Laboratory chemical safety involves identifying chemical hazards, evaluating how employees may be exposed, and establishing controls for the safe receipt, storage, handling, use, transfer, and disposal of hazardous chemicals. Effective chemical safety practices help prevent chemical exposures, burns, poisoning, fires, explosions, uncontrolled reactions, spills, and other laboratory incidents.
Laboratories may contain hundreds or even thousands of chemicals with very different properties. Some are toxic, corrosive, flammable, reactive, oxidizing, sensitizing, carcinogenic, or capable of causing serious health effects through inhalation, skin contact, ingestion, or injection.
For laboratories covered by OSHA’s Laboratory Standard, 29 CFR 1910.1450, employers must develop and implement a written Chemical Hygiene Plan (CHP) capable of protecting employees from health hazards associated with hazardous chemicals and keeping exposures within applicable limits.
What Is Laboratory Chemical Safety?
Laboratory chemical safety is the system of practices and controls used to protect employees and others from hazards associated with laboratory chemicals.
An effective program considers the entire chemical lifecycle:
Selection → Procurement → Receiving → Storage → Handling → Use → Transfer → Transportation → Waste → Disposal
Chemical safety begins before a container is opened and continues until the chemical and its waste have been properly removed from the laboratory.
OSHA’s nonmandatory Appendix A recommends that laboratories know the proper handling, storage, and disposal requirements before a chemical is received, purchase only the amount necessary, maintain appropriate protective equipment, and establish safe chemical-management practices from procurement through disposal.
Understanding Laboratory Chemical Hazards
Before using a chemical, employees should understand the hazards associated with it.
Chemical hazards generally fall into two broad categories:
Health hazards can cause adverse effects to the body.
Physical hazards involve properties that can contribute to fires, explosions, violent reactions, pressure hazards, or other dangerous events.
A chemical may present several hazards at the same time.
For example, a chemical might be:
Flammable + Toxic
or:
Corrosive + Oxidizing
or:
Water-Reactive + Flammable
Chemical safety procedures should consider all applicable hazards, rather than assigning each chemical to only one category.
Chemical Health Hazards
Laboratory chemicals can potentially produce acute or chronic health effects.
Depending on the substance, these may include:
- Skin or eye irritation.
- Chemical burns.
- Respiratory irritation.
- Sensitization.
- Organ damage.
- Reproductive effects.
- Neurological effects.
- Cancer.
- Acute toxicity.
- Other systemic effects.
Some effects occur rapidly following exposure. Others may develop after repeated or long-term exposure.
OSHA’s Laboratory Standard is specifically intended to address occupational exposure to hazardous chemicals in laboratory settings and requires covered employers to maintain employee exposures within applicable limits.
Routes of Chemical Exposure
Understanding how a chemical can enter or affect the body is essential when selecting controls.
Common routes include:
Inhalation
Vapors, gases, aerosols, fumes, mists, and airborne particles can enter the respiratory system.
Inhalation hazards may be controlled through measures such as:
- Chemical fume hoods.
- Local exhaust ventilation.
- Process enclosure.
- Glove boxes.
- Substitution.
- Reduced quantities.
- Respiratory protection when required.
For additional information, see Chemical Fume Hood Safety.
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Skin Contact
Chemicals can contact the skin through splashes, contaminated surfaces, spills, or improper handling.
Some chemicals can also be absorbed through intact skin.
Controls may include:
- Chemical-resistant gloves.
- Laboratory coats.
- Protective sleeves.
- Chemical-resistant aprons.
- Splash guards.
- Appropriate handling tools.
For additional information, see Laboratory PPE.
Eye Contact
Chemical splashes, aerosols, vapors, dusts, and contaminated hands can expose the eyes.
Depending on the hazard, protection may include:
- Safety glasses.
- Chemical splash goggles.
- Face shields used with appropriate primary eye protection.
Emergency eyewashes should be available where required by the hazards.
Ingestion
Laboratory chemicals can be accidentally ingested when contamination is transferred from hands, gloves, equipment, or work surfaces to the mouth.
Good hygiene practices are therefore an important chemical exposure control.
Injection
Needles, broken glass, contaminated sharps, or high-pressure equipment can introduce hazardous substances directly through the skin.
