Specialized Laboratory Hazards

Laboratory safety training helps employees understand the hazards they may encounter in laboratory work and the procedures, equipment, personal protective equipment, and emergency actions necessary to protect themselves and others. Effective training should prepare employees to recognize hazards, work safely, respond appropriately when something goes wrong, and understand the safety programs that apply to their laboratory.

For laboratories covered by OSHA’s Laboratory Standard, 29 CFR 1910.1450, employers must provide employees with information and training at the time of initial assignment to a work area where hazardous chemicals are present and before assignments involving new exposure situations. The employer determines the frequency of refresher information and training under the Laboratory Standard. (osha.gov)

Laboratory safety training should reflect the actual chemicals, equipment, procedures, and hazards present in the workplace rather than relying only on generic safety orientation.

Peroxide-Forming Chemicals

Certain chemicals can form shock-sensitive or explosive peroxides during storage.

Laboratories using peroxide-forming chemicals should establish procedures for:

• Dating containers when received and opened.
• Tracking storage time.
• Following manufacturer recommendations.
• Inspecting containers before handling.
• Testing for peroxide formation when appropriate.
• Proper disposal before unsafe concentrations develop.

Containers showing crystallization, discoloration, unusual deposits, or other evidence of instability should not be moved or opened until evaluated by qualified personnel.

Nanomaterial Safety

Engineered nanomaterials may have physical, chemical, and toxicological characteristics that differ from the same material in larger particle sizes.

Potential exposure can occur through inhalation, skin contact, ingestion, or accidental injection.

Operations involving dry or easily dispersed nanomaterials may present a greater inhalation concern and should generally be performed using appropriate containment or local exhaust ventilation.

Laboratory controls may include:

• Closed containers.
• Fume hoods or other ventilated enclosures.
• Glove boxes.
• Appropriate gloves and protective clothing.
• Methods that minimize dust generation.
• Specialized spill cleanup procedures.
• Proper waste collection and disposal.

Free nanoparticles should not be handled in open laboratory areas when effective containment can reasonably be used.

Ionizing Radiation

Laboratories may use radioactive materials or equipment capable of producing ionizing radiation.

Sources may include:

• Radioisotopes.
• X-ray equipment.
• Electron microscopes.
• Radiation-producing analytical instruments.
• Irradiators.
• Other research or testing equipment.

Radiation work may be subject to federal, state, licensing, institutional, and facility-specific requirements.

Controls may include restricted areas, shielding, time and distance controls, dosimetry, contamination monitoring, warning signs, specialized training, inventories, surveys, and procedures established by the organization’s Radiation Safety Officer or radiation safety program.

Employees should not perform radiation work unless they have received the required authorization and training.

Non-Ionizing Radiation

Laboratories may also contain equipment that produces non-ionizing radiation, including:

• Ultraviolet radiation.
• Infrared radiation.
• Radiofrequency energy.
• Microwave radiation.
• Strong electromagnetic fields.

The appropriate controls depend on the source, intensity, wavelength, duration of exposure, and equipment design.

Controls may include shielding, interlocks, enclosures, warning signs, restricted access, PPE, and procedures that prevent employees from entering hazardous exposure areas.

Laser Safety

Lasers can create serious eye and skin hazards and may also introduce electrical, chemical, fire, and collateral hazards.

Higher-powered lasers may require:

• Controlled laser areas.
• Beam enclosures.
• Interlocks.
• Beam stops and barriers.
• Warning signs.
• Restricted access.
• Appropriate laser protective eyewear.
• Alignment procedures.
• Training.
• Authorization of users.

Laser protective eyewear must be appropriate for the wavelength and optical density required for the particular laser system.

Employees should never look directly into a laser beam or intentionally place reflective materials in the beam path unless the procedure has been specifically evaluated and controlled.

Biological Hazards

Laboratories working with biological materials may encounter infectious agents, human blood or other potentially infectious materials, biological toxins, recombinant or synthetic nucleic acid materials, laboratory animals, or other biological hazards.

Controls should be based on a risk assessment of the biological material and procedure being performed.

Depending on the work, controls may include:

• Biological safety cabinets.
• Restricted laboratory access.
• PPE.
• Sharps controls.
• Aerosol-control procedures.
• Decontamination.
• Autoclaving.
• Biological waste procedures.
• Exposure-response procedures.
• Appropriate biosafety practices and containment.

