In industrial settings, hazardous substances and chemicals are a critical part of operations, but they come with significant risks if not managed properly. These substances, ranging from flammable liquids to corrosive acids and toxic gases, can pose serious threats to the human health and the safety of workers, the surrounding environment, and the overall operation of the factory. It is well known that improper storage of hazardous chemicals can lead to catastrophic incidents, including fires, explosions, and toxic releases. Beyond the immediate danger to human life and property, these incidents can have long-term environmental impacts, such as soil and water contamination, and can result in costly fines and legal actions against the company.

To mitigate these risks, it is crucial for factories to implement proper storage practices for hazardous substances. Not only is this important for safety, but is also a legal requirement under Thailand’s Hazardous Substance Act. This act outlines specific guidelines for the handling, storage, and disposal of hazardous substances to prevent accidents and protect public health and the environment.

This article will explore various risks associated with improper storage of hazardous substances, best practices for safe storage, and the legal framework that governs these practices in Thailand. By understanding and adhering to these guidelines, factory owners and managers can ensure the safety of their operations, protect their workers, and avoid costly penalties.

 

Three Risks arising from hazardous chemicals

Risks associated with improper hazardous substance storage are summarized as follows.

  • Health Risks:
    Hazardous substances, if not stored properly, can lead to severe health consequences for workers and people in the vicinity. For example, exposure to toxic fumes can cause immediate symptoms like dizziness, headaches, and respiratory issues, and in more severe cases, it can lead to chronic illnesses or even fatalities. Chemical burns from corrosive substances can cause permanent damage to the skin, eyes, and respiratory system. Long-term exposure, even at low levels, may result in chronic conditions like cancer, neurological damage, and reproductive harm.
  • Environmental Risks:
    Improper storage of hazardous chemicals poses a significant threat to the environment. Leaks or spills of such materials can contaminate local water sources, affecting both drinking water supplies and aquatic life. Soil contamination can render land unusable for agriculture or other purposes, potentially leading to long-term economic damage. Airborne toxins can also contribute to air pollution, harming not only the immediate surroundings but potentially spreading over a wide area, impacting communities far from the original source.
  • Operational Risks:
    In a factory setting, improper storage of hazardous materials can disrupt operations in a number of ways. Flammable substances stored incorrectly can lead to fires or explosions, causing extensive damage to property and halting production. These incidents can lead to costly repairs, decreased/lost productivity, and legal liabilities. Additionally, the lack of proper containment measures can result in chemical spills that require expensive cleanup efforts and could result in fines and penalties from regulatory bodies. The overall safety of the workplace is compromised, leading to a higher risk of accidents and injuries among workers.

 

Case Studies on chemical incident

Several case studies of hazardous substance storage can be raised. For example,  in 2019, a major fire broke out in a chemical manufacturing plant in Thailand due to improper storage of flammable liquids. The chemicals were stored in close proximity to an ignition source, leading to an explosion that caused extensive damage to the facility. Several workers were injured, and it took several hours to contain the fire, resulting in significant operational downtime and environmental contamination from the released chemicals. This incident highlighted the importance of segregating flammable materials and ensuring they are stored away from potential ignition sources. In another incident, a factory in Thailand experienced a major toxic spill due to the failure of a containment system. A large quantity of hazardous chemicals leaked into the nearby river, causing widespread environmental damage. The spill resulted in the death of aquatic life, contamination of drinking water sources, and long-term damage to the ecosystem. The factory was heavily fined and faced legal action. It took several years to complete the cleanup process, costing the company millions. This case underscores the critical need for proper containment systems and regular inspections to prevent such incidents.

 

Proper Storage Techniques

Department of Industrial Works’ Announcement on Handbook for Chemical and Hazardous Substance Storage B.E. 2550 (2007) can be used as a guide on hazardous substance storage. There are 3 main topics mentioned in the handbook, which composed of Chapter 1. storage classification, Chapter 2. storage location requirements, and Chapter 3. preventive measures. These chapters can be summarized below.

 

1. Storage classification:

To ensure the safe storage of hazardous substances and chemicals, it is essential to classify them for storage based on their specific hazardous characteristics.  Proper identification and labeling are the first lines of defense in ensuring the safe storage of hazardous substances. Every chemical container should be clearly labeled with the substance’s name, its hazard classification (e.g., flammable, corrosive, toxic), and any specific handling instructions. Labels should be durable and resistant to the particular conditions in which the chemicals are stored, such as exposure to moisture, heat, or chemicals. Safety Data Sheets (SDS) must be accessible to all employees, providing detailed information on the properties of the chemicals, potential hazards, safe handling practices, and emergency procedures. Training employees on how to read and interpret labels and SDS is essential to ensure that they understand the risks and precautions associated with the substances they handle. The primary hazardous properties that must be considered first include flammability, explosiveness, and oxidizing ability. Secondary properties to consider are toxicity and corrosiveness. Properties related to irritation, health hazards, and environmental hazards are not considered in the classification for storage purposes.  There are 20 types of chemical and hazardous substance as shown below.

