Industrial
Industrial DSEAR risk assessment expertise
We have provided DSEAR risk assessments for a wide range of industrial operations, including manufacturing plants, processing facilities, ports, materials handling sites, coating and paint operations, and heavy industry environments across the UK.
These sites often involve a combination of flammable liquids, gases, combustible dusts and large-scale processing equipment. Our work focuses on identifying where hazardous atmospheres may form, assessing ignition risks and ensuring appropriate controls are in place to support safe, compliant operations.
Pall – Industrial Hydraulics
The challengePall Industrial Hydraulics operates from its facility at Cardrew Industrial Estate, Redruth. In 2013 they were to move the Aerospace paint spray facility within the existing site. The survey undertaken on the 29th May …
Port of Tyne
The challengeThe Port of Tyne at South Shields required a DSEAR survey to be undertaken for the coal plant operations on-site. The coal transfer plant was a key focus of the survey as these operations …
Terex GB (Omagh)
The challengeTerex MP occupies a large industrial site on the outskirts of Omagh, County Tyrone. On site there are significant paint shop operations in the production areas and the majority of paints used were identified …
TK Components
The challengeAn independent survey of operations associated with the recently built spray plant building at TK Components site in Manchester was undertaken in 2012 at the request of senior management. Spray Plant facilities at the …
Taylormade Timber Products Ltd
The challengeAn independent survey of operations associated with timber production at the Sherburn Hill site was undertaken December 2011 at the request of senior management. Facilities at the Sherburn Hill site allow for large scale …
Trimite Coatings
The challengeA visit was made to the new Weilburger Paints (part of Trimite) site at Hayes, Middlesex, at the end of January 2016 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 …
Huyton Heat treatments
The challengeHuyton Heat treatments in Liverpool is an established small metal heat treatment specialist. Insurance requirements dictated a timely visit in order to assess the site’s compliance against with the Dangerous Substances and Explosive Atmospheres …
Knauf
The challengeThe Knauf UK Ltd site at Sittingbourne, Kent, is a large continuous plasterboard production site with finished product going to the construction industry. Part of the process involves use of combustible dusts and gas …
Beatson Clark
The challengeA visit was made to the Rotherham site of Beatson Clark to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). The DSEAR regulations came into force in the …
NICHE Magnesia
The challengeAn independent survey of NICHE Magnesia operations at the Saltend site in Hull was undertaken August 2011 at the request of senior management. This was subsequently reviewed in December 2019. Facilities at the Saltend …
DB Group
The challengeA visit was made to the DB Group’s Bourn Airfield site, in 2020 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR), incorporating Amendment 1: June 2015. At the site, …
Webro
The challengeA visit was made to Webro Cables and Connectors Ltd site, Nottingham in 2020 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR), incorporating Amendment 1: June 2015. At the …
Mc Cue Corporation
The challengeA visit was made to the Bletchley site of Mc Cue to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). The DSEAR regulations came into force in the …
RWC
The challengeDSEAR Risk Assessments Ltd was commissioned in 2023 to undertake a DSEAR review of the process operations at RWC operations at West Drayton. The site operations included a range of items that require assessment …
Hickman & Love
The challengeDSEAR Risk Assessments Ltd was commissioned to undertake a DSEAR review of the process operations at Hickman & Love in Bilston, Wolverhampton. The site operations included a range of items that require assessment under …
Morland
The challengeDSEAR Risk Assessments Ltd was commissioned to undertake a DSEAR review of the process operations at Morland, units in Welshpool, Powys, in May 2023 to consider compliance with the Dangerous Substances and Explosive Atmospheres …
DSEAR risk assessments for industrial processing, manufacturing and handling operations
Industrial environments frequently present complex DSEAR risks due to the scale of operations, variety of materials used and the interaction between processes.
Typical risk areas include:
- Paint spraying, coating and solvent-based processes
- Bulk material handling, conveying and transfer systems
- Combustible dust from materials such as wood, coal, minerals or powders
- Gas-fired plant, furnaces and heat treatment systems
- Storage and use of flammable liquids and solvents
- Compressed gas systems and LPG installations
- Battery charging areas generating hydrogen gas
- Workshops, maintenance activities and utility systems
Combustible dust is a common hazard across many industrial sites, particularly where materials are processed, conveyed or stored in bulk. Dust clouds can form during normal operation or from leaks and poor containment, and if ignited may lead to primary and secondary explosions.
At the same time, many industrial processes involve flammable liquids and vapours, such as paints, coatings, thinners and cleaning solvents. These can produce vapours that are heavier than air, allowing them to travel and ignite at a distance from the source if not properly controlled.
Gas systems and heat processes also present significant risks, particularly where fuel gases are used in furnaces, kilns or process equipment. In addition, hydrogen generated during battery charging or specific processes can form explosive atmospheres in enclosed or poorly ventilated areas.
Our DSEAR assessments consider how these hazards arise in practice, including both normal operations and foreseeable failures such as leaks, spills or equipment faults. We review ventilation, containment, ignition source control, maintenance systems, housekeeping and procedural controls.
Where required, hazardous area classification is applied and supported by detailed zoning drawings. Clear, prioritised action plans are provided to help businesses reduce risk and maintain compliance while supporting efficient industrial operations.
Frequently asked questions
They typically include combustible dust, flammable vapours from solvents and coatings, fuel gases, and hydrogen or other gases generated during processes or storage.
Often, yes. Industrial sites can involve multiple processes, materials and work areas, meaning risks may arise in different locations and require coordinated control measures.
In many cases, yes – particularly around spray processes, bulk handling systems, gas installations and areas where flammable vapours or dusts may be released.
It focuses on identifying hazardous substances, understanding how explosive atmospheres may form, assessing ignition risks, and recommending practical improvements including zoning, ventilation and control measures.