The Lab Safety Blueprint
Guidance for eliminating risks, managing
exposures, and creating a safety culture
FOSTER
Safety Culture
CHOOSE
the Right Protection
OPTIMIZE
Infrastructure
LAB SAFETY
RESOURCE GUIDE
2 Lab Manager Lab Safety Resource Guide
Table of Contents
Creating Safer Labs........................................................3
Engineering Controls ......................................................4
Hierarchy of Hazard Controls ............................................ 5
High-Efficiency Filtration: The Role of HEPA and
ULPA Filters in Lab Safety .................................................. 6
Encourage Safety with a Gas Generator.............................. 9
Safer Sterilization: Improvements in Autoclave Safety ..............11
Lab Equipment Safety
and Engineering Controls Checklist ....................................13
Administrative Controls.................................................14
Fostering Safety Expertise on Your Team..............................15
Laboratory Safety Best Practices: Strategies to Build
Safer Labs and Avoid Legal Risks.......................................18
Conducting a Chemical Risk Assessment in the Laboratory.......21
The Critical Role of Chemical Inventory Tracking in
Risk Management ......................................................... 24
Tips for Assessing Indoor Air Quality in the Laboratory........... 27
The User’s Impact on Fume Hood Performance .................... 30
Personal Protective Equipment (PPE) ............................. 33
Guidance and Consistency Ensure Effective PPE ................... 34
PPE: How to Ensure a Proper Fit........................................ 37
Laboratory Gloves Explained: Protection by Hazard Type ...... 39
3 Lab Manager Lab Safety Resource Guide Introduction
This eBook offers lab managers a comprehensive guide to strengthening safety
across all laboratory operations, from evaluating which hazards can be eliminated
or replaced to incorporating engineering controls and establishing clear policies and
training. It also covers proper selection and use of personal protective equipment.
Creating Safer Labs
Building strong safety programs through hazard reduction,
system design, and protective measures
Laboratories present diverse risks, from hazardous chemicals and biological agents to
high-pressure equipment and routine procedural hazards. Managing these risks requires more
than simply reacting to incidents; it demands a proactive approach that reduces hazards wherever possible and ensures strong protections are in place when risks cannot be eliminated.
With careful planning and thoughtful implementation, lab managers can build safety programs that protect staff, support compliance, and foster a culture of safety.
Chapter One
Engineering Controls
The most effective way to reduce risk is to eliminate hazards entirely or substitute safer
alternatives. However, many laboratory hazards cannot be fully eliminated or replaced.
In these cases, engineering controls, such as containment devices, filtration systems,
and equipment with enhanced safety features, become the next most effective layer of
protection. These controls reduce the chance of hazard exposure by physically isolating,
containing, or modifying the pathways through which hazards reach personnel.
This chapter examines engineering controls across different lab systems, highlighting
their roles in building reliable safety programs. By investing in equipment that minimizes hazard exposure, lab managers can dramatically reduce risk and create safer, more
efficient work environments.
Hierarchy of Hazard Controls
Exploring how lab managers can make smarter decisions by starting at the top
of the hazard control hierarchy
When it comes to lab safety, many managers default to policies, training, and personal protective equipment (PPE). These
are familiar, visible, and often mandated. But they’re also some of the least effective ways to manage risk. Instead, making
lab safety decisions should be a much more structured and effective process with the hierarchy of hazard controls.
Administrative controlss
Key decision: Can we reduce
exposure to the hazard?
Administrative controls focus on reducing
a lab worker’s exposure to hazards. These
controls involve implementing safety
policies, procedures, and guidelines that
workers must follow. Examples include
establishing SOPs, providing safety
training, performing a job hazard analysis
before beginning any experiment, and
limiting the time individuals work with
specific hazardous materials.
PPE
Key decision: How can we protect lab
personnel when working with
the hazard?
PPE is often the first control applied in
labs; however, it should be the last line
of defense, used only when upstream
controls can’t fully mitigate the hazard.
Inadequate or improper PPE can leave
workers vulnerable to hazardous
materials, resulting in burns, inhalation
of fumes, and skin absorption. PPE may
include gloves, goggles, lab coats,
face shields, and respirators. To ensure
maximum protection, lab staff should be
trained on the proper use, maintenance,
and disposal of PPE.
Elimination
Key decision: Can we completely
remove this hazard from our lab
environment?
Elimination is the most effective form of
hazard control because it removes the
risk entirely. Examples include choosing
not to purchase highly toxic or unstable
chemicals, removing unguarded
machinery, or sunsetting research
involving high-containment pathogens.
Substitution
Key decision: Can we replace this
material or method with something
less hazardous?
If elimination isn’t feasible, substitution
is the next best option. While most
applicable to chemical hazards, it can
apply to any risk factor, such as biological
agents, radioactive materials, and even
physical energy sources like noise or
temperature. Effective substitutions
reduce risk without compromising
research goals.
Engineering controls
Key decision: Can this hazard be
physically separated from personnel?
Engineering controls are robust,
consistent, and largely independent
of human behavior. Examples include
fume hoods and biosafety cabinets,
local exhaust ventilation, laser interlocks
and shielding, ground-fault circuit
interrupters, lockout/tagout systems, and
fire suppression systems. These solutions
often require upfront investment and
infrastructure planning, but they offer
significant returns in risk reduction.
Elimination
Most Effective Least Effective
Substitution
Engineering controls
Administrative
controls
PPE
6 Lab Manager Lab Safety Resource Guide
High-Efficiency Filtration: The
Role of HEPA and ULPA Filters in
Lab Safety
HEPA and ULPA both play pivotal roles in ensuring the protection of personnel
and product
By Dan Scungio, MT (ASCP), SLS, CQA (ASQ)
Maintaining a contaminant-free environment is paramount
for labs. Central to this endeavor are high-efficiency particulate air (HEPA) and ultra-low penetration air (ULPA) filters,
which serve as the frontline defense against airborne particulates. Understanding the distinctions between these filters,
their applications, and their integration into biological safety
cabinets (BSCs) is essential for ensuring both personnel and
product protection.
HEPA vs ULPA: A comparative analysis
Filters in a BSC are designed to remove airborne particulates before the air is returned to the workspace. That
7 Lab Manager Lab Safety Resource Guide
airborne material could be pathogenic spores, bacteria, or
even viruses. The filters do have limits; for instance, they do
not protect the user from harmful vapors. A chemical fume
hood should be considered if hazardous drugs or chemicals
are handled.
HEPA filters have long been the cornerstone of laboratory
air filtration systems. Designed to capture at least 99.995
percent of airborne particles measuring 0.3 micrometers in
diameter, they effectively trap contaminants such as dust,
pollen, mold, and bacteria. The efficiency of HEPA filters
stems from a combination of diffusion, interception, inertial
impaction, and electrostatic attraction mechanisms, which
collectively ensure that particles are effectively captured
and retained. ULPA filters also use these mechanisms to
trap particulates.
ULPA filters have been around since the 1970s. Like HEPA
filters, ULPA construction comprises small strands of
crossed and pleated glass fibers. Both filters are designed to
catch airborne particles, but that’s where their similarities
end. HEPA filters were developed for several industrial,
military, and government applications, and they work best
where airborne particulate matter is constant. Today, they
are even used in common household items like room purifiers and vacuum cleaners. ULPA filters were invented after
years of research to create an even higher level of indoor
air cleaning.
ULPA filters take filtration efficiency a step further. Capable of capturing 99.9995 percent of particles as small as 0.12
micrometers, ULPA filters offer an added layer of protection,
especially in environments where even the smallest contaminants can pose significant risks. This heightened efficiency
is particularly beneficial in settings that demand utmost
sterility and particulate control.
While both HEPA and ULPA filters are designed to maintain clean air environments, there are some important factors
to weigh before deciding which filter to use:
Airflow dynamics: Because the media of ULPA filters is
dense, there is an increased airflow resistance, potentially affecting ventilation systems’ performance. The use of
these filters can negatively affect the lifespan of a BSC. This
necessitates careful consideration when planning equipment
purchases for the laboratory.
Cost considerations: ULPA filters are generally more expensive than their HEPA counterparts due to their enhanced
filtration capabilities and more intricate manufacturing
processes. HEPA filters in a BSC can last between five and
15 years before needing to be replaced. Because they tend to
capture more materials, ULPA filters only last five to eight
years at most.
Applications of ULPA filters in
laboratory settings
Generally, HEPA filters would suffice for most labs. ULPA
filters are predominantly used in environments where maximum contamination control is critical to product quality.
In pharmaceutical laboratories, for instance, it is important
to ensure the sterility of the products handled. ULPA filters
help maintain aseptic conditions during production. Similarly, when manufacturing semiconductors, the presence of
microscopic particles can compromise the integrity of the
components. ULPA filters provide the necessary air purity to prevent such issues. In biomedical research facilities,
research may involve highly sensitive assays or cultivating
delicate cell lines that demand ULPA filtration.
HEPA filtration mechanisms
Diffusion: Airborne matter is spread out in the
filter because larger air molecules bombard small
particles. The particles become trapped in the filter
fibers when the air molecules push them over the
surface of the filter.