Injection exposures can be serious even when the quantity involved is small.
Know the Chemical Before You Use It
Employees should understand the hazards and precautions before beginning work with an unfamiliar chemical.
OSHA’s Appendix A recommends conducting a risk assessment before beginning work with a hazardous chemical for the first time and reading SDS and label information before first use.
Before using a chemical, determine:
What are its health hazards?
What are its physical hazards?
What chemicals is it incompatible with?
Can it be absorbed through the skin?
Is ventilation required?
What PPE is appropriate?
How should it be stored?
What should be done if it spills?
What first-aid measures apply?
How should the waste be managed?
For unusual or particularly hazardous procedures, additional review and written SOPs may be necessary.
Safety Data Sheets
A Safety Data Sheet (SDS) provides important information about a hazardous chemical.
Employees should know how to locate and use SDS information.
An SDS contains standardized sections addressing subjects such as:
- Identification.
- Hazard identification.
- Composition.
- First-aid measures.
- Fire-fighting measures.
- Accidental-release measures.
- Handling and storage.
- Exposure controls and PPE.
- Physical and chemical properties.
- Stability and reactivity.
- Toxicological information.
OSHA requires employers covered by the Laboratory Standard to maintain SDSs received with incoming hazardous chemicals and ensure they are readily accessible to laboratory employees.
An SDS should not simply be maintained for compliance purposes. Employees should actually use it when evaluating unfamiliar chemicals and procedures.
Chemical Labels
Chemical labels provide immediate hazard information at the container.
Incoming hazardous-chemical labels should remain intact and legible. OSHA’s Laboratory Standard requires employers to ensure that labels on incoming containers of hazardous chemicals are not removed or defaced.
Under OSHA’s Hazard Communication Standard, shipped-container labels use standardized elements that can include:
- Product identifier.
- Signal word.
- Hazard statements.
- Pictograms.
- Precautionary statements.
- Responsible-party information.
Employees should understand these elements and use the label together with the SDS and laboratory procedures.
Secondary Chemical Containers
Chemicals are frequently transferred from their original containers into:
- Wash bottles.
- Beakers.
- Flasks.
- Sample containers.
- Reaction vessels.
- Working containers.
- Other transfer vessels.
These containers should be identified according to applicable OSHA requirements and the laboratory’s established labeling system.
OSHA’s Appendix A recommends properly identifying the contents of chemical containers and transfer vessels and retaining identifying information when chemicals are repackaged.
Unidentified chemicals create unnecessary risks during normal use, spills, emergency response, and disposal.
Chemical Hazard Assessment
Before beginning a chemical procedure, evaluate what could reasonably go wrong.
Consider:
- Chemical identity.
- Quantity.
- Concentration.
- Temperature.
- Pressure.
- Toxicity.
- Volatility.
- Flammability.
- Reactivity.
- Corrosivity.
- Incompatibilities.
- Potential exposure routes.
- Equipment involved.
- Potential for splashing.
- Potential for aerosol generation.
- Possible reaction products.
- Waste generated.
- Consequences of equipment or ventilation failure.
The complexity of the assessment should reflect the hazard.
A routine procedure involving a small quantity of a familiar low-hazard chemical may require little additional analysis. A new procedure involving highly reactive, toxic, pyrophoric, explosive, or otherwise high-hazard chemicals may require a detailed written assessment and approval before work begins.
Use the Smallest Practical Quantity
Reducing the amount of hazardous chemical involved can reduce the consequences of:
- Spills.
- Fires.
- Releases.
- Exposure.
- Uncontrolled reactions.
- Waste generation.
OSHA’s Appendix A recommends ordering only the minimum amount necessary for planned laboratory work and reducing the scale of operations as one method of minimizing hazardous waste.
The same principle applies at the workbench.
Do not bring an entire stock bottle into an operation when only a small working quantity is necessary.
Engineering Controls
Whenever practical, hazardous chemicals should be controlled at or near their source.
Engineering controls can include:
- Chemical fume hoods.
- Glove boxes.
- Local exhaust ventilation.
- Process enclosures.
- Splash shields.
- Closed transfer systems.
- Specialized ventilated cabinets.
OSHA’s Appendix A identifies laboratory chemical hoods as especially important controls for hazardous chemical exposure and recommends preventing airborne contaminants from escaping into the laboratory atmosphere through appropriate ventilation.