Laboratories working with human blood or other potentially infectious materials should also evaluate the applicability of OSHA’s Bloodborne Pathogens Standard.

Laboratory Animal Hazards

Laboratory animal work can expose employees to hazards beyond the biological agents being studied.

Potential hazards may include:

• Bites and scratches.
• Allergens.
• Zoonotic diseases.
• Sharps.
• Anesthetic gases.
• Chemicals and disinfectants.
• Ergonomic hazards.
• Animal handling injuries.

Appropriate animal-handling procedures, PPE, containment, training, medical surveillance when appropriate, and exposure-response procedures should be established based on the animals and research activities involved.

Cryogenic Materials

Cryogenic liquids such as liquid nitrogen can cause severe cold burns and tissue damage and may rapidly displace oxygen as they vaporize.

Potential hazards include:

• Frostbite and cryogenic burns.
• Oxygen-deficient atmospheres.
• Pressure buildup.
• Container rupture.
• Embrittlement of incompatible materials.
• Splashing during transfer.

Cryogenic materials should be handled using compatible equipment, appropriate ventilation, and suitable PPE. Containers should never be sealed in a manner that allows pressure to build without relief.

Areas where a significant release could create an oxygen-deficient atmosphere may require additional ventilation, oxygen monitoring, or other controls based on the hazard assessment.

Compressed and Toxic Gases

Compressed gases can present high-pressure, fire, explosion, toxicity, corrosion, and oxygen-displacement hazards.

Laboratories using toxic, highly toxic, corrosive, pyrophoric, or flammable gases may require additional controls such as:

• Ventilated gas cabinets.
• Gas detection systems.
• Automatic shutoff devices.
• Restricted access.
• Emergency exhaust.
• Specialized regulators and piping.
• Written emergency procedures.

Gas cylinders should be properly secured, identified, stored, transported, and connected using equipment compatible with the gas and service.

High-Pressure Systems

Laboratory equipment operating under pressure can release significant stored energy if a component fails.

Examples include:

• Pressure reactors.
• Autoclaves.
• Gas systems.
• Hydraulic systems.
• Pressure vessels.
• Pressurized experimental apparatus.

Pressure equipment should be appropriate for the intended service and operated within its rated limits.

Protective measures may include pressure-relief devices, shields, barriers, remote operation, inspection, preventive maintenance, and procedures that prevent employees from standing in the likely path of released pressure or projectiles.

Vacuum Systems

Vacuum equipment presents different but equally important hazards.

Glass vessels under vacuum can implode, producing flying fragments and releasing hazardous materials.

Controls may include:

• Using glassware designed for vacuum service.
• Inspecting equipment for cracks, chips, and damage.
• Using shields or protective enclosures.
• Applying vacuum gradually.
• Protecting vacuum pumps from hazardous vapors.
• Using traps where appropriate.
• Venting systems safely before opening them.

Employees should never use ordinary damaged or unsuitable glassware for vacuum operations.

Strong Magnetic Fields

Equipment such as nuclear magnetic resonance (NMR) systems and other powerful magnets can create hazards involving ferromagnetic objects, medical implants, electronic devices, and compressed gas cylinders.

Uncontrolled ferromagnetic objects can become dangerous projectiles when brought near a strong magnetic field.

Laboratories with strong magnetic fields should establish controlled areas, warning signs, equipment restrictions, screening procedures, and appropriate training.

Emergency responders should also be informed when strong magnetic-field hazards could affect emergency operations.

Specialized Electrical Hazards

Some research equipment uses unusually high voltages, stored electrical energy, capacitors, custom electrical systems, or exposed energized components.

Specialized electrical work may require additional guarding, interlocks, grounding, discharge procedures, restricted access, and Lockout/Tagout procedures.

Employees should not defeat electrical interlocks or protective devices unless an approved procedure specifically addresses the work and appropriate controls are in place.

Ultraviolet Light

Ultraviolet lamps are commonly used in biological safety cabinets, sterilization equipment, imaging systems, and research applications.

UV exposure can injure the eyes and skin.

Where UV sources are used, laboratories should consider:

• Enclosures and shielding.
• Interlocks.
• Warning signs.
• Restricted access.
• Procedures for servicing equipment.
• Appropriate eye and skin protection.

Employees should not rely on visible brightness to judge UV exposure because hazardous UV radiation may be present even when the source does not appear intensely bright.