Interception: The fibrous material of the filter casts
a wide net in which larger particles get trapped
simply because of their size.
Inertial impaction: Some larger airborne particles
lose energy and become inert, such that they are
unable to move past the fibers of the filter.
Electrostatic attraction: The fibrous material of a
filter has a slight electrostatic charge. Any remaining
small free-floating particles with their own slight
charge will be drawn out of the airstream and
embedded into the filter.
8 Lab Manager Lab Safety Resource Guide
Biological safety cabinets: Integrating
filtration for protection
BSCs are essential fixtures in laboratories handling infectious
agents or hazardous biological materials. These cabinets are
designed to protect lab personnel by shielding workers from
exposure to potentially harmful airborne agents. BSCs also
protect the products being handled by preventing the contamination of samples and reagents. BSCs also offer environmental protection. Using a BSC ensures that hazardous agents
do not escape into the surrounding environment.
The effectiveness of a BSC is heavily reliant on its filtration system. Class II BSCs, used in many laboratories, are
equipped with HEPA filters to purify both the inflow and
downflow air, maintaining a sterile work zone and protecting both the user and the environment. In scenarios where
an added level of protection is required, ULPA filters may
be employed, especially in cabinets designed for handling
highly infectious or hazardous materials.
The regulatory requirements of
filtration
If your lab works with hazardous chemicals, infectious
agents, or sensitive electronic components, air filtration
is a non-negotiable part of your safety program. Regulatory agencies like the OSHA, CDC, and EPA, along with
industry-specific standards from the FDA or USP, require
air control measures to protect workers, products, and the
environment.
HEPA and ULPA filters serve as the frontline defense
against airborne contaminants. BSCs used in microbiological
labs rely on filters to trap bacteria, viruses, and other particulates, protecting both laboratory personnel and the external
environment. The CDC’s Biosafety in Microbiological and
Biomedical Laboratories (BMBL6) guidelines emphasize
filtration for containment.
The United States Pharmacopeia (USP) developed a set
of mandatory guidelines for handling hazardous drugs in
healthcare settings. The USP 797 and USP 800 standards
require HEPA filtration for sterile drug compounding to
prevent contamination. ULPA filters are used in advanced
cleanrooms where ultra-clean environments are mandatory.
OSHA’s laboratory standard (29 CFR 1910.1450) requires
proper ventilation and containment when handling hazardous chemicals. HEPA filtration in ductless fume hoods
ensures airborne toxins are captured and not released
into the lab.
To stay compliant with these regulations, labs must perform
regular inspections, certification, and replacement of filters.
A clogged or damaged filter can mean a non-compliant and
unsafe work environment. Annual or biannual testing of BSCs
and HVAC systems is crucial to maintaining effectiveness.
The future of lab filtration
Filtration technology isn’t standing still. Researchers and
manufacturers are actively developing new solutions to
enhance performance, efficiency, and sustainability. Key
advancements include self-cleaning filters, lower-energy
HEPA filtration, antimicrobial and smart filters, reusable and
recyclable filters, and more.
As filtration technology evolves, labs must adapt their safety
programs to incorporate new, more sustainable solutions
while maintaining compliance with regulatory requirements.
The choice between HEPA and ULPA filters hinges on the
specific requirements of the laboratory environment. While
HEPA filters offer robust protection for many applications,
ULPA filters provide enhanced filtration for scenarios where
even the smallest particulate contamination cannot be tolerated. Integrating these filters into BSCs, coupled with stringent operational protocols, fortifies the laboratory’s defense
against contamination, ensuring the safety of personnel, the
integrity of products, and the protection of the environment.
By staying informed about the capabilities and appropriate
applications of HEPA and ULPA filters, laboratory professionals can make educated decisions that uphold the highest
safety and efficacy standards in their workspaces.
“While both HEPA and ULPA filters
are designed to maintain clean
air environments, there are some
important factors to weigh before
deciding which filter to use.”
9 Lab Manager Lab Safety Resource Guide
Encourage Safety with
a Gas Generator
When it comes to providing a regular supply of certain gases to your lab, a
generator offers unique benefits over alternative options
By Ian Black, MSComm, MSc
Many research labs use equipment or perform experiments
that require a regular supply of gases such as hydrogen,
helium, and nitrogen, for example. Historically, labs purchase
and store these gases in relatively large (roughly four feet tall)
steel compressed gas cylinders. While this method has some
benefits, there are also numerous safety concerns that limit
the transportation and use of gas cylinders and the quantity
that can be stored in one space. Alternatively, installing a gas
generator can circumvent these safety issues and provide a
more sustainable option for supplying gas to your lab.
Gas generators tend to be safer than gas cylinders as potentially hazardous gases are only produced on an as-needed
basis and are not stored in a compressed form, limiting the
potential for dangerous accidents. Generating gas only as
needed is also a more sustainable option that can help limit
waste, both of the gas itself and of the waste from shipping
the cylinders. While gas cylinders allow users to order
specific gas mixtures, gas generators are quickly rising to
become a safer option for research laboratories.
10 Lab Manager Lab Safety Resource Guide
Gas generator versus gas cylinder
safety
When using any amount of potentially hazardous gases for
research, there are always safety concerns to consider. While
gas cylinders have the benefits of being replaceable and of
taking up relatively little floor space, storage can be tricky. A
given structure has building or fire codes with maximum allowable quantities (MAQs) of gas cylinders that can be stored
at one time. This means lab managers must make special
accommodations for cylinder storage or limit the number of
cylinders stored in a building.
“You can order cylinders to whatever specifications you
need—combinations with other gases, purities, calibrated to
an ASTM or NIST standard, sizes, etc.,” explains Jonathan
Klane, MScEd, CIH, CSP, CHMM, CIT. “But the fire and
building codes only allow so many cylinders within each hazard classification per fire control zone or area, which is usually the entire floor of the building unless it is divided with full
fire stops (such as chemical storage rooms, nano-fabs, etc.).”
Additionally, while it is less common, the compressed nature
of gas cylinders can lead to other safety concerns, such as
dangerous gas leaks or even explosions. If the gas being
stored is flammable, then a leak can cause a fire risk, but even
inert gases can be dangerous given the pressure they are
kept under. “If any gas cylinder (even with an inert gas) has
the stem broken off, it becomes a steel rocket and will smash
through concrete and brick walls,” adds Klane.
Gas generators take up more space than cylinders but are in
many ways much safer.
“Basically, gas generators create their gas on an as-needed
basis. It is ‘consumed’ or used up as it’s being created. So,
with no flammable gas accumulating, we have no hazards.
They are placed in one lab and used there,” explains Klane.
Finally, because gas produced from a gas generator is consumed immediately while it’s being generated and isn’t stored,
gas generators do not count toward a building’s MAQs.
As generators become increasingly prevalent and more
compact and efficient, many labs will benefit from switching from cylinders to central generators. The convenience
and consistency make generators a reliable option for labs
that need regular supplies. Coupled with the safety benefits
of not having to store unused gas in a potentially volatile
pressurized container and the added boost to sustainability
from decreasing shipping and waste, gas generators represent
a promising step forward for the future of research.
“Gas generators tend to be safer than
gas cylinders as potentially hazardous
gases are only produced on an asneeded basis and are not stored
in a compressed form, limiting the
potential for dangerous accidents.”
11 Lab Manager Lab Safety Resource Guide
Safer Sterilization: Improvements
in Autoclave Safety
Advances in autoclave technology help mitigate the hazards of high
temperatures and pressures
By Sarah Kirsh, MSc and Ian Black, MSComm, MSc
The autoclave, an invaluable sterilization and safety tool, can
be found in many labs and healthcare facilities. Ranging in
size from small, benchtop machines to larger walk-in systems,
there is an appropriate autoclave to match the needs of any
industry. Despite this variability and utility, autoclaves can
present a significant danger to the lab environment due to the
high temperatures and pressures involved in their function.
Fortunately, we have come a long way since the invention
of the autoclave in 1879, with most advancements revolving
around safety features that help keep researchers and lab
technicians safe.
Autoclave hazards and safety features
While autoclaves are vital equipment for most labs, they
represent a substantial risk due to the inherent high temperatures and pressures. A lack of instituted safety protocols,
poorly maintained autoclaves, or older autoclaves lacking
modern safety features can result in serious harm such as
12 Lab Manager Lab Safety Resource Guide
scalding, trauma injury, the spread of infectious diseases, and
damage to surrounding lab equipment and infrastructure.
Effective steam sterilization requires four elements: pressure,
temperature, steam, and time. Pressure, at a minimum of 15
psi, is used to raise the boiling temperature of water, resulting in superheated steam ideal for sterilization. This steam
typically reaches temperatures of 250°F (121°C) or 270°F
(132°C) and must be maintained long enough—based on the
item and autoclave—to kill microorganisms.