Engineering controls must be appropriate for the hazard and maintained so they continue to function properly.
For additional information, see Chemical Fume Hood Safety.
Laboratory PPE
PPE provides another layer of protection when chemical hazards cannot be adequately controlled by other measures alone.
Depending on the procedure, PPE may include:
- Safety glasses.
- Chemical splash goggles.
- Face shields.
- Laboratory coats.
- Chemical-resistant gloves.
- Chemical-resistant aprons.
- Protective sleeves.
- Specialized footwear.
- Respiratory protection.
PPE must be selected for the specific hazard.
For example, not every glove material protects against every chemical.
OSHA’s Appendix A specifically recommends careful glove selection based on chemical resistance and the protection required for the operation.
For additional information, see Laboratory PPE.
Safe Chemical Handling
Good laboratory chemical handling practices should become routine.
Employees should:
- Read the label before using a chemical.
- Review the SDS when necessary.
- Understand the procedure before beginning.
- Use required engineering controls.
- Wear appropriate PPE.
- Keep containers closed when not in use.
- Avoid unnecessary chemical quantities.
- Keep incompatible materials separated.
- Prevent contamination of common surfaces.
- Maintain an orderly work area.
- Use appropriate tools and equipment.
- Know emergency procedures before beginning hazardous work.
Avoid improvising when dealing with unfamiliar hazards.
If the hazards or controls are uncertain, obtain additional information before proceeding.
Never Pipette by Mouth
Chemicals should never be pipetted by mouth.
Mechanical pipetting devices should be used.
Mouth pipetting creates an obvious potential for accidental ingestion, aspiration, and direct chemical exposure and is inconsistent with accepted laboratory chemical-hygiene practices.
Do Not Smell or Taste Chemicals
Employees should not taste laboratory chemicals.
Chemical identification should not be attempted by deliberately inhaling vapors directly from a container.
Odor is also an unreliable indicator of safe exposure. Some hazardous chemicals may cause harm before a noticeable odor is detected, while repeated exposure to some substances can reduce the ability to detect them by smell.
Use established identification and exposure-control methods instead.
Chemical Transfer Safety
Chemical transfers can increase the likelihood of:
- Splashing.
- Spilling.
- Vapor release.
- Static discharge.
- Container breakage.
- Contact with incompatible materials.
Before transferring chemicals:
Know the receiving container.
Verify compatibility.
Confirm the receiving container has adequate capacity.
Use appropriate ventilation.
Wear appropriate PPE.
Have appropriate spill controls available.
OSHA’s Appendix A recommends adequate ventilation when transferring even small quantities of particularly hazardous substances and grounding and bonding where required to prevent static buildup during flammable-liquid transfer.
Chemical Storage and Compatibility
Hazardous chemicals should be stored according to their hazards and compatibility rather than simply alphabetically.
Important compatibility groups can include:
- Acids.
- Bases.
- Oxidizers.
- Flammables.
- Water-reactive chemicals.
- Pyrophoric materials.
- Reducing agents.
- Particularly hazardous substances.
- Other reactive chemicals.
OSHA’s Appendix A recommends separating chemicals by hazard category and compatibility, following SDS and label storage information, and keeping incompatible chemicals separated during transport, storage, use, and disposal.
For additional information, see Chemical Storage and Compatibility.
Flammable Chemicals
Flammable chemicals require controls to prevent ignition and limit fire consequences.
Precautions may include:
- Controlling ignition sources.
- Using appropriate containers.
- Using approved storage cabinets where required.
- Maintaining appropriate quantities.
- Separating flammables from incompatible oxidizers.
- Grounding and bonding where required.
- Using equipment appropriate for the hazardous environment.
Do not assume that refrigeration automatically makes flammable-liquid storage safe. OSHA’s Appendix A recommends laboratory-grade, flammable-rated refrigerators or freezers for sealed flammable liquids requiring cool storage.
Corrosive Chemicals
Acids, bases, and other corrosive substances can cause severe damage to the eyes and skin and may also attack equipment, containers, and storage surfaces.
Controls may include:
- Chemical splash goggles.
- Face protection where warranted.
- Compatible chemical-resistant gloves.
