Aerospace
Aerospace DSEAR risk assessments expertise
We have provided DSEAR risk assessments for a wide range of aerospace manufacturers, research facilities and specialist component producers across the UK. These environments typically involve flammable liquids, gases and combustible dusts, where understanding hazardous zones and controlling ignition risks is critical to safe, compliant operations.
Our work focuses on identifying where explosive atmospheres may arise, confirming hazardous area classifications, and providing clear, practical actions to reduce risk. The examples below highlight how this has been applied across different aerospace sites and processes.
Momentive CCT
The challengeMomentive Combined Composite Technologies Ltd based at Concorde Way, Fareham in Hampshire produces specialist components for the aerospace and marine industries. Typically the operations involve the use of GRP and carbon fibre technologies. A …
Aircraft Research Association
The challengeAircraft Research Association Ltd. (or ARA) operates from purpose-built facilities at Manton Lane, Bedford. As part of the site operations some powders used were known to be combustible and may generate a flammable atmosphere …
Blanco Aero Industries UK Ltd
The challengeThe Health, Safety and Environmental Officer at the Blanco Aero Industries UK Ltd, Rugby required the site DSEAR assessment to be updated. Although they had previously had an assessment from another consultancy he was …
Doncaster Precision Castings (DPC)
The challengeA visit was made to DPC (Doncaster Precision Castings) – Deritend site at Vines Lane in Droitwich, Worcestershire in May 2014 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). …
CAV Ice Protection
The challengeA visit was made to the Celtic Aerospace Ventures (CAV) Ice Protection in Consett, County Durham on the 16th September 2015 to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations …
Meggitt Aircraft Braking Systems (MABS)
The challengeThe Holbrook Lane site at Meggitt Aircraft Braking Systems (MABS) has been established in Coventry (Dunlop previously) since 1919, and provides a rich legacy of mature manufacturing facilities, interspersed with modern additions.MABS undertakes the …
GKN Aerospace Transparency Systems
The challengeGKN Aerospace Transparency Systems occupies a legacy site in Kings Norton, Birmingham, and required a thorough review and update of a previous DSEAR RA. The site is a mix of mature manufacturing facilities, interspersed …
Pall – Redruth
The challengePall Industrial Hydraulics operates from its facility at Cardrew Industrial Estate, Redruth. The site was again visited in May 2017 as further changes had been undertaken. In 2013 they were to move the Aerospace …
Kaman UK
The challengeA visit was made to the Kaman Composites site, Darwen, in December 2018 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR), incorporating Amendment 1: June 2015. At the site, …
Pall – Aerospace & Industrial
The challengeIn August 2012 a site visit was undertaken to follow up on a previous survey of the site operations at the Pall, St Columb Major Industrial Estate, St Columb, Newquay, TR9 6TT ; the …
DSEAR risk assessments for aerospace environments
A DSEAR risk assessment for an aerospace facility must reflect how materials, processes and people interact across the site, rather than relying on generic assumptions.
Common risk areas include the use of flammable solvents such as acetone, MEK, hexane and IPA, along with combustible dusts and vapours generated during composite manufacturing, coating, machining and finishing operations. Activities such as spraying, plating, decanting, extraction and storage can all contribute to the formation of explosive atmospheres under certain conditions.
In many aerospace environments, existing controls are already well established. The role of the DSEAR assessment is to review these in detail, confirm whether hazardous area classifications are appropriate, and identify any gaps against current regulations and best practice.
This typically includes assessing ventilation and extraction systems, reviewing storage and handling procedures, considering ignition sources such as equipment or static, and evaluating how substances behave in real operational conditions. Where improvements are needed, these are presented as a clear, prioritised action plan to support ongoing compliance and safe operation.
Frequently asked questions
Aerospace sites often combine multiple risk types in one environment, including flammable liquids, gases and combustible dusts. Processes can be highly specialised, and even small releases of vapour or dust can create explosive atmospheres under the right conditions.
Yes. Many aerospace businesses already operate to a high standard, but DSEAR requires a formal, documented assessment. This confirms that risks are properly understood, hazardous zones are correctly defined, and control measures meet current expectations.
Common examples include acetone, MEK, hexane, IPA, flammable gases and fine combustible dusts. The level of risk depends on how these substances are used, stored and handled within specific processes.
A typical assessment includes a detailed review of hazardous substances, process risks and existing controls, along with hazardous area classification where required. This is supported by a written report, site observations and a clear action plan with recommended improvements.