As with all pressurized containers, autoclaves can be dangerous if improperly handled. While rare, explosive opening
of the door, due to seal malfunctions or premature opening,
can cause structural damage, serious trauma injury, or even
death. The first line of defense is an electronic door-locking
system that prevents the sterilization cycle from starting if
the door is not properly secured. Additionally, some autoclaves are equipped with an emergency stop feature that
allows operators to terminate the sterilization process immediately if a critical failure is detected, providing additional
control and protection. Newer autoclaves may also have safety interlocks that sense temperature and pressure, preventing
users from opening the autoclave before the temperature
and pressure have dropped to a safe level. Most importantly,
autoclaves should be equipped with safety or pressure relief
valves designed to release steam pressure if the internal
temperatures exceed safe operating limits, acting as a critical
fail-safe should all electronic controls fail.
To further enhance safety, modern autoclaves incorporate over-temperature protection to prevent overheating,
over-pressure protection to manage excess steam pressure,
and over-current protection against electrical malfunctions
that could lead to equipment failure or fire hazards.
More commonly, autoclave injuries are a result of high
temperatures and steam. While most autoclaves are well
insulated to prevent heat from radiating out of the chamber,
scalding can easily occur when the user loads or unloads the
machine. This risk can be lessened by using an autoclave
with automatic door opening and closing, as this keeps the
operator away from escaping steam. Additionally, some models have a steam condensing mechanism, which condenses
superheated steam into a small amount of water post-sterilization, or a cooling cycle that decreases the temperature
inside the autoclave, making the removal of items safer.
A third, less obvious risk is the potential spread of infectious particles due to incomplete sterilization. This is where
automation, sensors, and remote monitoring excel. Modern
autoclaves employ intuitive user interfaces and programmable cycles, tailored to specific sterilization needs, to ensure
the correct application of time and heat, minimizing opportunities for human error. Embedded sensors actively monitor
the entire process and can trigger alerts or shutdowns for
immediate corrective action at any sign of deviation. Complementing this, remote monitoring enables lab personnel
to remotely track sterilization progress, offering real-time
insights on temperature and pressure levels, enhancing both
safety and efficiency. To further bolster the efficacy of sterilization, some autoclaves include a post-sterilization drying
cycle, which can help minimize the risk of microbial growth
during subsequent storage and handling.
While no amount of safety features can make up for a
rigorously trained and designed safety protocol, modern
autoclaves are better equipped to reduce the potential for
harm caused by human oversight or error in their operation.
Investing in these safety features and maintaining your autoclave will help ensure a safe laboratory environment.
“A lack of instituted safety protocols,
poorly maintained autoclaves, or
older autoclaves lacking modern
safety features can result in serious
harm such as scalding, trauma injury,
the spread of infectious diseases,
and damage to surrounding lab
equipment and infrastructure.”
General safety features
Emergency shutoff is clearly marked and accessible
Overload protection
Built-in alarms for temperature, pressure, or malfunction
conditions
Interlock mechanisms to prevent access during
hazardous operation (e.g., centrifuges, autoclaves, etc.)
Fail-safe design to ensure equipment defaults to a safe
state during power failure
Electrical and automation safety
Complies with electrical safety standards
(e.g., CSA, UL, CE)
Includes ground-fault protection and surge suppression
Automation systems include motion sensors, force limits,
or light curtains for safer interaction
Monitoring, logs, and maintenance
Offers automated safety logging or audit trails for
compliance
Alerts for required maintenance or failed safety checks
Offers remote monitoring and LIMS integration
Accessible maintenance areas with lockout/tagout
support
Decontamination and spill
management
Non-porous surfaces
Includes spill trays or containment basins for leaks
Sharps or chemical disposal integration, if appropriate
Ergonomic considerations
Designed for safe access and use by personnel of
varying heights
Clear operating instructions and visible safety labels
Compatible with PPE use (e.g., glove-friendly controls)
Ventilation and containment
Integrates with local exhaust ventilation and/or
incorporates HEPA or carbon filters
Safety is verified, including containment and face
velocity tests
Thermal, pressure, and chemical
hazards
Operates safely under high pressure or temperature
(e.g., autoclaves, ovens, etc.)
Includes pressure relief valves or temperature cutoffs
Includes chemical-resistant materials and is easy to
decontaminate
Components are non-reactive with hazardous
substances in the lab
Lab Equipment Safety
and Engineering Controls Checklist
It is important to consider safety features in addition to performance when selecting new laboratory equipment and instruments. The right
engineering controls can significantly reduce risk. This checklist is designed to help you evaluate essential safety features when procuring
instruments and equipment, ensuring compliance with best practices and creating a safer environment for all laboratory staff.
Chapter Two
Administrative Controls
Even with well-designed engineering controls, lab safety depends on how people work
within the environment. Administrative controls establish the policies, procedures, and
oversight that guide safe work practices. Through hazard evaluation, chemical tracking,
routine inspections, training programs, and well-defined responsibilities, these controls
create the structure needed to maintain safety across the lab.
This chapter explores how lab managers can strengthen administrative controls to
support safe behaviors, build a strong safety culture, ensure compliance, and proactively
identify areas for improvement.
15 Lab Manager Lab Safety Resource Guide
Fostering Safety Expertise
on Your Team
A variety of training styles contribute to a crisis-ready staff
By Tasmiha Khan
Developing safety expertise in your staff is critical to ensuring their safety, and this expertise is developed through
effective training. A staff with expertise will understand how
to act within the workplace to minimize risk and respond to
crises effectively. Safety training provides the collective understanding of safety protocols that puts the entire team on
the same page, allowing accurate and appropriate responses
if something goes wrong.
While recurring safety training may seem redundant to workers, it is important to recognize that work and safety are always
integrated rather than two separate entities. Proper safety enhances lab output by minimizing incidents and downtime. As
such, staff members must understand that they cannot attend to
their jobs without properly adhering to safety measures.
Fostering safety confidence through
effective training
Providing workers with proper training allows teams to feel
confident within their workplace, which results in high-quality outcomes and fewer incidents. Understanding how to
implement quality responses in an emergency gives workers
enough independence to keep institutions moving smoothly.
16 Lab Manager Lab Safety Resource Guide
“If employees have all the information they need on a
process or procedure, have had hands-on training, and
have someone knowledgeable they can go to if they need
to make changes or have additional questions,” says Becky
Grunewald, the associate director of environmental health
and safety at UC Davis Health in California, “then they can
have peace of mind that they are working safely and not in
danger of any long-term or short-term harm.”
It is important to ensure that every team member has adequate knowledge to implement protocols that keep the entire
team safe, even when a manager might be absent.
Alongside independence, safety training also provides a
sense of team reliability. Having the entire team on the same
page results in collective confidence, which is necessary
to ensure the safety of the workplace at large, as there is a
sense of security that arises knowing that every member will
respond to emergencies with the same level of preparedness.
So, how can labs identify and then offer effective safety
training for their staff? Before any training can be provided,
a learning needs assessment (LNA) should be conducted.
Conducting a learning needs
assessment
To find the right training approach for your team, it is key
that an LNA is conducted to personalize training in accordance with the needs of your workplace and staff. An LNA
is the process of asking questions, evaluating answers, and
considering organizational performance to identify areas
where staff need additional training. In short, the LNA is the
path to get to where you want to be.
According to the Association of Talent Development1
, there is a set of steps to go through in order to conduct
an LNA successfully—here’s an adjusted version tailored for lab safety LNAs:
1. Conduct an organizational scan:
Organizational scans involve solidifying
the context behind the LNA by examining
documentation, reports, existing training solutions,
and more. In an LNA for lab safety, consider
reviewing standard operating procedures (SOPs),
equipment, chemical inventory, current safety
training literature, and past incident reports,
particularly recurring incidents. This information
will help you tailor the training.
2. Collect data to identify performance, learning,
and learner needs: Speak to leadership
and bench staff about their existing safety
expertise. Do they feel comfortable in the event
of an emergency? Do they know what to do?
Supplement these conversations by examining
performance reviews and incident reports.
3. Analyze data: Comb through collected data for
gaps in staff safety knowledge and symptoms
of systemic issues (e.g., poorly defined SOPs).
Weigh the magnitude of these gaps against each
other, which will help you prioritize them when
you develop a training plan.
4. Deliver data analysis feedback: Labs are
businesses, and it’s up to you as the lab
manager to justify the time and money needed
for safety training. Collate the analyses you’ve
conducted and your recommendations to deliver
to senior leadership, making the case for why
additional safety training should occur and why
your recommendations will help solve tangible
problems and, ultimately, protect your staff.
5. Begin designing training: Once you’ve received
buy-in from leadership, you can begin designing
and implementing effective safety training tailored
to your lab’s staff, their unique learning styles, and
their current expertise.
17 Lab Manager Lab Safety Resource Guide
Implementing effective safety training
According to the Occupational Safety and Health Administration, there are several safety training methods.2
For
example, the traditional route of formal classroom training is
classic as it ensures that information is presented clearly in a
way that most can retain information. While in-class training is the most efficient because it reaches a large audience in
a limited time, it also lacks the engagement that keeps students present. Some attendees may miss important information because they are spacing out or bored. Formal classroom
training may be a viable starting point and can work well
to engrain standard knowledge; however, such instruction
should be supplemented with other approaches to bring out
its true potential. Managers should carefully evaluate what
can get through to employees utilizing in-class training and
what might be more difficult to grasp.