- Protective clothing.
- Chemical fume hood use where airborne exposure is possible.
- Secondary containment.
- Appropriate storage cabinets.
- Accessible eyewash and emergency shower equipment where required.
Corrosives should be segregated according to compatibility. Some corrosive chemicals have additional oxidizing or reactive properties that require special storage.
Oxidizers
Oxidizers can cause or intensify combustion and may react violently with incompatible materials.
Keep oxidizers appropriately separated from:
- Flammable chemicals.
- Combustible materials.
- Organic materials.
- Reducing agents.
- Other incompatible substances.
OSHA’s Appendix A specifically recommends separating oxidizers, reducing agents, and fuels to prevent accidental contact.
Reactive Chemicals
Reactive chemicals require particular care because a relatively small error can produce a significant event.
Examples can include:
- Water-reactive chemicals.
- Pyrophoric materials.
- Peroxide-forming chemicals.
- Self-reactive substances.
- Shock-sensitive materials.
- Explosive chemicals.
- Chemicals capable of dangerous polymerization.
Procedures should address the specific hazards of the substance rather than simply categorizing it as “reactive.”
Controls may require:
- Specialized storage.
- Inert atmospheres.
- Temperature control.
- Blast or splash shielding.
- Reduced quantities.
- Specialized PPE.
- Written SOPs.
- Prior approval.
- Specialized emergency procedures.
OSHA’s Appendix A emphasizes appropriate procedures and training for highly reactive and explosive materials.
Peroxide-Forming Chemicals
Certain chemicals can form hazardous peroxides during storage.
OSHA’s Appendix A recommends that peroxide formers be dated when received and again when opened, stored away from heat and light, and maintained with appropriate tight-fitting nonmetal lids.
Laboratories should have procedures for identifying and managing peroxide-forming chemicals.
Do not disturb a container showing suspicious crystallization, deposits, discoloration, or other evidence of potentially dangerous deterioration unless appropriately qualified personnel have evaluated the condition.
Particularly Hazardous Substances
OSHA’s Laboratory Standard requires special consideration for particularly hazardous substances, including select carcinogens, reproductive toxins, and substances with a high degree of acute toxicity.
Where appropriate, additional protections must include:
- Establishment of a designated area.
- Use of containment devices such as fume hoods or glove boxes.
- Procedures for safe removal of contaminated waste.
- Decontamination procedures.
Additional laboratory controls may also include restricted access, specific SOPs, specialized PPE, secondary containment, and prior approval based on the hazard.
Chemical Hygiene
Good personal hygiene is a fundamental part of chemical safety.
OSHA’s Appendix A recommends prohibiting eating, drinking, smoking, gum chewing, applying cosmetics, and taking medicine in laboratories where hazardous chemicals are used or stored. Food and beverages should not be stored in chemical-use areas or laboratory refrigerators used for chemicals.
Employees should also:
- Wash hands after handling hazardous chemicals.
- Wash hands after removing gloves when appropriate.
- Keep contaminated gloves away from common surfaces.
- Avoid touching the face with contaminated hands or gloves.
- Remove contaminated PPE appropriately.
- Keep personal items away from chemical work areas.
Laboratory gloves should not become a means of spreading contamination throughout the facility.
Transporting Chemicals
Chemicals may need to be moved between storage rooms, laboratories, buildings, or workstations.
OSHA’s Appendix A recommends using secondary containment during chemical transport and break-resistant transport containers when chemicals are moved outside the laboratory or between stockrooms and laboratories.
Depending on the chemical, appropriate transport equipment may include:
- Bottle carriers.
- Secondary containment.
- Stable laboratory carts.
- Cylinder carts.
- Closed containers.
Incompatible chemicals should not be transported together in a manner that could allow dangerous mixing if a container breaks.
Unattended Chemical Operations
Some reactions or processes may need to continue unattended.
Before leaving an operation unattended, evaluate potential:
- Loss of ventilation.
- Cooling failure.
- Heating failure.
- Power failure.
- Pressure buildup.
- Reaction runaway.
- Container breakage.
- Spill.
- Fire.
- Gas release.
Higher-hazard unattended operations may require alarms, automatic shutdowns, secondary containment, reduced quantities, emergency contact information, or other safeguards.
