Workplace chemical fires pose serious risks, from severe burns, toxic exposures, and even fatalities.
Preventing chemical fires (and all fires) should remain one of your top priorities, in order to save lives, reduce injuries, avoid costly damages, ensure regulatory compliance, and maintain continuity of business operations.
In fact, a recent OSHA news release (April 7, 2025) highlighted a tragic event that occurred last September, in which an Atlanta-based chemical manufacturer now faces penalties from a preventable fire. This underscores the importance of proper workplace chemical safety-protocols.
So, how can you and your employees reduce the risk of chemical fires?
Let’s break down the key steps, OSHA guidelines, and best practices to keep your workplace safe.
Related Article: Industrial Gas Manufacturing Plant Faces $201K in Fines Following Diborane Explosion, Injuries
Related Article: 5 Key Steps to Workplace Emergency Preparedness
OSHA Proposes $61K in Penalties After Investigation
First, to touch on the OSHA incident above, investigators determined that improperly stored hazardous chemicals caused a fire at the manufacturer’s Conyers facility, originating in a warehouse containing multiple unsecured chemical substances.
Federal investigators uncovered four serious and two other-than-serious violations, leaving the chemical manufacturer facing $61,473 in proposed penalties.
They have 15 business days from receipt of its citations and penalties to comply, request an informal conference with OSHA’s area director, or contest the findings before the independent Occupational Safety and Health Review Commission.
– See OSHA’s Guidelines on Chemical Hazards and Toxic Substances.
Key Steps to Prevent Workplace Chemical Fires
Preventing workplace chemical fires requires a proactive approach. Here are 7 key steps to ensure safety and compliance:
1. Understand Chemical Hazards
Before handling any chemicals, workers must know their properties. OSHA’s Hazard Communication Standard (HCS) (29 CFR 1910.1200) requires employers to provide Safety Data Sheets (SDS) and proper labeling for all hazardous substances.
Key Actions to Take:
– Review SDS documents: Check flammability, reactivity, and storage requirements.
– Label all containers: Ensure chemicals are clearly marked with hazard warnings.
– Train employees: Workers must recognize hazards and know emergency procedures.
2. Proper Chemical Storage
Improper storage is a leading cause of chemical fires. OSHA’s 29 CFR 1910.106 outlines flammable liquid storage rules, while 29 CFR 1910.119 covers Process Safety Management (PSM) for highly hazardous chemicals.
Best Practices:
To prevent these issues, you’ll want to follow best practices.
Separate incompatible chemicals. For instance, store oxidizers away from flammables (e.g., peroxides away from solvents). You’ll also need to use approved containers. For instance, flammable liquids should be in OSHA-compliant safety cans.
Additionally, you’ll need to ensure both controlled temperatures and adequate ventilation. For instance, keep chemicals away from heat sources and direct sunlight, and make sure storage areas maintain proper airflow to prevent vapor buildup.
3. Implement Safe Handling Procedures
Even a small spark can ignite flammable vapors. OSHA’s 29 CFR 1910.132 requires personal protective equipment (PPE), while 29 CFR 1910.157 mandates fire extinguisher accessibility.
Preventive Measures:
First, use non-sparking tools, and avoid metal equipment near flammables. Keep in mind that even static electricity discharge can create a spark, so ground storage containers when possible, and limit static electricity buildup when transferring liquids.
When handling flammable materials, make sure your team wears proper PPE, like flame-resistant clothing, gloves, and goggles, to reduce any injury risks.
And, of course, limit open flames, and prohibit smoking near chemical storage areas or at-risk locations.
4. Maintain Equipment and Electrical Safety
Unfortunately, faulty wiring or overheated machinery can also trigger fires. OSHA’s 29 CFR 1910.303 covers electrical safety, while NFPA 70 (National Electrical Code) provides additional guidelines.
Critical Checks:
Conduct routine inspections of electrical systems, looking for frayed wires, loose connections, or overloaded circuits.
Use explosion-proof equipment, and in areas with flammable vapors, use OSHA-compliant devices.
And, don’t forget that poorly maintained machinery can overheat, so make sure your equipment is regularly serviced.
5. Train Employees on Emergency Response
Although your goal should focus around prevention of chemical fires, preparing for worst-case scenarios can save lives when it matters most. As such, your team should know how to react to workplace fires. In fact, OSHA’s Emergency Action Plan standard (29 CFR 1910.38) requires evacuation plans and fire response training.
Training Essentials:
When it comes to fire extinguisher use, teach the PASS technique (Pull, Aim, Squeeze, Sweep).
You’ll also want to train workers on spill containment & chemical neutralization. And, finally, make sure to train your employees on established evacuation routes, and maintain clear exit paths and assembly points.
6. Conduct Regular Inspections & Risk Assessments
There’s no doubt that proactive safety checks prevent disasters. To this end, OSHA’s General Duty Clause (Section 5(a)(1)) requires employers to identify and mitigate potential hazards.
Inspection Tips:
Check for leaks or corrosion in storage tanks and containers. Damaged containers increase fire risks. Make sure to regularly audit your safety protocols to ensure compliance with OSHA and NFPA standards.
And, make sure you routinely update risk assessments of existing products and re-evaluate hazards when introducing new chemicals.
7. Have a Fire Suppression System in Place
Workers should need to know that not all workplace fires can be stopped with an extinguisher. OSHA and NFPA standards recommend automatic suppression systems for high-risk areas.
Key Solutions:
For larger storage areas, you may need to install sprinkler systems. For chemical fires, in particular, you’ll need to use chemical-specific extinguishers, like Class B (flammable liquids) or Class D (combustible metals).
Finally, keep fire blankets accessible for small fires or wrapping an injured worker.
Key Takeaways on Chemical Fires
The recent OSHA case in Atlanta serves as a stark reminder that chemical fires are preventable with the right precautions.
Employers and employees should identify hazardous chemicals, store them safely, train team members to handle them correctly. And, you’ll need to carry out inspections regularly to fix potential hazards before they cause fires.
By following OSHA’s guidelines, training employees, and maintaining strict safety protocols, you can drastically reduce fire risks and ensure well-being of both your team, and your business.
Stay In Compliance With Worksite Medical
In most cases, OSHA requires medical surveillance testing, and at no cost to employees.
Worksite Medical makes that program easier with mobile medical testing.
We conduct drug and alcohol screenings, silica exam physicals, on-site respirator fit tests (including N95 masks), audiometric exams, as well as pulmonary function tests and heavy metal lab work, and much more, right on your job site. We also keep accurate, easy-to-access medical records for your convenience. You’ll keep your employees at work, and stay ahead of OSHA inspections.
With Worksite Medical, a mobile medical testing unit — we can bring all the resources of a lab to you. Our certified lab technicians can perform both qualitative and quantitative respirator tests to ensure a perfect fit.
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