An alternative to classroom training is peer-to-peer training. Often manifested as on-the-job training, peer-to-peer
training is effective because teaching others reinforces those
concepts in yourself, demanding constant interaction and
face-to-face conversation. However, peer-to-peer training
may be less effective if both the teacher and the student
already have similar levels of expertise. Seek to pair up the
right people to make the most of this option.
The final approach to consider is live demonstrations, which
implement visual learning techniques that engage audiences
more effectively. Lab training plans should utilize demos
within their program to showcase information that might be
difficult to understand through lectures. Offering a live or
recorded demo will provide attendees with a visual aid to
refer to, eliminating barriers of vocabulary that may interfere
with the understanding of a concept.
Ultimately, lengthy training sessions of any kind can make
attendees feel bored and drained. So, lab managers should
utilize a combination of approaches to achieve well-rounded
results, tailored to the needs of diverse learners and offering
variety that will encourage engagement.
Continuous reinforcement
Even if your staff complete a course or training session,
safety training should never be “over” in your lab. Working
in a lab safely requires diligence and consistency, demanding regular reinforcement. As such, safety training must be
baked into the fabric of your lab’s day-to-day operations.
Grunewald adds, “Ideally, safety training is embedded into
processes and SOPs. That way, when you are working in the
lab, as you learn a task, safety is part of it and is discussed
with the person training you. And if you are innovating and
developing a new process, there would be an expectation
that you assess the hazards and risks and include mitigation
in your protocol. So that encompasses both peer-to-peer
training and demonstrations.”
Establishing a proper safety training program is critical to
building safety expertise in your staff. It will minimize risk
to staff, facility, and reputation. Employing varied, tailored
teaching methods is part and parcel to fostering safety
expertise.
References
1. “How to Conduct a Needs Assessment.” https://www.
td.org/content/atd-blog/the-what-why-and-how-ofneeds-assessments
2. “Recommended Practices for Safety and Health Programs.” https://www.osha.gov/safety-management/
education-training#:~:text=Peer%2Dto%2Dpeer%20
training%2C,and%20promoting%20good%20work%20
practices
“While recurring safety training may
seem redundant to workers, it is
important to recognize that work and
safety are always integrated rather
than two separate entities.”
18 Lab Manager Lab Safety Resource Guide
Laboratory Safety Best Practices:
Strategies to Build Safer Labs
and Avoid Legal Risks
Outline essential laboratory safety best practices to strengthen your lab’s safety
program, avoid legal pitfalls, and create a safer, compliant work environment
By Lauren Everett
Laboratory safety is not merely a matter of compliance—it’s
a foundational aspect of creating effective and ethical work
environments. Understanding the legal implications of lab
safety is critical for managers and professionals responsible
for protecting their teams and ensuring smooth operations.
This article explores key strategies and actionable steps to
strengthen safety programs and minimize risks, drawing
on essential insights into the legal and practical aspects of
lab safety.
Breaking the cycle of ignorance
According to James Kaufman, founder of the Laboratory
Safety Institute (LSI), one of the most significant challenges in laboratory safety is the “cycle of ignorance.” Many
19 Lab Manager Lab Safety Resource Guide
students and new lab employees enter the workforce without a solid foundation in laboratory safety best practices
and protocols or a developed safety ethic. To address this,
organizations must take a proactive approach to onboarding
and lab safety education. Immediate supervisors should dedicate time during new employee orientation to discuss the
importance of safety, review hazards, and set expectations.
Additionally, providing a comprehensive safety manual—
regularly updated and collaboratively developed—ensures
employees understand and adhere to procedures.
Evaluating and improving lab safety
programs
During Lab Manager’s Safety Digital Summit, Kaufman
introduced a scoring system to evaluate lab safety programs,
ranging from reactive measures (one point) to integrating
safety as a core organizational value (five points). To advance
your program, begin with a thorough assessment of current
practices and utilize checklists and audits to identify gaps.
Leading indicators—proactive measures like hazard assessments and near-miss reporting—should be prioritized over
solely relying on past incident data. Furthermore, establishing a rotating safety committee ensures diverse perspectives
and a shared commitment to reviewing safety protocols,
training effectiveness, and incident management.
Building a culture of safety
Leadership plays a pivotal role in cultivating a culture of
safety. Supervisors must consistently follow laboratory safety
best practices and protocols to set a strong example for
their teams. Recognizing and rewarding exceptional safety
practices, such as highlighting top-performing labs during
monthly inspections, fosters motivation and accountability.
In addition, Kaufman suggests engaging employees in safety
initiatives through inclusive language, such as “I need your
help.” This can encourage a collaborative environment that
prioritizes shared responsibility for safety.
Employees should also be encouraged to contribute to
emergency preparedness efforts by drafting and reviewing
response procedures and sharing these during regular safety
meetings. Cultivating a culture of open communication
ensures that accidents, injuries, and near misses are promptly
reported and addressed.
Avoiding negligence and legal pitfalls
Negligence—whether through malfeasance (forcing unnecessary risk), misfeasance (improper execution of tasks), or
nonfeasance (failing to act)—can lead to severe consequences. To mitigate these risks, lab leaders should:
) Define and communicate safety rules and policies: Use written guidelines, regular meetings, and
accessible resources to ensure everyone understands
expectations
) Provide proper training: Include both general safety
protocols and job-specific hazards, supplemented with
hands-on demonstrations and assessments to verify
understanding
) Maintain thorough documentation: Keep detailed
records of inspections, including dates, findings,
corrective actions, and follow-ups. Document training
sessions with participant names, dates, and covered
topics. Log all rule violations or near-misses and review
them during safety meetings to promote continuous
improvement.
These practices not only ensure compliance but also
demonstrate due diligence, which is essential in avoiding
legal repercussions.
20 Lab Manager Lab Safety Resource Guide
Prudent practices and proactive policies
Effective safety programs require continuous evaluation
and adaptation. Regular inspections are vital for identifying
and addressing potential hazards, and involving employees
in these inspections fosters a sense of ownership. A “Safety
Data Sheet of the Month” program can help team members
stay informed about hazardous materials and necessary precautions. Similarly, emergency simulations and drills ensure
readiness and confidence in responding to various scenarios.
The importance of recognition
and accountability
Excellence in safety requires both recognition and accountability. Simple gestures, such as thank-you notes or certificates
for outstanding safety performance, can reinforce positive
behaviors. At the same time, supervisors must hold employees
accountable for adhering to lab safety rules and guidelines.
Leading discussions on challenges and solutions ensures consistent compliance and a shared commitment to safety goals.
Moving forward
Safety is a continuous journey, not a destination. Lab leaders
can create safer, more compliant, and productive environments by making safety a core value, involving all stakeholders, addressing gaps proactively, and following laboratory
safety best practices. Kaufman explains, “No lesson is so
important and no task so urgent that we cannot take time to
teach, learn, and practice science safely.”
“By making safety a core value,
involving all stakeholders,
addressing gaps proactively, and
following these laboratory safety
best practices, lab leaders can
create safer, more compliant, and
productive environments.”
21 Lab Manager Lab Safety Resource Guide
Conducting a Chemical Risk
Assessment in the Laboratory
An overview of the critical steps to carrying out a successful chemical risk
assessment
By Dan Scungio, MT (ASCP), SLS, CQA (ASQ)
Most laboratories, whether clinical, research, or industrial,
contain a wide array of chemicals. These chemicals are essential for operations but also pose potential risks to personnel and the environment. A well-structured chemical risk
assessment ensures that laboratories maintain a safe working
environment while complying with the Occupational Safety
and Health Administration (OSHA) regulations and other
safety standards. Performing a chemical risk assessment
involves several critical steps: evaluating chemicals and
reagents, utilizing chemical inventories as a risk assessment
tool, and assessing the effectiveness of the laboratory’s chemical hygiene plan (CHP). The use of these assessment tools
will help create a safer overall lab environment.
Evaluating chemicals and reagents
The foundation of a strong chemical risk assessment is a
thorough evaluation of all chemicals and reagents used in
the laboratory. This process involves understanding the
hazards associated with each substance and determining the
22 Lab Manager Lab Safety Resource Guide
necessary controls to mitigate any accompanying risks. This
evaluation can be performed by using a stepwise process.
First, the laboratory should review its chemical safety data
sheets (SDS). OSHA’s Hazard Communication Standard
(HCS - 29 CFR 1910.1200) mandates that laboratories maintain up-to-date SDSs for all hazardous chemicals. The SDS
provides crucial information on:
) Chemical composition and properties
) Potential health hazards
) Storage and handling precautions
) First aid and emergency procedures
) Personal protective equipment (PPE) requirements
Since the United States adopted the Globally Harmonized
System for Hazard Communication in 2012, chemical
manufacturers now generate a standardized, sixteen-section
SDS for every hazardous product. That makes it easier for
labs to evaluate these documents in an orderly fashion. Lab
personnel should review SDSs regularly to ensure that all
staff are familiar with the hazards of the chemicals they work
with daily.
