Industrial & Commercial Warehouses: Guidelines For Hazardous Material Use, Handling & Storage

Nearly all industrial and commercial facilities maintain warehouse storage of raw materials and/or finished products. Warehouse activities often involve the use, handling and storage of hazardous materials. Commercial warehouse operations magnify these exposures because they specialize in fast-paced, high-turnover storage and transportation of raw materials, intermediate components and finished products. Cold storage warehouses present additional risks associated with mechanical refrigeration systems used for the storage of food-grade products, as well as agricultural and pharmaceutical products.

To operate a workplace that minimizes potential exposures for pollution and worker injury liability, management should implement warehouse Best Management Practices. These practices include identifying facility hazards, implementing effective controls, and planning and preparing for emergencies.

Identify Hazards

• Hazardous material identification – Label all hazardous material and waste containers (i.e., above-ground tanks, drums) with material contents and hazards. Maintain an inventory list and material safety data sheets (MSDSs) for all hazardous materials stored on-site.
• Hazardous material storage areas – Dedicate and identify all hazardous material storage areas. Storage areas should be located away from high risk areas such as loading docks, heavy forklift traffic areas, building exits, doors and floor drains. Outdoor storage of hazardous materials should be eliminated to reduce the potential for spills and contamination of storm-water, soils and surface waters

Implement Controls

• Hazardous material handling – Do not open, handle or stack containers in a manner that might cause them to rupture or leak. Ensure that pallets are in good condition and materials are shrink-wrapped or banded. During use and temporary storage, ensure that hazardous material containers are labeled with their contents and appropriate hazard markings. Close containers when not in use and store in designated temporary storage areas.
• Incompatible material segregation – Separate materials by hazard class such as flammables, corrosives and oxidizers. Do not store flammables near oxidizers or strong acids.
• Spill containment – Provide berms or containment pallets for 55-gallon drums and above-ground storage tanks. Appropriate storage cabinets can be used for smaller containers.
• Compressed gases – Secure and store compressed gas cylinders in designated areas, separating oxygen and fuel gases. Forklift propane cylinders should be stored outside in an area protected from heavy forklift or other vehicle traffic. Aerosol cans stored in caged areas can minimize the impact of projectiles during accidents or fires.
• Fire prevention – Establish dedicated storage areas for flammables and combustibles, and prohibit smoking. Small containers of flammable materials should be stored in locked, fire-resistant metal safety cabinets. Ensure routine collection and disposal of cardboard, paper and other packaging materials to decrease the risk of housekeeping fires. Consult local authorities on compliance with hazardous material storage fire codes.
• Loading Docks – Loading docks should be designed with berms or ramps that provide secondary spill containments. Cover storm drains prior to loading/unloading. Ensure that trucks are secured from movement during loading and unloading. Avoid temporary storage of hazardous materials in outdoor loading dock areas.
• Facility and Vehicle Maintenance Areas – Designate specific areas for forklift and vehicle maintenance and establish controls and restrictions on high hazard activities such as welding and hazardous waste storage. Ensure that forklift battery-recharging areas are adequately ventilated.
• Refrigeration systems – Identify special hazards associated with refrigeration systems and implement necessary controls. Establish a process safety management program for refrigerants such as ammonia. Conduct routine maintenance of refrigeration systems. Establish an emergency response plan specifically for accidental releases of refrigerant.

Plan And Prepare

• Emergency response planning – Establish an emergency response and evacuation plan to address fires, spills and other emergencies. Include plan instructions on hazardous material spill response and cleanup. Designate employees responsible for emergency response procedures. Train employees on their responsibilities and conduct emergency response drills at least annually.
• Emergency Response Equipment – Spill response equipment, absorbent materials, fire extinguishers and personal protective equipment should be stored near, but not in, hazardous material storage areas and loading docks. Ensure that employees are trained on equipment use and storage locations.
• Fire suppression – Conduct routine inspections tests and maintenance of sprinkler systems, fire alarms and fire extinguishers. Ensure that the local fire department is aware of the locations of hazardous material storage areas on-site.
• Employee training – Establish an employee safety program. Conduct routine safety meetings to increase employee awareness and reduce the potential for serious accidents.

XL Environmental • Risk Control Division • 520 Eagleview Boulevard, PO Box 636, Exton, PA 19341 • Phone: 800-327-1414 • Fax: 610-458-7285 • xlenvironmental.com

XL Environmental is a division of XL Specialty Insurance Company.