  • Type 1: Explosive substance – which should meet the criteria for explosives set by Ministry of Defense.
  • Type 2A: Compressed liquefied and dissolved gases.
  • Type 2B: Pressurized small gas containers; aerosol can/aerosol container
  • Type 3A: Flammable liquids with flash point of less than 60 degrees Celsius
  • Type 3B: Flammable liquids with flash point of between 60–93 degrees Celsius
  • Type 4.1A: Flammable solids with explosive property according to UN-Recommendations
  • Type 4.1B: Flammable solids without explosive property according to UN-Recommendations
  • Type 4.2: Substances liable to spontaneous combustion, which are composed of 2 groups Pyrophoric and Self-healing materials.
  • Type 4.3: Substances that emit flammable gases in contact with water
  • Type 5.1A 5.1B 5.1C: Oxidizing substances, depending on the reaction rate
  • Type 5.2: Organic peroxides
  • Type 6.1A and 6.1B: Taxic substances (combustible toxic substances and Non-combustible toxic substance)
  • Type 7: Radioactive substances
  • Type 8A and 8B: Corrosive substances (Combustible corrosive substances and Non-Combustible corrosive substances)
  • Type 9: Other hazardous substance that can be separated for transport but not for storage
  • Type 10: Combustible liquids that do not belong to type 3A or 3B
  • Type 11: Combustible Solids that do not belong to type 4.1B
  • Type 12: Non-combustible liquids
  • Type 13: Non-combustible Solids

Factory must provide safety data for all hazardous substances to be stored. The safety data must be structured by: general information, hazard identification, composition and ingredient information, first-aid measures, firefighting measures, measures for dealing with spills or leaks, handling and storage, exposure controls and personal protection, physical and chemical properties, stability and reactivity, toxicological information, ecological impact information, disposal considerations, transport information, regulatory information, and other relevant information.

Storing incompatible chemicals together can lead to dangerous reactions, including fires, explosions, and the release of toxic gases. Therefore, segregation is a critical aspect of hazardous substance storage. Chemicals should be grouped by hazard class, with clear separation between flammable, corrosive, reactive, and toxic substances. For example, flammable liquids should be stored away from oxidizers, which can cause a fire if they come into contact. Corrosive substances, such as acids and bases, should be stored separately to prevent them from neutralizing each other and potentially creating heat or toxic byproducts. Storage areas should have clearly marked zones for each type of chemical, and barriers or distance should be used to maintain separation.

Containment systems are essential to prevent spills, leaks, and the spread of hazardous substances in the event of a container failure. Secondary containment, such as bunds, drip trays, or spill pallets, should be used to catch any leaks or spills that occur. These containment systems should be large enough to hold at least 110% of the volume of the largest container stored in the area.

Personal Protective Equipment (PPE) is essential for protecting workers who handle hazardous substances. The types of PPE required will depend on the specific chemicals to be handled, which may include but not limited to protective gloves, safety goggles, face shields, respiratory protection, and protective clothing. Training workers on the proper use, maintenance, and inspection of PPE is crucial to ensure their safety. Every PPE should be regularly inspected for signs of wear and tear, and any damaged equipment should be replaced immediately. It’s also important to ensure that PPE is stored correctly, away from contamination and in conditions that will not degrade its effectiveness.

 

2. Storage location requirements:

Hazardous substance storage buildings must be structurally sound and comply with building control laws, and they must meet the following requirements.