Continue the evaluation by identifying hazard categories for
each chemical. Chemicals should be categorized based on
their primary hazards:
) Flammable (e.g., ethanol, methanol, acetone)
) Corrosive (e.g., hydrochloric acid, sodium hydroxide)
) Reactive (e.g., peroxides, sodium metal)
) Toxic (e.g., formaldehyde, benzene)
) Carcinogenic or mutagenic (e.g., ethidium bromide,
acrylamide)
) Reproductive toxins (e.g., mercury, toluene)
Grouping chemicals based on hazards allows the lab to
implement appropriate safety measures. These measures can
include special handling procedures, designated storage areas, specialized engineering controls (such as chemical fume
hoods), and PPE.
Next, the safe handling procedures for all chemicals used in
the laboratory must be assessed. Proper handling of chemicals is vital to prevent accidents. Comprehensive chemical
procedural risk assessments should evaluate:
) The potential for spills, splashes, or vapor release
) Engineering controls (e.g., fume hoods, ventilation systems)
) Proper transport methods (e.g., secondary containment)
) Compatibility with other substances to avoid dangerous reactions
Once this portion of the chemical risk assessment is completed, the laboratory can establish or modify the CHP to
include the safety measures that apply. At this point, specific
spill kit types can be purchased and placed in appropriate
locations. An analysis of the location of emergency eyewash stations and showers should also occur at this step of
the process.
Utilizing chemical inventories as a risk
assessment tool
A comprehensive and up-to-date chemical inventory, while
required by regulations, is also a critical tool in the total risk
assessment process. A complete inventory helps the laboratory track chemical quantities and expiration dates. Regular inventory audits help ensure that expired or degraded
chemicals, which may become unstable or hazardous, are
removed promptly. Inventory management also prevents
the overstocking of chemicals, which reduces unnecessary
exposure risks.
Chemical inventories are also helpful for identifying highrisk chemicals in the lab. By analyzing the chemical inventory, lab managers can pinpoint substances that require
additional precautions, such as highly reactive agents or
known carcinogens. This enables targeted safety interventions, such as limiting the volume of hazardous chemicals
stored onsite or requiring additional training for handling
certain substances.
23 Lab Manager Lab Safety Resource Guide
The inventory can also help the laboratory manage chemical
storage and segregation. A well-maintained inventory helps
enforce proper storage practices by:
) Ensuring flammable chemicals are stored in approved
flammable storage cabinets
) Keeping acids and bases in separate, dedicated
storage areas near the floor
) Preventing incompatible chemicals from being stored
together (e.g., oxidizers away from organic solvents)
) Confirming proper labeling and hazard communication compliance
An effective chemical inventory system, whether paper-based or digital, enables real-time tracking and rapid
access to hazard information, making it an invaluable component of laboratory risk assessments.
Evaluating the effectiveness of the
laboratory’s CHP
The CHP is the laboratory’s guiding document for chemical
safety, and its efficacy must be evaluated at least annually
to ensure it meets OSHA’s requirements and protects lab
personnel. Various methods can be employed to analyze the
plan’s effectiveness:
Conduct regular laboratory safety audits that include
chemical hygiene practices: Routine safety audits help
identify gaps in the CHP. Audits should include observations of chemical handling and storage practices, a review
of engineering controls (e.g., fume hood functionality tests),
and an emergency preparedness assessment, including spill
response capabilities.
Review lab chemical incident and exposure reports:
Past incidents provide valuable lessons for improving safety
protocols. Reviewing exposure records, near-miss reports,
and accident logs can reveal recurring safety concerns that
require corrective actions.
Deliver training on chemical safety: A CHP effectiveness assessment should evaluate whether staff receive initial
training on the plan and chemical handling procedures.
Ongoing education should include annual refresher courses
on hazard communication as well as hands-on spill response
and emergency procedures training. Spill drills should also
be routinely performed to ensure staff readiness for a chemical release incident. A successful training program ensures
that lab personnel understand the risks associated with their
work and know how to mitigate them.
Evaluate PPE compliance to assess effectiveness: PPE is
the last line of defense against chemical hazards. Check for
the availability and proper use of gloves, lab coats, goggles
or face shields, and respirators. Gauge the appropriateness of
PPE used for specific chemical hazards (e.g., selecting chemical-proof gloves for solvent use), and ensure the maintenance
and replacement schedules for PPE used in the lab.
Keeping chemical safety a priority
The laboratory is a dynamic environment. Processes and
instrumentation change often, and the chemicals in use will
not remain static. Therefore, a chemical risk assessment
cannot be a one-time event; it’s an ongoing process that
requires vigilance, training, and adaptation. By systematically evaluating chemical hazards, maintaining an accurate
chemical inventory, and regularly reviewing the effectiveness of the CHP, laboratories can foster a culture of safety
and compliance.
When was the last time your lab performed a full chemical
risk assessment? If it’s been a while, now is the perfect time
to start. Safe chemical management isn’t just about compliance—it’s about protecting the health and well-being of everyone in the lab. Stay proactive, stay informed, and stay safe!
“An effective chemical inventory
system, whether paper-based
or digital, enables real-time
tracking and rapid access to
hazard information, making it
an invaluable component of
laboratory risk assessments.”
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The Critical Role of
Chemical Inventory Tracking
in Risk Management
Efficient chemical inventory tracking is key to preventing hazards, fines, and
reputational damage in laboratory environments
By Jonathan Klane, MScEd, CIH, CSP, CHMM, CIT
Safety and risk problems of not
tracking your chemical inventory
There are costs to tracking and costs to not tracking. Costs
matter, and they include both safety-related costs and others. People get injured. Labs can be harmed or destroyed.
Entities can be cited and fined. There’s downtime, loss of
research, or lost time. Perhaps the greatest risk is reputational harm (research grants or investors may dry up, schools can
end up with fewer students, staff, or faculty).
Another significant risk to the organization is exceeding
the maximum allowable quantities (MAQs). Building and
fire codes set limits for total amounts of hazardous materi-
25 Lab Manager Lab Safety Resource Guide
als across several hazard categories (e.g., flammable liquids,
toxic gases, etc.). If the aggregate of all labs—on a floor for
instance—in any category, exceeds its MAQ , it’s a violation
and is considered unacceptable risk. The authority having
jurisdiction, or AHJ (e.g., a fire marshal), has the power to
stop operations until MAQ issues are resolved.
Here are two real-world examples of risk problems that could
have been prevented with an effective tracking program.
Another lab asked if you had space to store their excess HF acid.
They stockpiled it with purchases in larger containers to save
money. The AHJ discovered it put their entire fire control zone over
the MAQ. Your other labs have no free space, thus creating a huge
operational problem for everyone in that zone.
You’re having lunch with another lab staff member who complains
about having to purchase two chemicals on short order and pay for
fast shipping. You comment, “That’s too bad, we have extra bottles
of both of those!” It turns out that these same instances of excess
chemicals have occurred many times among the various labs, costing
thousands and adding to an overflowing inventory.
Developing a robust hazardous waste
safety program
So, how does chemical inventory management fit into your
lab’s overall risk management strategy? Hint: It should be a
core area of your safety strategy from purchase through disposal. Without an accurate inventory, you don’t have a complete picture of all the hazards in your labs. Making it worse,
these all add up to a colossal mess at the choke point—your
hazardous waste facility or locations. Here are just a few
potential adverse outcomes of poorly managed inventory:
) Your hazardous waste facility is beyond capacity. You
must stop accepting wastes, immediately ship enough
out to be disposed of, or call in a contractor—all of
which have significant costs.
) The ongoing cost constraints for hazardous wastes are
way over your budget. Now the organization must
determine better cost allocations on a lab or department basis.
) Lab packing risks and incidents rise. Old chemicals
present significant hazards. Packaging them up individually and shipping them to a hazardous waste facility
is costly and can result in an incident.
) Weather events can create bigger problems with more
chemicals (e.g., high heat facilitating fires, cold freezing pipes and walkways, flooding shutting down labs,
hurricanes, wildfires, etc.).
How confident are you as a lab leader that you’re
aware of all the potential risks and hazards in
your lab? Can you answer these easily and with
confidence?
• How close to expiry are any energetic chemicals
or peroxide formers?
• How easily can labs share excess and unneeded
chemicals (and reduce their overflowing
inventory)?
• How close are your fire control zones to
their MAQs?
If you can’t answer these and other risk-based
questions, you should reevaluate your lab’s safety
program and chemical tracking system.
26 Lab Manager Lab Safety Resource Guide
All the above can incur various costs, including regulatory
citations, fines, injuries and exposures, production slowdowns, and reputational risk.
Other key elements of a safety
program
Your lab chemical tracking system should also facilitate
other beneficial aspects, such as:
) Safety document management (e.g., SDSs and chemical hazard reports)
) Safety equipment tracking (e.g., multi-gas meters, photoionization detectors, etc.)
) Preparedness/resources/materials for safety inspections (e.g., weekly checklists, risk tools)
) Safety-related SOPs (e.g., for higher hazard chemicals,
biologicals, and radioactive sources)
) First responder resources (e.g., high hazard inventory)
and hazard info for medical personnel
Software tracking systems
As discussed above, the risks of not properly tracking
your chemical inventory are much greater than the cost of
purchasing a tracking system. There are many options with
similarities and differences. Considerations for choosing one
are critical to your success. For example:
) What’s a “lab” (i.e., the physical space, group of
people, or what the lab does)?
