Workplaces that handle flammable substances face risks that can escalate quickly if not controlled. Additional fire and explosion hazards arise where vapours are released or poorly managed. Gases and dust present similar risks under the same conditions. Fires and explosions place people at serious risk and disrupt operations with little warning. UK legislation sets expectations for how these hazards must be identified and assessed, with suitable controls applied to reduce the likelihood of harm.
What is Covered by DSEAR?
The regulations apply where dangerous substances that could create a fire or explosion are present. These substances include flammable liquids. Gases, vapours and combustible dusts can also ignite under certain conditions.
The regulations apply across many sectors. Manufacturing and logistics are commonly affected. Storage operations and maintenance activities also fall within their scope. Work processes, not industry labels, determine whether the regulations apply. Any task that releases or handles a dangerous substance must be reviewed.
Understanding what is covered is the starting point for compliance. It allows employers to identify where formal assessment and controls are required before incidents occur.
Which Substances Create Fire and Explosion Risk?
Dangerous substances are not limited to obvious fuels. Materials used daily within work processes may present risk when released, heated or handled incorrectly.
Examples include solvents used for cleaning. Flammable gases used for welding also present risk. Vapours from fuels and aerosols can also present an ignition risk, especially in areas with poor ventilation.
Substances are assessed under DSEAR based on how they behave when in use. Flash points and explosive limits determine how risk is managed. The potential for dust clouds also requires assessment.
How Are Dangerous Substances Identified on Site?
Identification begins with a structured review of activities. Employers need to examine tasks where substances are used, transferred or stored.
Safety data sheets provide important information, but they are not enough on their own. Observation of work practices helps reveal where releases occur during normal operation or during maintenance.
Once identified, substances are logged and linked to the tasks that use them. This forms a decent starting point for a formal assessment that reflects how work is actually carried out.
What Does a DSEAR Risk Assessment Examine?
A DSEAR risk assessment evaluates how dangerous substances could cause harm. It considers sources of ignition, the likelihood of release and who may be affected.
The assessment examines whether substances could form explosive atmospheres and where this might happen. It also considers existing safeguards and whether they are adequate for the level of risk present.
Documentation should explain how conclusions were reached. Inspectors look for evidence that risks were identified systematically and that decisions were based on conditions present on site.
How Are Ignition Sources Reviewed?
Ignition sources must be identified and controlled where dangerous substances are present. These sources are not limited to open flames.
Electrical equipment and hot surfaces can ignite flammable atmospheres. Static electricity also presents ignition risk if not controlled. Mechanical friction and welding activities also present risk if not managed correctly.
Employers are required to review how ignition sources interact with substances under the regulations. Removing or controlling these sources reduces the likelihood of fire or explosion.
Where Can Explosive Atmospheres Form?
Explosive atmospheres can form where dangerous substances mix with air under the right conditions. These conditions may occur during routine tasks or during abnormal events.
Areas near filling points and decanting stations require attention. Dust generating processes also create conditions where explosive atmospheres may form. Enclosed or poorly ventilated spaces increase risk by allowing vapours or dust to accumulate.
These locations are identified through DSEAR assessments so controls can be applied proportionately and consistently.
How is Hazardous Area Classification Used?
Hazardous area classification is used to describe where explosive atmospheres may occur and how frequently. This information guides the selection of equipment and controls.
Areas are classified based on the likelihood and duration of an explosive atmosphere forming. This classification informs what type of electrical or mechanical equipment is suitable.
Clear classification helps prevent inappropriate equipment being installed where it could act as an ignition source.
What Control Measures Are Expected?
Control measures focus on preventing the formation of explosive atmospheres and avoiding ignition. Where prevention is not possible, their mitigation reduces potential consequences.
Common controls include substituting less hazardous substances, improved ventilation and improved containment. Equipment selection and maintenance influence how effectively these controls perform.
Administrative arrangements support these controls. Procedures must reflect actual work activities and be understood by those carrying them out.
How Should Ventilation be Considered?
Ventilation helps disperse vapours and dust before they reach hazardous concentrations. Its design must reflect what substances are present and how they are released.
General ventilation may be suitable for low-level releases. Local exhaust systems are required where substances are released at source.
Ventilation effectiveness must be reviewed as part of the assessment under DSEAR. Poorly performing systems increase risk and require attention.
What Training is Required For Workers?
Workers must understand the hazards associated with dangerous substances and how controls protect them. Training should relate directly to tasks performed.
Topics include recognising fire and explosion risk, understanding procedures and responding to abnormal conditions. Training records provide evidence that information has been communicated.
An emphasis is placed on competence within regulatory expectations. Training must be suitable for the level of risk and reviewed when work changes.
How Should Equipment Maintenance be Managed?
Equipment used in hazardous areas must be suitable for the classification assigned. Maintenance keeps this equipment in a condition that does not introduce new risk.
Inspection regimes identify deterioration, damage or modification that could compromise safety. Repairs must maintain the original specifications. DSEAR assessments must consider these tasks and how they are controlled.
What Documentation is Expected by Inspectors?
Inspectors expect to see a written assessment that reflects the conditions of your site. Supporting documents show how decisions were implemented.
Records may include hazardous area drawings and equipment registers. Maintenance schedules and training records demonstrate how arrangements are made in practice.
The quality of your documentation matters. Generic paperwork that does not reflect site activities raises concern during inspection.
How Often Should DSEAR Arrangements be Reviewed?
Arrangements require review under DSEAR when changes occur that could affect risk. Changes to substances and processes can trigger reassessment. Equipment changes should also be reviewed.
Periodic review also helps confirm controls remain suitable. Wear and modification can alter risk profiles. Changes in work practices require the same attention.
How Can Employers Use This Cheatsheet?
This cheatsheet provides a structured overview of what the regulations expect in the workplace. It can be used to check whether key elements are in place and whether assessments reflect real activities.
Employers can use it as a reference when planning assessments, reviewing controls or preparing for inspection. It highlights where specialist input may be required. If you need support with assessments or advice on risk management, contact us and our team can advise on suitable arrangements for your site.