Do not assume an operation is safe to leave unattended merely because it has operated successfully before.
Chemical Spill Prevention
Preventing a spill is preferable to responding to one.
Good spill-prevention practices include:
- Keeping containers closed.
- Using stable work surfaces.
- Using secondary containment.
- Keeping containers away from edges.
- Using appropriate bottle carriers.
- Avoiding overcrowded work areas.
- Maintaining chemical-storage systems.
- Inspecting containers for deterioration.
- Using appropriate transfer equipment.
Before beginning hazardous chemical work, employees should know what to do if a spill occurs.
Laboratory Chemical Spills
Not every chemical spill should be handled the same way.
A small incidental spill that trained laboratory personnel can safely control may be very different from a release involving:
- Highly toxic material.
- Significant vapor generation.
- Fire or explosion potential.
- Unknown chemicals.
- Large quantities.
- Reactive chemicals.
- Oxygen-deficient conditions.
- Immediate danger to employees.
Employees should understand which spills they are authorized and trained to handle and when they must evacuate and obtain emergency assistance.
The laboratory’s emergency procedures should establish appropriate response criteria before an emergency occurs.
Chemical Exposure
Employees should know how to respond immediately to chemical exposure.
Depending on the substance and route of exposure, response may involve:
- Emergency eyewash.
- Safety shower.
- Removal of contaminated clothing.
- Moving to fresh air.
- First aid.
- Emergency medical treatment.
- Immediate notification.
- Review of SDS information.
The appropriate response depends on the chemical and circumstances.
OSHA’s Laboratory Standard requires an opportunity for medical attention when an employee develops signs or symptoms associated with hazardous chemical exposure, when exposure monitoring reveals routine exposure above an applicable action level or PEL, or following certain spills, leaks, explosions, or other events likely to have resulted in hazardous exposure.
Exposure Monitoring
Chemical exposure monitoring may be necessary when there is reason to believe employee exposure routinely exceeds an applicable action level or, where no action level exists, an applicable OSHA PEL.
OSHA’s Laboratory Standard establishes requirements for initial monitoring under those circumstances and additional monitoring when required by the applicable substance-specific standard. Employees must generally be notified of monitoring results within 15 working days after the employer receives them.
Exposure monitoring should be performed using appropriate methods and interpreted by qualified personnel.
Chemical Waste
Chemical safety does not end when an experiment is finished.
Laboratory chemical waste should be managed according to applicable environmental requirements and facility procedures.
OSHA’s Appendix A recommends:
- Minimizing waste generation.
- Using compatible waste containers.
- Clearly labeling waste.
- Keeping containers sealed when not in use.
- Separating incompatible waste streams.
- Using appropriate secondary containment.
- Planning waste management before laboratory work begins.
Never mix waste chemicals unless the waste-management procedure specifically permits it and compatibility has been established.
Do not use evaporation in a chemical fume hood simply as a method of chemical disposal.
Laboratory Chemical Safety Training
Employees who work with hazardous laboratory chemicals need sufficient information and training to understand the hazards and protect themselves.
Under 29 CFR 1910.1450, covered employees must receive information and training at the time of initial assignment to an area where hazardous chemicals are present and before assignments involving new exposure situations. The employer determines the frequency of refresher information and training.
Training should address applicable:
- Chemical hazards.
- Signs and symptoms of exposure.
- SDSs.
- Chemical labels.
- Chemical Hygiene Plan requirements.
- Engineering controls.
- PPE.
- Safe handling practices.
- Storage and compatibility.
- Spill procedures.
- Emergency procedures.
- Waste procedures.
- Particularly hazardous substances.
Employees should also understand the limitations of the controls they use.
For additional information, see Laboratory Safety Training.
Common Laboratory Chemical Safety Mistakes
Common problems include:
- Using an unfamiliar chemical without reviewing its hazards.
- Assuming all chemicals in the same broad category are compatible.
- Storing chemicals alphabetically without first segregating incompatibles.
- Using unlabeled secondary containers.
- Leaving chemical containers open.
- Using excessive quantities.
- Using chemicals outside a fume hood when ventilation is needed.
- Assuming nitrile gloves protect against every chemical.
- Wearing contaminated gloves on common surfaces.
- Storing chemicals in fume hoods.