) Does it link to purchasing?
) Is it integrated with hazardous waste?
) Can it auto-calculate MAQs?
) How is data displayed?
) How much are the total costs—initial and ongoing?
Be sure to do your homework. Decide what features are most
important to your safe operations. Try using a nominal group
process with your lab and get a rank order of features by importance that is specific to your situation. Then discuss these
with a provider to compare your needs with their capabilities.
Improving safety and risk culture in your lab should always
be the driving motivator behind developing a comprehensive
safety program. Tracking systems are now the norm; be sure
that yours serves your lab’s needs before it’s too late.
27 Lab Manager Lab Safety Resource Guide
Tips for Assessing Indoor Air
Quality in the Laboratory
Recommended protocol for regular IAQ assessment
By Vince McLeod, CIH
Indoor air quality, known as IAQ , and more broadly indoor
environmental quality, began with a few cases of tight
building syndrome and mushroomed into prominence due to
cases of multiple chemical sensitivity and indoor mold contamination. Now, thanks to efforts from the Environmental
Protection Agency (EPA), Occupational Safety and Health
Administration (OSHA), American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE), and
the US Green Building Council (USGBC), we have a robust
knowledge base for dealing with these important issues.
The EPA and OSHA have extensive information and guidance about IAQ on their respective websites. The information covers building systems, preventing problems, and
troubleshooting with comprehensive guidance provided.
In addition, non-governmental organizations like ASHRAE
and USGBC have augmented the science of IAQ. ASHRAE’s
ventilation guide is considered an invaluable IAQ resource,
especially regarding office and general workspace basic parameters. The USGBC Leadership in Energy and Environmental Design (LEED) program offers guidance for design-
28 Lab Manager Lab Safety Resource Guide
ing and building the new generation of green buildings with
a focus on occupant health and IAQ.
Even so, IAQ issues arise due to many different and common
reasons. Here are a few examples:
) Poor preventive maintenance
) Broken belt on a crucial exhaust fan
) New furnishings and floor coverings
) Delivery vehicle parked near an air intake
Assessing IAQ
As the “Safety Guy,” having dealt with IAQ issues for more
than a couple of decades and studied the guidance documents, I have developed an air testing protocol that may help
prevent many common IAQ issues. My recommended testing
protocol is based on EPA studies and the USGBC LEED
IAQ commissioning requirements.
It entails a survey (of the concerned area or as an overall
preventive, the entire facility or building) for specific parameters and contaminants. It is straightforward and inexpensive, even if consultants are hired to perform the work. Most
importantly, the data is compared to existing OSHA, EPA,
ASHRAE, and LEED standards or other recommended
guidance levels and related directly to occupational health
conditions.
HVAC evaluation
This IAQ survey starts by taking measurements of the classic
four ASHRAE comfort parameters: temperature, relative humidity, carbon dioxide, and carbon monoxide. This is most
easily done using a modern handheld IAQ meter.
Temperature, relative humidity, and carbon dioxide are
important indicators of HVAC system performance as well as
occupant comfort. ASHRAE standard 62.1-2010 recommends
ranges for these criteria. If these indicators are out of range,
it could mean the HVAC system is out of balance or the
amount of outside air is insufficient.
Carbon dioxide depends on occupant loading and tends
to increase during the workday. If accumulation or buildup is noted, first verify the proper amount of outside air,
then check the supply flows and distribution in the area.
ASHRAE recommends keeping carbon dioxide levels below
the ambient level plus 700 ppm. The theoretical amount of
carbon dioxide in outdoor air is around 350 ppm.
Carbon monoxide is introduced from combustion sources.
The OSHA permissible exposure limit is 50 ppm, a level we
should never come close to inside a building or research laboratory facility. The EPA and LEED recommend an upper
limit of 9 ppm, or 2 ppm above the ambient level, whichever
is lowest. My experience indicates that if you see levels of
carbon monoxide above a few parts per million, you should
seek out the source and eliminate it.
IAQ contaminant survey
After checking the ASHRAE comfort parameters, I recommend evaluating common contaminant levels, dust or
particulates, and volatile chemical vapors. The amount of
particulates in the air indicates HVAC system performance
and filter condition compared to outdoor levels.
Measuring particulate or dust can be more involved than
measuring the classic comfort parameters. Dust is usually
measured in milligrams per cubic meter of air (mg/m3
) and
reported for a specific particle size, median diameter of 10
microns or less, and designated PM10. Like carbon dioxide,
dust levels are compared to OSHA permissible exposure
limits and LEED recommended criteria. For acceptable
IAQ , we should never approach the OSHA PEL, which is 10
mg/m3
. The amount recommended by LEED standards is
0.05 mg/m3
. Typical ambient levels with normal activity are
about half the LEED standard, and indoor office spaces will
usually be in the microgram per cubic meter range.
Handheld instrumentation is also used to evaluate volatile
organic compounds (VOCs) levels. In typical office envi-
“By surveying your indoor air quality
regularly, you can find and prevent
many common problems before they
become serious.”
29 Lab Manager Lab Safety Resource Guide
ronments, these readings result from perfumes, colognes,
and air fresheners. However, these sources do not compare
to common commercial sources such as paints, adhesives,
thinners, strippers, and lubricants. And, in research settings,
there may be a multitude of chemicals in use. Therefore,
VOC levels are very important given the many potential
sources and serious health and safety consequences. The
recommended level under LEED is less than 500 μg/m3
. For
comparison, I typically see background levels between 200
and 300, even in hospital and laboratory buildings.
One last contaminant to consider is formaldehyde, especially if your facility has undergone recent new construction
or renovation, as formaldehyde is contained in many urea
resins, insulation, plywood, particleboard, adhesives, and
textiles. In addition, given its use as a preservative and sterilizer, research labs should definitely include this parameter.
However, real-time measurements necessitate the use of
portable infrared spectrophotometers, which are expensive
to buy or rent and take some expertise to operate correctly.
I recommend calling an industrial hygienist who will likely
use low-flow sample pumps with appropriate media, with the
analyses done by an accredited laboratory. For reference, the
OSHA PEL is only 0.75 ppm, and the LEED standard for
IAQ is 27 ppb.
Summary
Above, I presented the Safety Guy Protocol for regular IAQ
assessment. I recommend performing this screening at least
annually and more often if your facility has serious issues or
lots of employee complaints. By surveying your IAQ regularly, you can find and prevent many common problems before
they become serious.
30 Lab Manager Lab Safety Resource Guide
The User’s Impact on Fume Hood
Performance
A cause of fume hood failure that is often overlooked is the user’s own
work practices
By Chip Albright
Fume hood testing not only measures performance but also
demonstrates how user behavior influences the hood’s ability
to keep them safe.
A chemical fume hood is an exposure control device whose
purpose is to contain hazards and protect the user from exposure. A fume hood is also part of the overall laboratory mechanical system, and there are a variety of potential causes of failure
that can occur, both within and outside the user’s control. A
cause of failure often overlooked is the user’s work practices.
While this article focuses on chemical fume hoods, many of
the key takeaways apply to ventilated enclosures.
How do you know if your fume hood
is working?
The only way to know for sure if a hood is losing containment is to run a test. When doing containment testing, at
least 25 percent of failures are caused by user work practices.
If a fume hood is performing poorly, the lab manager may
31 Lab Manager Lab Safety Resource Guide
not be able to replace the hood or revamp the laboratory ventilation system, but they can educate the user to help protect
themselves by ensuring good practices and expanding their
knowledge of how fume hoods perform best.
The biggest challenge with fume hood performance is that
users typically cannot see the hazards—most are invisible
and odorless. Therefore, there is no easy way to know if your
fume hood is working properly and protecting you. Many
think that face velocity, which is defined as the speed of the
air entering the sash opening, indicates safety. The ANSI/
AIHA Z9.5 Laboratory Ventilation states: “Face velocity had
been used historically as the primary indicator of laboratory
hood performance for several decades. However, studies
involving large populations of laboratory fume hoods tested
using a containment-based test like the ANSI/ASHRAE
Standard 110, ‘Method of Testing the Performance of
Laboratory Fume Hoods,’ reveal that face velocity alone is
an inadequate indicator of hood performance.” In fact, most
hoods that fail containment testing have acceptable face
velocity readings.
So, what causes loss of containment in a fume hood? The
two biggest causes are turbulence and pressure shifts (room
pressure versus fume chamber pressure).
Air is a liquid; it follows the laws of fluid dynamics. It flows
from high pressure to low pressure. Picture a smooth flowing
river, the surface only moved by the wind. Add lots of boulders, and now there are rapids. The smooth-flowing river
has transformed into a raging obstacle course. People do the
same in and around fume hoods. Their actions create turbulence in the airflow that increases the chance of loss
of containment.
Components of a fume hood
By definition, a fume hood is an enclosure with a movable
sash, an upper airfoil, a lower airfoil, and baffles. An enclosure without these features is named a ventilated enclosure.
To the user, the most important feature of a fume hood is the
sash. The sash, or sash panels, are the pieces of transparent
material—usually glass—located at the front of the fume
chamber and are movable. The sash position greatly impacts
the airflow within the fume chamber, but the sash is also a
barrier between the fume chamber and your breathing zone.
