers.

• Common Materials:
  • Engine oil (industrial equipment maintenance).
  • Hydraulic oil (forklift or crane maintenance).
  • Grease (industrial equipment protection).

Hazardous Waste

Typical Scenarios: Manufacturing warehouses, recycling centers.

• Common Materials:
  • Oily waste liquid (generated during mechanical maintenance).
  • Used chemical reagents (laboratory or production processes).
  • Used batteries (production or consumer product recycling).

Cleaning Agents and Solvents

Typical Scenarios: Retail warehouses, logistics centers.

• Common Materials:
  • Bleach (cleaning supplies).
  • Isopropyl alcohol (for industrial or medical cleaning).
  • Styrene (paint thinner).

Batteries (including lithium batteries)

Typical Scenarios: Electronics warehouses, logistics transit centers.

• Common Materials:
  • Lithium-ion batteries (consumer electronics).
  • Lead-acid batteries (vehicles or industrial equipment).

Regulations on Hazardous Materials

Hazardous materials are subject to strict regulations to ensure their safe handling, storage, and transportation. Below is an overview of the primary regulations and standards governing hazardous materials in regions like the United States, Canada, and Australia, along with international frameworks.

United States

OSHA (Occupational Safety and Health Administration)

1. Hazard Communication Standard (HCS):
   • Requires employers to provide Safety Data Sheets (SDS) to ensure employees are informed about hazardous materials in the workplace.
   • Mandates proper labeling and warning signs for hazardous materials.
2. Process Safety Management (PSM):
   • Applies to facilities storing large quantities of hazardous chemicals.
   • Requires risk management plans to prevent accidents like leaks or explosions.

DOT (Department of Transportation)

1. Hazardous Materials Regulations (HMR):
   • Covers transportation of hazardous materials by road, rail, air, and sea.
   • Includes detailed requirements for packaging, labeling, and documentation.
   • Applies to 9 classes of hazardous goods, such as flammable liquids, corrosive substances, and toxic materials.

EPA (Environmental Protection Agency)

1. Resource Conservation and Recovery Act (RCRA):
   • Regulates the generation, handling, transportation, and storage of hazardous waste.
   • Implements a tracking system to monitor hazardous waste from generation to disposal.
2. Clean Air Act (CAA):
   • Controls emissions of hazardous air pollutants.
   • Establishes strict guidelines for storing toxic chemicals to prevent harmful emissions.

NFPA (National Fire Protection Association)

1. NFPA 400: Hazardous Materials Code:
   • Provides guidelines on the storage and use of hazardous materials, including volume limits and fire protection measures.
2. NFPA 101: Life Safety Code:
   • Addresses potential risks hazardous materials pose to human safety.
   • Offers guidance on emergency evacuation and fire protection.

Canada

Workplace Hazardous Materials Information System (WHMIS)

• Similar to the U.S. Hazard Communication Standard (HCS), WHMIS requires:
  • Provision of safety labels and Safety Data Sheets (SDS) for hazardous materials.
  • Employee training to ensure awareness of risks and safe handling procedures.

Transportation of Dangerous Goods Regulations (TDG)

• Focused on the safe transportation of hazardous goods, ensuring proper labeling, packaging, and documentation during transit.

Australia

Work Health and Safety Regulations (WHS)

• Emphasizes risk assessment and control measures for the storage, handling, and use of hazardous chemicals.
• Establishes requirements for labeling, emergency planning, and protective equipment to minimize workplace risks.

European Union (EU)

Registration, Evaluation, Authorization, and Restriction of Chemicals (REACH)

• Obligates manufacturers and importers to provide detailed safety information about chemicals throughout their lifecycle.
• Ensures comprehensive risk assessments for human health and environmental protection.

Classification, Labeling, and Packaging (CLP) Regulation

• Harmonizes hazardous chemical classification and labeling across the EU.
• Aligns with the Globally Harmonized System (GHS) to ensure consistency in warnings and information.

ATEX Directives

• Governs the storage and use of materials and equipment in explosive atmospheres.
• Aims to reduce risks associated with flammable substances and ensure equipment safety in hazardous environments.

International Standards

UN Recommendations on the Transport of Dangerous Goods

• Provides a globally recognized framework for the classification, labeling, and safe transport of hazardous goods.
• Serves as a foundational reference for national and regional hazardous materials regulations.

