STORAGE OPTIMISATION
Hazardous chemical storage:
Common failures and how to avoid them By Shane O’Carroll, Managing Director, Chemstore
S
toring hazardous chemicals safely is a routine responsibility in many workplaces, but inspections and storage audits continue to
reveal the same recurring problems.
STORING INCOMPATIBLE CHEMICALS TOGETHER
One of the most serious storage failures is placing incompatible substances in the same cabinet or storage area. Certain chemicals react violently if they come into contact, producing heat, toxic gases, fires, or explosions. For example, storing acids near bases or oxidisers next to flammable liquids creates a clear hazard. Even a minor leak or spill can trigger a dangerous reaction.
Chemical storage should always be organised by compatibility group, not simply by convenience or available space. Dedicated cabinets for flammables, corrosives, acids and oxidisers reduce the risk of accidental mixing.
This issue is also frequently identified in external chemical stores where space constraints or poor stock management result in incompatible materials being stored together.
UNSUITABLE CABINETS FOR HAZARDOUS SUBSTANCES
Another common issue is the use of general- purpose cupboards, shelving units, or tool cabinets to store hazardous chemicals. These types of storage units provide little protection against fire, leaks, or chemical vapours. In the event of a fire, flammable liquids stored in unsuitable cabinets can accelerate flame spread and increase the fire load within the workspace. Best practice is to use fire-rated cabinets tested to EN 14470-1 for flammable liquid storage. These cabinets typically incorporate:
• 30, 60, or 90 minutes fire resistance • Automatic door closing during fire • Integrated spill containment sumps • Ventilation connection points • Thermal fuses and self-closing vents Using certified cabinets helps organisations
comply with regulatory requirements such as DSEAR while improving fire protection within the workplace.
VAPOUR BUILD-UP IN INTERNAL STORES
Internal chemical cabinets usually store products that are already in use. As a result, containers may have been opened and their original manufacturer seals broken, allowing vapours to escape and accumulate within the cabinet. When the cabinet door is opened, these vapours can be released directly into the user’s breathing zone. In the case of flammable vapours, inadequate
extraction can create a significant hazard. When cabinet doors are opened, any accumulated vapours may escape and form a temporary ATEX zone. As a result, care must be taken to ensure that any nearby electrical equipment is suitably rated and that no ignition sources, such as hot work, are present in the area. To control this risk, internal cabinets should
ideally be connected to an extraction system vented safely to atmosphere, similar to a laboratory fume cupboard or if this is not possible standalone activated carbon filters. Many modern filtration systems incorporate
traffic-light indicators that provide a clear visual signal when filters require replacement.
POOR VENTILATION AND EXTRACTION IN CHEMICAL STORAGE AREAS
Vapours can also be given off in external stores can accumulate in enclosed spaces. Without adequate ventilation, these vapours may reach levels that
34 July/August 2026 Irish Manufacturing
present both health hazards and explosion risks. This issue is frequently encountered in walk-in chemical stores, particularly those created from converted shipping containers. While widely used, these units were not originally designed for chemical storage and often lack properly engineered ventilation systems. Typical issues include:
• Walk-in stores with no extraction system • Extraction systems installed at high level even when vapours are heavier than air
• Insufficient airflow for the volume of chemicals stored
Where vapours are heavier than air, high-level
extraction systems remove very little of the hazardous atmosphere. Ventilation design must therefore consider the vapour density and physical properties of the chemicals being stored.
LACK OF SECONDARY CONTAINMENT Leaks and spills are common when handling chemicals. Without appropriate containment, a leaking container can quickly contaminate floors, drains, or surrounding work areas. Secondary containment systems, including bunded
shelving, sump trays, or drip trays, capture leaks before they spread. External chemical stores often suffer from bund
failure, particularly where containment materials are not suitable. For example, corrosive chemicals stored in a steel
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