Many chemicals used in the workplace are incompatible — meaning they can create violent reactions if they’re mixed (or sometimes even just contact one another). Mixing incompatible chemicals like bleach and ammonia creates dangerous vapours; water or steam contacting calcium oxide (lime) generates heat; and oxidisers contacting flammables cause fires and explosions. This blog outlines the steps required for chemical segregation of incompatible substances at your worksite, so you can prevent dangerous reactions and emergency situations.
What Is an Incompatible Chemical?
Are you searching for the ‘incompatible chemicals meaning’? Before we get into the rules of chemical segregation, let’s look at the definition of incompatible chemicals.
Incompatible chemicals and dangerous goods are those that are listed as incompatible in the Australian Dangers Goods (ADG) Code — or are declared incompatible by the regulatory authority. If the incompatible substances are mixed or even brought into contact with goods, they’re likely to interact, thereby increasing the hazard.
To determine incompatible chemicals, you must refer to your Safety Data Sheet for each chemical that you have onsite. Segregation charts, like our Storemasta DG Segregation Chart, can assist with general segregation considerations for each chemical class. However, you must always refer to your Safety Data Sheet, while using the segregation chart as your general guide.
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Identify Each Chemical You Store at Your Worksite
Correctly identifying each of the chemicals used and stored at your worksite is the first (and arguably the most critical) step to safely segregating incompatible chemicals. You’ll do this by creating a master register to document each and every chemical you have onsite and collate a copy of all the Safety Data Sheets (SDS). You may have to conduct a walk-around to physically identify each chemical, taking the time also to note how they are labelled and stored.
Once you have your list, you can take a deeper dive and identify the following for each chemical product:
- Hazard class
- Physical and chemical properties
- Stability and reactivity
This information is specialised and may not be printed on the label, so you’re going to have to read that SDS carefully. Now it’s time to work out which chemicals require segregation and how you are going to do it.
TIP: Conduct visual inspections of hazardous chemicals and their containers regularly — noting worn or missing labels, damaged containers, out-of-date chemicals.
Determine Chemical Segregation Requirements
To begin your segregation scheme, you should group chemicals according to their hazard class. But also remember it’s not simply a matter of placing all the flammable liquids in one corner and the flammable solids in another.
Most chemicals have multiple hazards, with many substances having sub-risks. Things get tricky when you have (for example) flammable solids that are also a corrosive, or a flammable liquid that is also a toxic substance.
Ultimately, your decision will be based on a complete hazard analysis and risk assessment that identifies the consequences of an accidental release or dangerous chemical reaction.
Here at Storemasta we’ve developed a free Dangerous Goods Segregation Chart to help you quickly identify chemical hazard classes that are incompatible, and those which must be either isolated or completely separated.
The chart is easy to navigate, and in less than a minute you can work out that flammable solids must be stored at least 3 metres from flammable liquids, and in a separate compound or building (at least 5 metres apart) from flammable gases.
TIP: Your segregation scheme must also include procedures for safe removal and disposal of hazardous chemicals, such as organic peroxides, corrosive chemicals or flammable liquids, so they don’t mix with incompatible substances.
Implement Chemical Segregation and Risk Control
Now it’s time to implement the plan and setup those storage areas. For example, proper segregation of incompatible chemicals in warehouse storage is vital for operational and community safety, so specific measures (storage, handling practices, delivery procedures, administrative controls) must be put in place to control the risks.
Again, the actual control measures you use and how the chemicals are separated will depend on the chemicals you use, the hazards they possess, how often they are used, as well as any special features of your workplace.
Here are some general tips and reminders:
- Chemical quantities should be kept to a minimum
- Make sure hazardous chemicals are correctly labelled. This prevents substances being placed in the wrong containers causing accidental mix-ups
- Use the correct chemical storage containers for the hazard class: flammable cabinets, corrosive cabinets, gas bottle cages, stainless steel cabinets etc
- Use safety cabinets that offer a compliant liquid tight sump to contain spills and doors that automatically release in the event of a build-up of pressure inside the cabinet
- Develop safe, consistent operating procedures. Train your team properly. (There’s no point segregating flammable liquids if your staff are going to create a further hazard by bringing unsafe machinery and potential ignition sources into chemical storage areas)
- Install eye wash stations, dedicated PPE cabinets and safety showers
- Remember to keep container lids, safety cabinets, cages, and all chemical storage areas secured
Tip: For expert segregation, Involve the manufacturer or supplier of the chemicals, as well as professional safety consultants. They can recommend segregation methods that have been successful at other worksites, and fully explain the WHS legislation that applies to the chemical hazards in your workplace.
Segregating Incompatible Materials and Substances
Would you like to know more about chemical segregation? We recommend you access your free copy of our helpful eBook How to manage the risk of Hazardous Chemicals in the workplace. Our comprehensive guide outlines our step-by-step methodology for managing the risks associated with hazardous chemicals. Download your copy today and take the next steps towards ensuring you meet your WHS obligations for chemical safety.