Globally Harmonized System of Classification and Labeling of Chemicals (GHS)

• Standardizes the classification and labeling of hazardous materials worldwide.
• Includes a universal template for Safety Data Sheets (SDS), adopted by many countries to ensure consistency and clarity in hazard communication.

How to Store Hazardous Materials

Classification and Segregation

1. Storage by Hazard Class
   • Follow the United Nations classification system to group materials by hazard class (e.g., flammable liquids, corrosive substances, oxidizers).
   • Keep incompatible materials separated. For example:
     • Flammable materials should not be stored with oxidizers.
     • Acids must be kept away from alkalis.
     • Cyanides must be stored separately from acids to prevent toxic gas release.
2. Physical Separation
   • Use fire-resistant walls, dedicated storage rooms, or isolated storage zones to segregate different types of hazardous materials.
   • Maintain minimum safety distances as per regulatory requirements.

Environmental Controls

1. Temperature and Humidity
   • Maintain controlled temperatures to prevent degradation or chemical reactions.
   • For materials requiring refrigeration (e.g., some chemical reagents), install cold storage systems.
2. Ventilation
   • Ensure proper ventilation to prevent the accumulation of toxic or flammable gases.
   • Install local exhaust systems in areas with volatile substances.
3. Fire and Explosion Prevention
   • Use explosion-proof lighting and equipment in flammable material storage areas.
   • Prohibit open flames or high-temperature devices in hazardous areas.

Containers and Packaging Requirements

1. Approved Containers
   • Use corrosion-resistant, pressure-resistant, and leak-proof containers.
   • Ensure containers comply with UN marking and DOT standards.
2. Clear Labeling
   • Each container must have a clear label indicating the substance name, hazard symbol, and storage requirements.
   • Labels should follow the Globally Harmonized System (GHS) for classification and labeling.
3. Secondary Containment
   • Use spill trays or secondary containment systems for liquid hazardous materials to prevent leaks from contaminating floors or the environment.

Safety Equipment and Facilities

1. Firefighting Equipment
   • Provide fire extinguishers appropriate for the type of hazardous materials stored (e.g., CO₂ extinguishers for flammable liquids).
   • Install automatic sprinkler systems, but avoid water-based systems near water-reactive chemicals.
2. Leak Control
   • Stock spill control equipment such as absorbent pads, spill barriers, and emergency containment drums.
3. Personal Protective Equipment (PPE)
   • Equip personnel with gloves, goggles, protective suits, and respirators specific to the hazards of the stored materials.

Storage Capacity and Layout

1. Segregated Storage
   • Adhere to maximum allowable storage quantities per NFPA or local regulations to minimize risk.
2. Stable Stacking
   • Stack containers securely to prevent tipping or collapse.
   • Avoid storing other items above hazardous material containers.

Management and Documentation

1. Safety Data Sheets (SDS)
   • Make SDS documents accessible in storage areas and for employees. These should detail material properties, risks, and emergency measures.
2. Regular Inspections
   • Inspect containers, labels, ventilation systems, and spill control equipment periodically.
   • Keep inventory records up-to-date and dispose of expired or damaged materials promptly.
3. Training and Drills
   • Conduct professional training for staff on hazardous material storage, handling, and emergency response.
   • Hold regular drills for incidents like fires or leaks.

Compliance with Regulations

1. Follow Local Laws
   • USA: Comply with OSHA, NFPA, EPA, and DOT regulations.
   • EU: Follow REACH and CLP standards.
2. Obtain Permits
   • Secure permits for storing high-risk materials and undergo regular inspections by regulatory authorities.

Common hazards of hazardous materials and ways to avoid them

Damaged or leaking containers

Regularly check the sealing of containers and replace aged or deformed containers in time.

Fire caused by static sparks

Install anti-static equipment (grounding wire, anti-static floor) in storage areas. Operators wear anti-static gloves and shoes.

Uncontrolled temperature leads to decomposition or explosion

Install automatic temperature monitoring systems and alarm devices for hazardous material areas.

Mixing of incompatible materials

Provide detailed material compatibility charts and conduct regular audits of storage layouts.

Inadequate emergency response

Regularly train employees in emergency response to fires, leaks and gas diffusion, and ensure that drill procedures are consistent with realistic scenarios.

Conclusion

In closing, we hope that what we’ve talked about will help you manage hazardous materials better and safer in your warehouse. If you have more needs and questions about storage and racking, you are welcome to contact us!