Chemical
Chemical DSEAR risk assessment expertise
We have provided DSEAR risk assessments for a wide range of chemical manufacturers, formulators and processors, including blending plants, solvent handling operations, coatings producers, lubricant manufacturers and specialist chemical sites across the UK.
These environments typically involve flammable liquids, vapours, gases and transfer operations where controlling ignition sources, ventilation and hazardous area zoning is essential. Our work focuses on identifying where explosive atmospheres may arise, assessing existing controls and providing practical actions to support safe, compliant operations.
Structural Adhesives
The challengeStructural Adhesives Limited operates out of a facility in Leicester LE5 3NW; the facility had been established for twenty years and incorporates the production of both acrylic and epoxy adhesives. The company intended to …
Icon Polymer Group Limited
The challengeIcon Polymer Limited develop and manufacture an extensive range of composite products at their site in Retford, Nottinghamshire. An independent survey of operations associated with this site was undertaken at the request of senior …
Interpet
The challengeInterpet Ltd, Dorking has been producing products for the pet and aquatic trade on the Dorking site since 1987; in 2004 they became part of the Central Garden and Pet Group of companies. The …
Technical Textile Services Limited
The challengeThe site at Middleton processes large volumes of IPA and Ethanol over the period of a year; this is used in the preparation of industrial and hygienic wipes. Production across the site can be …
Tecan
The challengeTecan is a leading manufacturer of customised precision parts. A range of innovative, photolithography-based technologies enables highly accurate, burr and stress-free production. The business supplies to a range of industries including Pharmaceutical, Aerospace and …
Ascent Media
The challengeAn independent survey of the Ascent Media premises at the Soho Film Laboratories was undertaken;the main purpose of the site survey was to determine whether any areas that Nitrate Base film is stored or …
Whitminster
The challengeWhitminster International Limited based in Stafford, produces various types of industrial wipes and cleaning solutions for industrial, catering and healthcare use. The wipes are mostly produced under the Klenzeen brand name using non-woven materials …
Humiseal
The challengeHumiseal Europe Limited were proposing to introduce a new layout and site arrangements at its production facility in Rye. Humiseal Europe Limited is an integral part of Chase Electronic Coatings and has a unique …
Ferguson & Menzies
The challengeA visit was made to Ferguson & Menzies Ltd. premises in Glasgow on 21st October 2014 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). Operations carried out on-site incorporate …
Nazdar
The challengeAn independent survey of operations associated with the then recently built spray plant building at Nazdar Ink Technologies site in Stockport was undertaken in February 2012 at the request of senior management. The focus …
Coventry Chemicals
The challengeA visit was made to the Coventry Chemicals site near Siskin Drive on 22nd September 2015 to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). Coventry Chemicals supply …
BWOC
The challengeA visit was made to the BWOC forecourt site at Brent Knoll in Somerset in November 2013, to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). The BWOC premises are …
Clover Chemicals
The challengeA visit was made to the Whaley Bridge site of Clover Chemicals to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). The DSEAR regulations came into force in …
Comma Oils
The challengeA visit was made to Comma Oils site in Gravesend November 2016 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR).Operations incorporate storage, blending and filling of various liquid components …
Moove Lubricants
The challengeA review visit was made to the Moove Lubricants (formerly Comma Oils) site in Gravesend in December 2019 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). Previously we had …
Arran Aromatics
The challengeA visit was made to the Arran Aromatics site, Brodick, in August 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 chemical manufacturing, blending and solvent handling
Chemical manufacturing and blending environments often present some of the clearest DSEAR risks, particularly where flammable liquids and vapours are routinely stored, transferred, mixed or dispensed.
Typical risk areas include:
- Bulk solvent storage and transfer systems
- Mixing, blending and filling operations
- Drum, IBC and container handling
- Dispensing of flammable liquids into open or semi-open vessels
- Cleaning operations using flammable solvents
- Pipework, pumps and transfer equipment
- Laboratory and small-batch process areas
Common hazardous substances in this sector include materials such as MMA, toluene, MEK, acetone, ethanol, methanol, IPA and other flammable solvents or gases. In many cases, these materials are integral to production, so the focus of the DSEAR assessment is not elimination, but reducing risk so far as is reasonably practicable.
This typically involves reviewing ventilation, ignition controls, anti-static precautions, earthing and continuity arrangements, storage standards, maintenance of equipment and the suitability of process layouts. Where flammable vapours may be released, hazardous area classification is often required to define where additional controls or ATEX-rated equipment are necessary.
Many chemical sites already operate with purpose-designed equipment and good controls in place. The role of the DSEAR assessment is to confirm where risks remain, identify any gaps against current regulations and guidance, and provide a clear, prioritised action plan for improvement.
Frequently asked questions
The main risks usually come from flammable liquids, vapours and gases used in storage, mixing, transfer and filling operations. If vapours are released in the presence of an ignition source, fire or explosion can occur.
Yes. Even relatively small volumes of flammable liquid can generate a significant vapour cloud under the right conditions. The risk depends on the substance, how it is handled, the level of ventilation and the presence of ignition sources.
Hazardous area classification is needed where flammable vapours or gases may be present in sufficient quantity to create an explosive atmosphere. This is commonly required around storage, dispensing, transfer and mixing activities.
Key measures include suitable ventilation, minimising releases, controlling ignition sources, anti-static and earthing arrangements, appropriate storage, planned maintenance and ensuring equipment is suitable for the environment.