Automotive
Automotive DSEAR risk assessment expertise
We have provided DSEAR risk assessments for a wide range of automotive manufacturers and component suppliers, from specialist parts producers to large-scale vehicle and engine production facilities.
These environments typically involve flammable gases, fuels, coatings and process chemicals, often alongside high-temperature equipment and automated production systems. Our work focuses on identifying hazardous zones, assessing ignition risks and ensuring appropriate controls are in place to support safe, compliant operations.
Unipart Eberspacher
The challengeThe H&S team within the Unipart Eberspaecher, vehicle part manufacture units had recognised they had processes that fell within the DSEAR Regulations and requested a full survey of these areas to be undertaken. Unipart …
NV Tools
The challengeNV Tools, Brentwood, a small specialist automotive parts manufacturer, contacted MESH Safety after an HSE audit resulted in issue of an improvement notice requiring a suitable and sufficient risk assessment be carried out under …
Honda UK
The challengeHonda UK Manufacturing (HUM) at Swindon is Honda’s main UK production facility, with approximately 600 cars a day rolling off the production lines. Several plants operate Hazardous environments and/or handle Hazardous materials. Due to …
IAC Group
The challengeA visit was made to the International Automotive Components (IAC) site at Solihull, West Midlands on 16th December 2014 to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR).IAC …
BMW
The challengeTwo visits were made to the BMW Hams Hall facility at Coleshill, West Midlands during May and June 2015 to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). …
Hydro Components Ltd
The challengeA visit was made to the Hydro Components site, at Gloucester, in 2020 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR), incorporating Amendment 1: June 2015. At the site, …
DSEAR risk assessments for automotive manufacturing environments
Automotive manufacturing environments present a varied DSEAR risk profile, with hazards arising from fuels, gases, vapours, coatings and, in some cases, combustible dusts generated during production processes.
Typical risk areas include:
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Furnace and heat treatment operations
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Paint spray booths and coating lines
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Fuel handling and engine test cells
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Storage and use of flammable liquids and solvents
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Compressed gas systems, including hydrogen
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Battery charging areas and associated gas release
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Chemical treatment and surface finishing processes
Flammable gases such as hydrogen, along with petrol vapours and solvent-based coatings, can create explosive atmospheres where releases occur in the presence of ignition sources. These ignition sources may include hot surfaces, electrical equipment, static discharge or maintenance activities.
Many automotive sites operate with strong engineering controls already in place. The role of the DSEAR assessment is to review these controls in detail, confirm hazardous area classifications and ensure alignment with current regulations and guidance.
This includes assessing ventilation and extraction systems, reviewing storage and handling arrangements, evaluating ignition controls and considering how processes interact across the site. Where improvements are required, these are presented as a clear, prioritised action plan to support compliance and ongoing safe operation.
Frequently asked questions
Risks typically arise from flammable gases, fuels, solvent-based coatings and chemical processes. These can generate vapours or atmospheres that may ignite if suitable controls are not in place.
Where flammable gases, vapours or dusts may be present, hazardous area classification is usually required. This helps define where controls are needed and ensures equipment is suitable for the environment.
Yes. Hydrogen is highly flammable and can ignite easily, often with a low ignition energy. Systems involving hydrogen storage or use require careful assessment, control and zoning.
A detailed report covering hazardous substances, processes and controls, supported by hazardous area classification drawings and a prioritised action plan for any improvements required.