Guide to Handling Hazardous Substances
Handling hazardous substances in the workplace carries a higher level of risk than standard materials handling. Alongside common hazards such as manual handling injuries and slips or trips, there is also the risk of exposure to harmful chemicals, vapours, or dust if substances are accidentally released during transport or use.
Such incidents can impact staff health, disrupt workflows, and lead to contamination of work areas or equipment. In some cases, they may also result in environmental damage and operational downtime.
To manage these risks, organisations must follow strict safety regulations, including COSHH requirements, which set out how hazardous substances should be assessed, controlled, and handled safely.
What are the risks when handling hazardous substances?
When a container is not handled correctly or becomes damaged during transport or storage, there is a risk of an uncontrolled spill. If the container holds hazardous substances, the consequences can be serious for both workers and the environment.
These can include:
Substances classified as dangerous for the environment can contaminate soil and water, potentially making areas unsafe or unusable and requiring costly clean-up or remediation.
Many hazardous substances can cause harm through direct contact, inhalation, or ingestion, leading to irritation, burns, respiratory issues, or more severe health effects.
Flammable substances may create a highly dangerous atmosphere, increasing the risk of fire or explosion, particularly in enclosed or poorly ventilated areas.
More detailed information about each hazardous substance should always be obtained from the Safety Data Sheets (SDS) available within your organisation. Employers also have a legal duty under COSHH requirements to ensure that hazardous substances are correctly labelled, clearly identified, and handled in a way that minimises risk to employees and the workplace.
Here are a few examples of hazard symbol labels:
It is important to note that larger containers present greater risks during handling and transport. Where hazardous substances are stored in heavy units such as steel drums, manual movement significantly increases physical strain on employees and raises the likelihood of muscle and joint injuries, drops, or impacts that could result in a spill.
In addition, poor ergonomics during handling can further increase risk. Repeated lifting, awkward postures, and insufficient handling equipment all contribute to fatigue and reduce control over the load, making accidents more likely. This not only increases the risk of injury but also raises the potential for uncontrolled release of hazardous substances and subsequent operational disruption.
What form do hazardous substances come in?
Hazardous substances can exist in a range of physical forms, each presenting different risks depending on how they are stored, handled, or released into the workplace. Understanding what form hazardous substances come in is essential for selecting appropriate control measures and meeting COSHH requirements.
Common forms include:
Gases - carbon monoxide, chlorine, ammonia. These can spread quickly and may pose serious inhalation or toxicity risks, especially in confined spaces.
Vapours - petrol or solvent vapours released during storage, transfer, or use. These can accumulate in poorly ventilated areas and create fire or health hazards.
Liquids -bleach, acids, or paint strippers. These are commonly involved in spill incidents and can cause burns, contamination, or environmental damage.
Solids - powders, dusts, or granules such as cement, detergents, or chemical powders. These may become hazardous when airborne or during handling.
Mists and sprays - fine droplets released during processes such as spraying, cleaning, or industrial coating, which can be easily inhaled or absorbed.
Fumes - particles formed from heating or chemical reactions, such as welding fumes, which can pose respiratory risks.
Biological agents - e.g. mould spores, bacteria, or viruses found in healthcare, waste management, or laboratory environments, which can cause infection or illness through exposure.
What are COSHH Requirements for Handling Hazardous Materials?
COSHH requirements (Control of Substances Hazardous to Health Regulations 2002) are UK laws that protect workers from hazardous substances. They apply to any workplace where chemicals, gases, dusts, or other dangerous materials are used or stored.
Employers must assess risks and put controls in place to keep people safe. This includes safe handling methods, correct storage, and using the right equipment.
Do Employers Have To Provide Equipment?
Yes. COSHH says employers must provide suitable equipment to help workers handle hazardous materials safely.
This can include:
Drum handling equipment for moving heavy containers
Spill control equipment for leaks or spills
Gas cylinder handling equipment for safe transport
Employers must also provide PPE (personal protective equipment) when needed.
COSHH requires that:
Suitable work equipment is provided and used
PPE is provided when other controls are not enough
Why COSHH matters
COSHH helps prevent injuries, spills, and workplace disruption. Using the right equipment makes handling hazardous substances safer and reduces the risk of accidents.
Can any employee work with hazardous materials?
Not automatically. Under COSHH requirements, employees must not handle hazardous substances unless a suitable risk assessment has been carried out first. This is set out in COSHH 2002, Section 6, which requires employers to assess the risks before any work with hazardous materials begins.
The risk assessment must consider the substance being used, how it is handled, and the level of exposure employees may face. It should also be reviewed regularly, especially when processes change, such as introducing new chemicals, equipment, or working methods. Even where no major changes occur, it is good practice to review assessments every 3–5 years.
Under COSHH requirements, employees must also be properly informed, trained, and supervised. Simply keeping Safety Data Sheets (SDS) on file is not enough to meet legal obligations.
Employees working with hazardous substances should be given clear information on:
The name of each hazardous substance they may be exposed to
The risks associated with those substances
Required safety measures and control procedures
How to use personal protective equipment (PPE) correctly
Any workplace exposure limits
Results of exposure monitoring or health surveillance
Emergency procedures in case of spills or incidents
Without this information and appropriate training, employees should not be expected to handle hazardous substances.
FAQs
The main risks include exposure through skin contact, breathing in fumes, or accidental swallowing. Spills and leaks can also cause injuries, fires, or workplace disruption. Poor handling and large containers can increase the chance of accidents and manual handling injuries.
Hazardous substances are materials that can harm health during use, such as chemicals or dust. Dangerous goods are substances that pose a risk during transport, such as flammable or explosive materials.
Spills or leaks can cause harm to workers, including burns, irritation, or breathing problems. They can also contaminate soil and water, damage the environment, and lead to downtime while the area is cleaned up.
Businesses should carry out COSHH risk assessments, provide training, and make sure employees know what to do in an emergency. Spill kits, PPE, and safe storage systems should also be in place to help deal with incidents quickly.
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