It offers protection from other hazards, such as fire and explosion. Using the sash properly is one of the most important
things you can do, not only to protect yourself but also to
save energy.
The next component to focus on is the baffles. These are
usually located in the rear of the hood and create the exhaust
plenum along with the back wall. The exhaust plenum has
the lowest pressure within the hood, so the air naturally
wants to flow there. There are usually slots or holes in the
baffles to allow the air to flow into the exhaust plenum.
There are many baffle designs, and some perform better than
others. The baffles are the most critical component in fume
hood performance, so users must pay close attention.
The lower airfoil is also a critical component. The sash
normally closes onto this airfoil. It is the nose of the work
surface. There are many designs, but typically, they are
constructed of metal and are designed to create a stream
of air that sweeps across the work surface rearward toward
the baffles.
The purpose of most fume hood tests, like the ASHRAE 110
and EN 14175, is to test the validity of the fume hood design
as manufactured (AM) and the interface of the fume hood
with the laboratory ventilation system as installed (AI). Both
tests are useful tools to ensure the system works to specification. They do not focus on the user, except for the ASHRAE
110-AU (as used) test. The much more common AM and AI
tests are conducted using empty hoods, without people, and
with very limited movement.
Even when the hood tests well, your actions at the hood can
negatively impact its ability to properly contain. As the user,
you are a critical element of the ventilation system.
How to safely work with a fume hood
Let’s examine some specific examples of fume hood use.
As a best practice, the lower the sash handle is, the safer the
user will be. Hoods should never be used at full open—this
is for setup only. Working with an 18-inch opening on a
vertical sash is far safer than working at full open.
When you stand in front of the sash opening, your body acts
like an airplane wing; the air drawn into the hood flows over
your shoulders and around your sides, creating a low-pressure zone directly in front of you. This low-pressure area
in front of you will attempt to pull air from inside the hood
outward, creating a loss of containment and possible expo-
32 Lab Manager Lab Safety Resource Guide
sure. This is why you always work at least six inches behind
the sash to keep chemicals out of the area of reverse flow.
Next, extend your hands and arms into the hood and move
them about. What are they doing to the airflow? Picture
yourself in a canoe, your arms are the paddles, and just as
the paddles can displace large amounts of water, your arms
can displace large amounts of air, creating turbulence and
disrupting the airflow. This is a recipe for loss of containment. When working in the hood, move your hands and arms
slowly and deliberately.
Do not place objects directly on the work surface. The airstream flowing over and under the lower airfoil is attempting
to sweep chemical fumes back toward the baffles. Placing
objects directly on the work surface is like putting boulders
in that smooth river. It creates rapids, greatly increasing
the chances of loss of containment. Everything in the hood
should be elevated off the surface one to two inches. Blocks,
shelving, or elevators can be used to lift the objects.
Baffles have been designed to organize the airflow through
the fume chamber into the exhaust plenum. Never tape
notes and such to the baffles or use the hood for storage.
Blocking any of the slots or penetrations in the baffles will
disrupt the airflow and create turbulence, which increases
the loss of containment.
It is not just what happens in the hood that matters, but what
happens around the hood as well. For instance, just walking
past the hood with a raised sash almost guarantees a loss of
containment. Why does loss of containment matter? The
fugitive chemicals escaping the hood contaminate the room
air, which means everyone in the lab is breathing these potentially hazardous chemicals.
There is a long list of dos and don’ts beyond what has been
outlined here. Remember, users are a critical element of the
overall fume hood system. How lab staff work in and around
the hood can create hazards that may impact the safe performance of the hood and everyone in the lab.
Strategies for improving
fume hood safety
Fume hoods are a staple in many research labs,
playing an important role in protecting personnel and
the environment from exposure to hazardous fumes and
volatile vapors. However, the effectiveness of a fume
hood heavily depends on proper usage and routine
maintenance. This includes ensuring adequate airflow,
placing the sash at an optimal level, and verifying that
alarm systems are functional.
Our free fume hood safety checklist provides lab
managers with clear, actionable steps to follow before,
during, and after fume hood operation.
BEFORE USE
Check the safety data sheet for the
chemicals you are using
Verify that the hood is working and the
alarm is functioning
Open the sash to the proper operating
level, which should be marked at 18”
or less
Make sure the airflow is appropriate
using the airflow monitor
Make sure nothing is happening around you
that will interfere with operation (e.g., open
doors and windows and foot traffic)
AFTER USE
Tightly close the caps on all chemical
bottles immediately after each use
Remove all chemicals, containers,
and equipment
Ensure all equipment that resides in
the hood is in a safe and off condition
Close the sash when not working in
the hood—it’s more sustainable
Turn off the interior lights
ONGOING CHECKS
Ensure everyone is trained on safe
fume hood usage, including how to
troubleshoot problems
Schedule inspections and ensure proper
certification is in place
Place new fume hoods in appropriate
locations
Test at least once a year to ensure proper
function and operation
DURING USE
Wear appropriate personal protective
equipment, including eye protection, lab
coats, gloves, and attire (no bare skin
below the neck)
Check for airflow blockages
Ensure the baffles and baffle exhaust slots
are clear
Keep all materials inside the hood at least
6” from the sash opening
Turn on interior lighting
Keep all equipment elevated at least 2”
above the base of the fume hood
Keep hood sash closed except to allow
room to work
Keep your head out of the fume hood
Fume Hood
SAFETY CHECKLIST
Lab safety is a critical responsibility for all lab managers.
With the Lab Safety Management Certificate program from
Lab Manager Academy, you will learn how to mitigate risks,
improve safety culture, and manage your lab’s EHS systems.
Take the first steps towards a safer lab today by visiting
www.academy.labmanager.com
Chapter Three
Personal Protective
Equipment (PPE)
PPE is the final line of defense between lab personnel and hazardous substances or conditions. However, PPE effectiveness depends on proper selection, fit, maintenance, and use.
Poorly fitted or improperly used PPE can create a false sense of security, leaving personnel vulnerable to serious harm.
This chapter focuses on selecting and managing PPE in the lab, emphasizing fit, functionality, and compliance. From gloves and lab coats to respirators and eye protection,
proper PPE use complements upstream controls and provides essential protection when
lab personnel interact directly with hazards.
34 Lab Manager Lab Safety Resource Guide
Guidance and Consistency
Ensure Effective PPE
When are lab coats necessary? When should gloves be worn?
What types are best?
By Vince McLeod, CIH
Modern laboratories today contain serious threats to worker
health and safety. Whether from biological agents or bloodborne pathogens, toxic or hazardous chemicals, or physical
hazards from dangerous equipment such as autoclaves,
centrifuges, or sterilizers, we, as lab managers, know that
accidents happen. Here are a couple of examples from our
recent experience:
A researcher using strong nitric acid suffered only minor burns
thanks to his knowledge of proper procedures and the location of
a nearby safety shower, and quick action by fellow lab workers.
While pouring acid from a standard four-liter glass container into
a smaller container, he spilled acid on his lap. With assistance, he
quickly made it to the safety shower in the hall outside the lab and
removed his shirt and pants while drenching himself under the
shower. Although his clothes were destroyed, he received only minor
burns to his stomach and upper thighs.
A researcher was burned on the hand and upper arm when she
accidentally knocked over a Bunsen burner while sterilizing samples
35 Lab Manager Lab Safety Resource Guide
in a clean flow bench. Alcohol quickly spread over the bench work
surface and ignited the researcher’s lab coat sleeve as she tried to
wipe up the spill. Fortunately, the safety shower was nearby and the
coat sleeve was quickly extinguished.1
The two incidents above are all too common but serve to
demonstrate a point. In the first, no lab coat was worn. In
the second, a lab coat was worn, but gloves were not. When
are lab coats necessary? When should gloves be worn? What
types are best? We hope to answer these and other questions
in this article.
Personal protective equipment (PPE)
determination
The first step in identifying hazards and proper controls is
conducting a thorough job hazard analysis (JHA). A thorough JHA will identify the potential risks associated with
each job and devise ways to control or eliminate them before
an injury or accident occurs. The JHA technique looks at
the individual tasks connected to a job and identifies controls
for the hazards in each job step. When the hazard cannot be
removed or controlled adequately, for example, unexpected
splashes or spills, PPE must be used. The JHA uses a system
that considers each body area: eyes, face, head, hands, feet,
ears/hearing, respiratory system, and whole body.
Determining exposure from toxic materials is usually
performed and entails air sampling and analysis that is best
conducted by a safety and health professional, such as an
industrial hygienist.
Basic laboratory PPE
We recommend setting basic PPE requirements for all laboratories. Included are long pants, closed-toe shoes, lab coats,
and safety glasses. The primary piece is the lab coat, and
the selection must be based on expected hazards. We would
recommend serious consideration of new-generation, multihazard lab coats. Those offering both flame resistance and
chemical splash protection cover many potential common
incidents and are economical.
Add gloves to your basic outfit if the prevention of skin
contact and contamination is needed. Consult chemical
compatibility charts (available from all major chemical glove
manufacturers or distributors) before deciding on type
and material.