- Keeping old or deteriorating chemicals indefinitely.
- Improperly mixing chemical waste.
- Ignoring unexpected odors.
- Using household refrigerators for inappropriate chemical storage.
- Failing to plan for spills before work begins.
- Performing unfamiliar high-hazard reactions without adequate review.
- Continuing work when an engineering control has failed.
Many chemical incidents can be prevented by recognizing these basic problems before an exposure or emergency occurs.
Laboratory Chemical Safety Checklist
A practical Laboratory Chemical Safety Checklist can include:
☐ A written Chemical Hygiene Plan is maintained where required.
☐ Employees understand the chemical hazards associated with their work.
☐ SDSs are readily accessible.
☐ Incoming chemical labels remain legible and intact.
☐ Secondary chemical containers are appropriately identified.
☐ Chemical hazards are evaluated before new procedures begin.
☐ Appropriate engineering controls are used.
☐ Chemical fume hoods are functioning properly.
☐ Required PPE is available and used.
☐ Chemical-resistant gloves are selected for the chemicals involved.
☐ Employees use the minimum practical quantity of hazardous chemicals.
☐ Chemicals are stored according to hazard and compatibility.
☐ Incompatible chemicals are adequately separated.
☐ Flammable liquids are properly controlled and stored.
☐ Oxidizers are separated from incompatible materials.
☐ Reactive chemicals receive appropriate specialized controls.
☐ Peroxide-forming chemicals are identified and managed.
☐ Particularly hazardous substances receive additional controls.
☐ Chemical containers are kept closed when not in use.
☐ Chemical containers are periodically inspected for deterioration.
☐ Appropriate secondary containment is provided.
☐ Chemical storage areas are orderly and accessible.
☐ Chemicals are safely transported within the facility.
☐ Employees understand spill-response procedures.
☐ Appropriate spill-control materials are available.
☐ Eyewashes and emergency showers are accessible where required.
☐ Employees know how to report chemical exposures.
☐ Chemical waste is appropriately labeled and segregated.
☐ Incompatible wastes are not mixed.
☐ Eating and drinking are prohibited in chemical-use areas.
☐ Employees wash their hands after chemical work as appropriate.
☐ Required laboratory chemical safety training is provided.
☐ Chemical safety deficiencies are documented and corrected.
Building a Strong Laboratory Chemical Safety Program
An effective laboratory chemical safety program does not rely on one procedure, one piece of PPE, or one annual inspection.
It creates several layers of protection:
Understand the Hazard → Plan the Work → Use the Smallest Practical Quantity → Apply Engineering Controls → Follow Safe Work Practices → Use Appropriate PPE → Prepare for Emergencies → Inspect and Improve
This approach is especially important because laboratory work changes. New chemicals arrive, experiments evolve, equipment changes, and employees develop new procedures.
Chemical safety must change with the work.
Laboratory Chemical Safety and the Chemical Hygiene Plan
For laboratories covered by 29 CFR 1910.1450, the Chemical Hygiene Plan provides the framework for controlling occupational exposure to hazardous laboratory chemicals.
OSHA requires the CHP to address matters including:
- Standard operating procedures relevant to safety and health.
- Criteria for engineering controls, PPE, and hygiene practices.
- Proper functioning of fume hoods and other protective equipment.
- Employee information and training.
- Circumstances requiring prior approval.
- Medical consultation and examinations.
- Designation of personnel responsible for implementation.
- Additional protection for particularly hazardous substances.
The CHP should therefore connect the laboratory’s chemical-safety rules into a coherent program rather than leaving individual procedures disconnected.
For additional information, see Chemical Hygiene Plan.
Chemical Safety Is Everyone’s Responsibility
Management establishes the laboratory’s safety system, but chemical safety also depends on the decisions employees make during everyday work.
Employees should be encouraged to:
Ask questions when hazards are uncertain.
Review information before using unfamiliar chemicals.
Report unsafe conditions.
Report spills, exposures, incidents, and near misses.
Stop and obtain assistance when a procedure cannot be performed safely.
OSHA’s Appendix A emphasizes a laboratory culture based on safety awareness, accountability, teamwork, risk assessment, planning, and personal responsibility.
The objective is to make chemical safety a normal part of laboratory work—not something considered only after an incident occurs.
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