  • Building Walls and Firewalls:
    Building walls and firewalls must be fire-resistant.
  • Flooring:
    The floores must be strong enough to support the weight of all hazardous substances stored. The construction materials used must be resistant to water and hazardous substances.
  • Doors and Emergency Exits:
    There must be at least two doors for entry and exit, including an emergency exit door on the opposite side. Entry and exit doors used for transporting goods must be safe for workers to pass through, free of obstructions, and clearly marked with signs. Emergency exit doors must open easily in one direction from the inside with a minimum width of 1.10 meters, must not be locked or sealed with a key, must not be sliding doors, or must not lead to a dead-end area.
  • Roofing:
    In addition to providing protection from rain, the roof must be designed to allow for heat ventilation within the storage building and smoke ventilation during a fire. The main structure supporting the roof must be protected with non-combustible materials. The roofing material must be fire-resistant.
  • Ventilation System:
    Hazardous substance storage buildings must have good ventilation, considering the types of hazardous substances stored and safe working conditions. The building’s ventilation system must provide ventilation through natural or mechanical means.
  • Electrical System, Emergency Lighting, and Electrical Equipment:
    The design and installation must comply with the latest edition of the Thai Electrical Installation Standards, as prescribed by the Electrical Engineering Committee of the Engineering Institute of Thailand under Royal Patronage. The electrical system and emergency lighting in hazardous substance storage buildings must be designed and installed to prevent fire or explosion.
  • Lightning Protection:
    Compliance with the lightning protection standards for buildings, as set by the Electrical Engineering Committee of the Engineering Institute of Thailand under Royal Patronage, is required.
  • Alarm System:
    There are two types of alarm signals: Fire Alarm and Gas Leak Alarm, both of which must be distinct from each other. Push-button alarm systems must be installed at appropriate intervals, not exceeding 30 meters. The sound of the alarm must be loud and distinct from regular environmental sounds, and the system must be tested at least once a month.
  • Fire Suppression:
    • Firefighting Equipment:
      Hazardous substance storage buildings must have fire extinguishers of appropriate size and number, based on the quantity of hazardous substances stored, and they must be inspected at least once every six months. For example, dry chemical ABC extinguishers (12 kg) should be provided at a ratio of at least one per 200 square meters, and two 50-pound extinguishers should be available for flammable liquid warehouses. Firefighting equipment must be installed in suitable locations, easy to move and convenient to use. The type of extinguishing agent should be selected based on the class of fire which range from A to D.
    • Fire Water System:
      The sprinkler system installed in the warehouse must be positioned so that it can spray water or fire-extinguishing chemicals mixed with water effectively. It should cover the stored goods thoroughly. For in-rack sprinklers, at least one sprinkler head must be installed for every two shelves. Water Hydrant System: The number of fire hydrants and the distance between them depend on the length of the fire hoses and the water pressure. Generally, fire hydrants are spaced 50 meters apart. The design and installation of the fire water system must be inspected and certified by an engineer, as endorsed by the Board of Professional Engineers and Architects.
  • Firewater Containment System:
    Firefighting water must be drained into a containment pond and treated appropriately before being discharged into public water sources. The containment pond must have sufficient capacity to prevent overflow and spillage. The volume capacity depends on the size of the storage facility.

 

3. Preventive measures

The safety management system for hazardous materials storage facilities must include the following measures:

  • Hygiene Management:
    Hygiene management refers to the control of environmental factors to prevent adverse effects on the health of workers.
  • First Aid:
    Hazardous materials storage facilities must have basic first aid equipment, such as scissors, tweezers, tourniquets, thermometers, cotton, adhesive bandages and/or gauze, wound-cleaning solutions, topical antiseptics, smelling salts, fever and pain relief medication, burn ointments, eye wash equipment, and a first aid kit. Such equipment must be maintained in a clean, hygienic, and ready-to-use condition.
  • Personal Protective Equipment (PPE):
    Basic Personal Protective Equipment includes: safety footwear, protective clothing, safety helmets, safety glasses, gloves and respiratory protection (mouth and nose).
  • Safety Signs:
    Different types of safety sings to be used can be prohibition, warning, mandatory, or information s
  • Traffic Routes and Loading/Unloading Areas:
    Such routes and/or areas must be designed for safety and convenience, considering the number of workers and vehicles used. It should be clearly marked with contrasting colors, typically white or yellow, to indicate safe distances between vehicles, objects, and pedestrians.
  • Moving Hazardous Materials:
    When moving hazardous materials into storage, containers, packaging, labels, and quantities must be inspected. Damaged containers or packaging should not be stored in the hazardous materials storage building.
  • Measures for Storing Hazardous Materials in Buildings
  • Management of Spills and Emergency Response:
    Spills of hazardous materials can occur due to movement of materials or damaged containers. Measures to reduce risks from spills must include having the necessary equipment ready and promptly cleaning up any spills. This should be done by consulting the Safety Data Sheets (SDS or MSDS) and taking precautions to ensure that the spilled hazardous materials do not negatively impact the environment.
  • Waste disposal:
    Used hazardous material packaging materials must be disposed of or recycled according to legal requirements.
  • Safety Equipment Maintenance Program:
    Regular maintenance of safety equipment is essential to ensure that it functions effectively at all times.
  • Work Instructions:
    Work instructions must be prepared and made available to personnel in hazardous material storage areas.
  • Training:
    Training for personnel working in hazardous material storage areas must be conducted to ensure they have the necessary knowledge, understanding, and skills to perform their duties safely and effectively. Therefore, hazardous material storage facilities must provide training for both new and existing personnel at least once a year.

In conclusion, proper storage of hazardous substances is not just a regulatory requirement—it is a fundamental aspect of ensuring the safety of workers, protecting the environment, and maintaining the smooth operation of factory processes. By understanding and complying with the provisions of Thailand’s Hazardous Substance Act, factory owners and managers can avoid costly penalties, reduce the risk of accidents, and contribute to a safer, healthier workplace. Factory operators are encouraged to take proactive steps to assess their storage practices, invest in necessary infrastructure, and prioritize ongoing training for their employees. In doing so, they not only comply with the law but also demonstrate a commitment to sustainability and corporate responsibility.