A note on PPE fitting
Remember that employees need several different PPE
options (that meet the safety requirements) to select for personal comfort and preference. If PPE does not fit properly, its
use and effectiveness are often drastically reduced.
PPE use training
Workers need to know when PPE is necessary and what
tasks or areas require the use of PPE. This should be spelled
out in your JHA, and all the PPE required for specific tasks
should be listed. When training employees on PPE use, be
sure to show how to properly check, put on, take off, adjust,
and wear the assigned PPE. Training should also cover the
limitations of PPE. PPE gear is specific for the anticipated
hazard(s). Misunderstandings or confusion can lead to more
serious injuries, or worse. Workers must have a thorough
understanding before using any PPE.
Remember to include proper care, maintenance, useful life,
and disposal of PPE. OSHA inspectors will often quiz workers to see whether they understand why they are wearing
36 Lab Manager Lab Safety Resource Guide
PPE, the hazards they are protecting themselves against, and
how they care for and store their equipment.
Follow-up, auditing, and revising
Proper maintenance of PPE is paramount to protecting the
worker. Poorly maintained or dirty equipment puts workers
in greater danger. Conduct regular checks of workers’ PPE to
ensure equipment is handled appropriately.
Monitoring or auditing the program on an ongoing basis is
very important. Thoroughly investigate any accidents or
near-misses involving the use of PPE. Use findings to support safety committee meetings and discuss case studies.
PPE is very effective in preventing injury. But, it is also the
most vulnerable to failure, as it relies on consistent and proper use by the worker every time. If you devise and apply solid
PPE guidance, your employees will maximize protection.
References
1. Lab Safety Incidents, personal communique, Environmental Health and Safety Division, University of Florida,
Gainesville, FL.
Choose the Right PPE
To Match the Hazard
Laboratory hazards generally
fall into three categories:
In addition to engineering and administrative controls,
individuals working in the laboratory environment require
appropriate personal protective equipment (PPE) to carry
out their work safely. Not just any equipment will do—the
PPE must be appropriate for the specific hazards.
Ergonomic, Thermal,
Acoustic, and
Mechanical Hazards
Physical Hazards: Allergens,
Infectious Zoonotics,
and Viral Vectors
Biological Hazards: Compressed Gases, Solvents,
Anesthetic Gases,
Drugs, Cleaning Agents,
and Disinfectants
Chemical Hazards:
PERSONAL
PROTECTIVE
EQUIPMENT
Laboratory Choose the right PPE to
match the hazard
Laboratory hazards generally fall into three categories:
chemical, biological, and physical. In addition to
engineering and administrative controls, individuals
working in the laboratory environment require
appropriate PPE to carry out their work safely. Not just
any equipment will do—the PPE must be appropriate for
the specific hazards. Download this free infographic to
learn how to match PPE to specific hazards.
37 Lab Manager Lab Safety Resource Guide
PPE: How to Ensure a Proper Fit
Properly fitted PPE is vital for minimizing risk and promoting a positive
safety culture
By Aimee Cichocki
Personal protective equipment (PPE) is vital in keeping
lab personnel safe. Items such as lab coats, gloves, eyewear,
safety shoes, and respirators can help avoid mild and severe
injury, as well as fatalities.
The appropriate PPE will depend on several factors, including the type of work carried out, the materials being
handled, and any regulations imposed by relevant governing bodies. For example, specialized containment labs
have particular requirements regarding which PPE items
must be worn and how they should be donned. There are
also requirements to display lab safety symbols and signs
throughout areas in the lab to further emphasize to lab staff
and visitors what type of PPE is required.
But even if personnel are kitted out with the appropriate
PPE, if it doesn’t fit properly, it may not do its job. Poor fit
can also lead to discomfort, which in turn could result in
discontinued use.
Hazards resulting from improperly
fitting PPE
Of course, if people aren’t wearing PPE due to discomfort,
they’re not reaping these items’ benefits. Not wearing gloves,
for example, could lead to harmful substances coming in
contact with the skin. Lack of proper footwear could expose
personnel to the risk of falling objects, causing injury. Respirators protect against the inhalation of harmful substances,
38 Lab Manager Lab Safety Resource Guide
and not wearing one in some instances could lead to serious
harm or even death.
Poorly fitting PPE could actually introduce hazards instead
of minimizing risk. For example, glasses that don’t fit can slide
down the nose, prompting the wearer to look over the top of
the frames. There’s a danger here that this person has a false
sense of security, making the situation even more precarious.
Risks can also be introduced with lab coats, gowns, or gloves
that fit too loosely. Rogue sleeves can knock over vessels
or equipment, causing dangerous spills and other hazards.
Loose gloves may get caught in machinery, and shoes that
are too big can become tripping hazards. Respirators or earplugs that fit loosely are essentially useless and can lead to a
false sense of security.
Proper PPE fit as part of a broader
safety culture
While individuals are ultimately responsible for complying
with PPE regulations, management can reinforce best practices by fostering a culture of care. This follows the ideals
behind the “Safety Differently” movement—also known as
Safety II—which recognizes that human error is inevitable,
but encourages management to provide employees with the
tools to mitigate risks. It acknowledges that people’s actions
should be considered as the solution to safety concerns, not
the cause of them. Providing workers with the right environment for success makes them more likely to take the
correct actions.
PPE protocols should be designed in such a way that not only
helps employees do their job properly, but also signals to
them that management cares about their well-being. As part
of this approach, management provides the correct PPE and
takes the necessary steps to ensure a good fit.
How to ensure the correct fit
Some PPE items are simpler to fit than others. For example,
lab coats, gowns, coveralls, and gloves come in multiple sizes
and can be tried on or ordered based on an individual’s size
measurements. Here, studying the manufacturer’s sizing
guide and taking proper measurements is essential.
Other items present hurdles, often because there aren’t
standard methods to determine fit. For example, safety
glasses are often an overlooked item. Everyone has a different
face shape, so while the bow could be tight on one person, it
could easily slide down the nose of the next. Safety eyewear
should be comfortable with no pinching on the nose or side
of the head. Visibility must be clear in all directions, and the
glasses should stay in place during regular front, back, and
side-to-side head movements. Lenses must cover the wearer’s
eyebrows and should not come in contact with eyelashes.
A respirator is another PPE item that must fit properly for
the wearer to see the core benefits. In workplaces where respirators are mandatory, OSHA requires that they be fit tested
at least annually. Qualitative or quantitative fit tests may be
used depending on the type of respirator being fitted.
Air follows the path of least resistance, so if there’s even a
slight gap between the face and the respirator, this is a big
issue. For example, even a small amount of facial hair could
interfere with the fit, so wearers of styles such as N95 masks
or dual-cartridge respirators must be clean-shaven
(if applicable).
Another area that can represent issues is safety shoes. It’s not
uncommon for people to have different-sized feet, and shoes
must be fitted for the larger foot for maximum comfort. Arch
height should also be considered.
When PPE fits incorrectly, it can do more harm than good.
Aside from introducing physical hazards, it can lead to
dangerous complacency and a relaxed attitude toward safety.
Properly-fitting PPE can not only help mitigate the obvious
risks, but also encourage positive safety practices within
an organization.
“PPE protocols should be designed
in such a way that not only helps
employees do their job properly, but
also signals to them that management
cares about their well-being.”
Evaluate glove materials and performance
Thickness: Thicker gloves
can offer greater resistance
to punctures or chemical
breakthroughs, but can also
limit dexterity and tactile
feedback.
Fit: Gloves should fit
snugly without restricting
movement. Poor fit can
restrict dexterity and
increase the risk of errors
and accidents.
Breakthrough time:
Choose gloves with a
breakthrough time that
exceeds the duration of
exposure for a given task
Permeation and
degradation: Ensure
gloves won’t weaken, swell,
or degrade when exposed
to specific chemicals.
Choosing laboratory gloves isn’t one‑size‑fits‑all. Find the right
type for chemical, biological, thermal, and mechanical hazards
Laboratory gloves are essential personal protective equipment in any lab. Grabbing what’s available on the
shelf isn’t enough—the hazard and task must drive glove selection. A glove that works well in one scenario may
fail entirely in another.
Laboratory Gloves
Explained:
Protection by Hazard Type
Chemical
hazards
Different glove materials
offer varying chemical
resistance. Nitrile gloves
protect against a wide
range of solvents, but may
fail against strong acids
or oxidizers. Butyl and
neoprene gloves may offer
better protection for some
chemicals. Always consult
chemical compatibility charts
before selecting gloves for
chemical handling.
Biological
hazards
When working with
infectious agents, gloves
must create a reliable barrier
against microorganisms.
Nitrile and latex gloves are
widely used for biosafety
applications because they
offer excellent fit and tactile
sensitivity. Be aware of
latex allergies and provide
alternatives if needed.
Thermal
hazards
Standard gloves don’t
protect against extreme
temperatures. Use cryorated gloves for cryogenic
work and heat-resistant
gloves made from insulated
or aluminized materials for
handling hot items.
Mechanical
hazards
Tasks involving sharps or
glassware may require
thicker, cut-resistant gloves
with a textured surface
for better grip, protecting
against punctures,
abrasions, and strain.
Match gloves to the hazard