Specialized Laboratory Equipment

Research laboratories may contain custom-built or uncommon equipment for which conventional equipment-safety procedures are insufficient.

Before specialized equipment is placed into service, the laboratory should evaluate:

• Mechanical hazards.
• Electrical hazards.
• Pressure and vacuum hazards.
• Thermal hazards.
• Radiation.
• Chemical exposure.
• Moving components.
• Stored energy.
• Unexpected startup.
• Emergency shutdown.
• Maintenance and servicing.

Manufacturer instructions should be incorporated into laboratory procedures where applicable.

Custom-built equipment should receive an appropriate safety review before use.

Changes to Experiments and Scale-Up

Changing an experiment can change its hazards.

A procedure should be reevaluated when there are significant changes involving:

• Chemical quantities.
• Concentrations.
• Reaction temperatures.
• Pressures.
• Equipment.
• Energy sources.
• Materials.
• Ventilation.
• Process duration.
• Location.
• Personnel.

A reaction safely performed at a small scale should not automatically be assumed safe when larger quantities are used.

Scale-up can substantially increase heat generation, pressure, reaction rate, toxic releases, fire potential, and the consequences of an equipment failure.

Prior Approval for High-Hazard Laboratory Work

Certain laboratory activities should require authorization before work begins.

Examples may include:

• Particularly hazardous substances.
• Highly reactive or explosive materials.
• Pyrophoric chemicals.
• High-pressure reactions.
• Radiation.
• High-powered lasers.
• Novel biological agents.
• Large-scale chemical reactions.
• Experiments with uncertain reaction characteristics.
• Procedures outside established laboratory experience.

The laboratory should establish who has authority to approve high-hazard work and document approval when appropriate.

Emergency Planning for Specialized Hazards

General emergency procedures may not adequately address every specialized laboratory hazard.

Emergency planning should consider:

• Chemical spills.
• Fires and explosions.
• Radiation incidents.
• Biological exposures.
• Cryogenic releases.
• Oxygen-deficient atmospheres.
• Toxic gas releases.
• Pressure-system failures.
• Laser injuries.
• Electrical incidents.
• Loss of ventilation.
• Equipment failures.

Employees should understand when they may safely respond to an incident and when they should evacuate and obtain assistance from trained emergency personnel.

Emergency responders should be informed of unusual hazards that could affect their response.

Training for Specialized Laboratory Hazards

Employees should receive training before performing work involving specialized hazards.

Training should address, as applicable:

• Hazard recognition.
• Safe operating procedures.
• Engineering controls.
• Required PPE.
• Equipment limitations.
• Warning signs and alarms.
• Inspection requirements.
• Emergency shutdown procedures.
• Spill and exposure response.
• Waste handling.
• Reporting requirements.
• Restrictions on unauthorized work.

Additional training should be provided when new hazards, equipment, materials, or procedures are introduced.

Review Specialized Laboratory Work Before It Begins

Many serious laboratory incidents occur when the hazards of an unusual experiment or process are not fully recognized before work starts.

Before beginning specialized or high-hazard laboratory work, employees and supervisors should ask:

• What can go wrong?
• What could cause an exposure, fire, explosion, release, or equipment failure?
• What is the worst reasonably foreseeable outcome?
• Can the hazard be eliminated or reduced?
• Are appropriate engineering controls available?
• Is specialized PPE necessary?
• Does the procedure require a written SOP?
• Is prior approval required?
• Are employees adequately trained?
• What should employees do if something goes wrong?

A thoughtful hazard assessment before work begins can prevent an unusual laboratory hazard from becoming an emergency.

Specialized Hazards and the Laboratory Safety Program

Specialized laboratory hazards should not be managed separately from the laboratory’s overall safety system. Hazard assessments, SOPs, training, inspections, emergency procedures, equipment maintenance, exposure controls, incident investigations, and corrective actions should work together.

OSHA’s Laboratory Standard requires covered employers using hazardous chemicals to develop and implement a written Chemical Hygiene Plan. Among other requirements, the plan must establish criteria for selecting control measures, identify circumstances requiring prior approval, and provide additional employee protections for work with particularly hazardous substances.

Not every specialized laboratory hazard is governed by the same regulation. Radiation, biological materials, lasers, pressure systems, nanomaterials, and other hazards may be subject to different federal, state, local, licensing, consensus-standard, or institutional requirements.

The laboratory should therefore evaluate each specialized operation individually and establish controls appropriate for the actual hazards involved.