Heavy manufacturing facilities rely on large quantities of industrial chemicals to drive their daily operations. High-performance degreasers, hydraulic fluids, coolants, and solvents are just some examples of the chemicals needed to keep assembly lines moving. However, these valuable chemicals also pose significant risk if stored improperly.
Keeping large quantities of hazardous chemicals on-site poses significant Work Health and Safety (WHS) risk. If not stored carefully, they can cause catastrophic industrial incidents that affect your workers, the environment, and your operations. To avoid this, heavy manufacturing plants must have close monitoring protocols in place.
At Chemron, we provide high-grade industrial chemical products to manufacturing companies all over Australia, while also helping facility managers create safer, fully compliant storage and handling environments. In this blog, we’ll unpack how to reduce risk when storing chemicals to give you added peace of mind over your operations.
Dangers of Improper Chemical Storage
As demand grows in your manufacturing plant, you’re likely to experience increased operational pressures. This is usually when chemical storage protocols drift. Standard storage containers deteriorate under harsh ambient conditions, labels become obscured by grease, and incompatible compounds are frequently staged together out of convenience.
Failing to secure your facility’s chemical storage environment creates severe risks, including:
- Chemical Incompatibility Reactions: Storing oxidising agents next to flammable solvents, or acids near cyanides, can trigger violent exothermic reactions, explosions, or toxic gas releases.
- Corrosion: Corrosive vapours escaping from improperly sealed acid carboys can deteriorate concrete floors, weaken steel support beams, and ruin nearby electrical systems.
- Environmental Spills and Runoff: Uncontained leaks from damaged intermediate bulk containers (IBCs) or 205-litre drums can enter stormwater drains, resulting in severe environmental pollution and heavy EPA fines.
- Workplace Exposure and Acute Health Risks: Leaking volatile organic compounds expose workers to chronic respiratory illness, neurological damage, and severe skin burns.
How to Eliminate Storage Risks in Your Manufacturing Plant
Eliminating risks in a heavy manufacturing environment requires a structured, multi-layered approach.
Perform Rigorous Incompatibility Segregation
One of the most critical safety rules in industrial storage is strict segregation based on chemical classification. Simply grouping chemicals by operational process rather than hazard class is a dangerous mistake.
Facility managers must run audits on their current inventory against the Dangerous Goods Classification System and ensure adequate physical separation:
- Flammable Liquids (Class 3): Must be isolated in fire-rated, ventilated safety cabinets away from ignition sources and strong oxidisers.
- Corrosive Substances (Class 8): Acids and bases (alkalis) must be physically separated from one another, as direct contact produces intense heat and spattering.
- Toxic Substances (Class 6.1): Should be stored in secure, locked enclosures with dedicated local exhaust ventilation to capture fugitive vapours.
Set Up Your Secondary Containment Spaces
A secondary container acts as a crucial safety net in case primary storage breaches due to mechanical impact from forklifts, material degradation, or thermal expansion. Every chemical storage area must feature robust secondary containment capable of holding at least 110% of the largest single container’s capacity, or 25% of the total aggregate volume stored, whichever is greater.
Keep Absolute Temperature and Ventilation Controlled
It’s typical for heavy industrial environments to experience extreme temperature fluctuations, particularly in the Australian summer. Radiant heat build-up inside uninsulated steel sheds increases vapour pressure within sealed chemical drums, heightening the risk of swelling, venting, or explosion.
Store volatile industrial chemical products in climate-controlled or well-shaded, mechanical-ventilation-equipped storage units. Ensure intrinsic, explosion-proof extraction fans are installed to clear heavy, flammable vapours before they reach their Lower Explosive Limit.
Standardise Labelling and Safety Data Sheet Access
Under Australian WHS Regulations, every chemical container must be clearly labelled in accordance with the Globally Harmonised System (GHS). The original manufacturer labels must remain legible, and any secondary decanted container, such as a spray bottle, must have a compliant GHS label.
Safety Data Sheets must be accessible to all workers with digital access terminals placed in the storage area. There should also be waterproof SDS binders mounted nearby to ensure that labels are well preserved on each chemical stored.
Have Spill Response Protocols in Place and Provide Personal Protective Gear
Even with strict controls and careful monitoring, accidents can happen. Responding quickly is essential in mitigating risk and preventing a minor drip from turning into a major disaster.
Have specialised chemical spill kits—containing suitable absorbent pads, neutralising agents, booms, and non-sparking tools—within 10 metres of all chemical storage and transfer stations. Also ensure that you have working emergency eyewash stations and safety showers nearby. Equip workers entering the zone with chemical-resistant PPE tailored to the specific SDS requirements.
Trust Chemron for Innovative Chemical Solutions
Safeguard your heavy manufacturing plant from chemical risks by following the steps above. By combining proper storage infrastructure with clear protocols, you can protect your workers from injury and maintain your workflow.
At Chemron, we provide reliable industrial chemical products engineered for optimal performance and safety within heavy manufacturing environments. From heavy-duty machinery degreasers and specialty metalworking formulations to eco-conscious cleaning solvents, our chemical range meets the rigorous demands of modern manufacturing while helping you maintain WHS compliance.
Our experienced team will help you find a chemical solution that serves your plant and help you set up the infrastructure to store them correctly. We can also recommend safer product alternatives that maintain performance without compromising worker safety.
Contact us today to discuss your industry’s chemical requirements or explore our chemical products for yourself.
