Chemical Safety

physical and chemical hazards

chemical safetyphysical and chemical hazards, chemical physical and biological hazards

Understanding physical and chemical hazards in chemical safety

In chemical safety, recognizing physical and chemical hazards is the foundation for preventing fires, explosions, toxic exposures, and costly incidents. OSHA’s Hazard Communication Standard (HCS), 29 CFR 1910.1200, requires employers to identify chemical hazards, maintain Safety Data Sheets (SDSs), ensure labeling, and train workers so they understand the risks and protective measures.

This article explains what physical and chemical hazards are, how they differ from other hazard types (including chemical physical and biological hazards), and how to use the SDS—especially Sections 2, 9, 10, and 11—to build practical controls. We’ll also highlight how SwiftSDS streamlines SDS access and hazard communication across your organization.

What are “physical hazards” under OSHA HCS?

Under OSHA’s HCS (aligned with GHS), physical hazards refer to a chemical’s ability to cause harm through physical effects—most commonly fire, explosion, corrosion of metals, or dangerous reactivity. These hazards depend on properties such as volatility, flammability limits, oxidizing ability, and incompatibilities.

Common examples of physical hazard classes

Physical hazards show up in SDS Section 2: Hazard(s) identification and are supported by data in Sections 9 and 10.

  • Flammables (gases, aerosols, liquids, solids): ignite easily and burn rapidly
  • Oxidizers: intensify fires by releasing oxygen or promoting combustion
  • Explosives / self-reactives / organic peroxides: can detonate or rapidly decompose
  • Gases under pressure: risk rupture, projectile hazards, cryogenic burns (refrigerated gases)
  • Water-reactives / pyrophorics / self-heating substances: ignite or generate heat dangerously
  • Corrosive to metals: degrade containers, piping, and storage systems

Physical hazards are often “invisible” until conditions are right—vapors accumulate, ignition sources appear, or incompatible chemicals mix.

OSHA requirements tied to physical hazards

OSHA 29 CFR 1910.1200 requires that:

  1. Chemical containers are labeled with hazard information.
  2. SDSs are readily accessible to employees during each work shift.
  3. Employees are trained on the hazards and protective measures.

For example, if a product is labeled as a flammable liquid (Category 2), workers need training on ignition source control, proper storage, spill response, and compatible extinguishing methods—information typically found across SDS Sections 5 (Fire-fighting measures), 7 (Handling and storage), and 10 (Stability and reactivity).

What are “chemical hazards” (health hazards) under OSHA HCS?

In everyday workplace language, “chemical hazards” often means the health hazards associated with chemical exposure—effects from inhalation, skin contact, eye contact, ingestion, or injection. OSHA HCS addresses these through health hazard classifications that also appear in SDS Section 2.

Common chemical (health) hazards

  • Acute toxicity: harmful or fatal after short exposure
  • Skin corrosion/irritation and serious eye damage/irritation
  • Respiratory or skin sensitization: allergic reactions or asthma-like symptoms
  • Carcinogenicity, mutagenicity, reproductive toxicity
  • Specific target organ toxicity (STOT): single or repeated exposure effects
  • Aspiration hazard: chemical enters lungs, causing severe injury

These hazards are supported by SDS Section 11: Toxicological information and exposure guidance in Section 8: Exposure controls/personal protection.

Exposure control is required, not optional

If your SDS lists an OSHA Permissible Exposure Limit (PEL) or other exposure guideline, you should translate that into controls such as:

  • Engineering controls (local exhaust ventilation)
  • Administrative controls (process changes, task rotation, restricted access)
  • PPE (gloves, goggles/face shields, protective clothing, respirators when required)

OSHA’s HCS requires you to train employees on these protective measures and ensure SDS access. Other OSHA standards may also apply depending on the chemical and process (e.g., respiratory protection, PPE, flammable liquids storage), but HCS is the baseline for hazard communication.

Chemical physical and biological hazards: how they relate

Workplaces often discuss chemical physical and biological hazards together because real-world tasks rarely involve only one hazard type.

How to distinguish the three

  • Physical hazards: fire/explosion/reactivity/pressure-related harm caused by a chemical’s properties
  • Chemical (health) hazards: toxic or harmful effects from exposure to a substance
  • Biological hazards: bacteria, viruses, molds, bloodborne pathogens, and other living agents (not covered by SDS in the same way, but can coexist with chemical hazards)

Examples of overlap:

  • A disinfectant may present physical and chemical hazards (flammable solvent + respiratory irritation).
  • A lab may handle solvents (chemical/physical) while also working with cultures (biological).
  • Maintenance work may involve mold (biological) plus chemical cleaners (chemical) plus aerosolized flammable propellants (physical).

The safest programs treat hazard identification as task-based: what’s used, how it’s used, what can go wrong, and what controls prevent harm.

Using the SDS to identify physical and chemical hazards

The SDS is your primary tool for consistent hazard identification and communication, as required by 29 CFR 1910.1200.

Key SDS sections for hazard identification

  1. Section 2 – Hazard(s) identification: GHS classification, signal word, hazard statements, pictograms
  2. Section 4 – First-aid measures: immediate response for exposures
  3. Section 5 – Fire-fighting measures: suitable extinguishing media and special hazards
  4. Section 7 – Handling and storage: incompatibilities, ventilation, storage conditions
  5. Section 8 – Exposure controls/personal protection: exposure limits and PPE guidance
  6. Section 9 – Physical and chemical properties: flash point, vapor pressure, pH, etc.
  7. Section 10 – Stability and reactivity: incompatible materials, hazardous decomposition, conditions to avoid
  8. Section 11 – Toxicological information: exposure routes and health effects

A strong chemical safety program doesn’t just file SDSs—it makes them easy to find at the point of use and ensures the workforce understands what the information means.

Common workplace scenarios and practical controls

Scenario 1: Flammable solvent in a cleaning process

Physical hazards: ignition, vapor accumulation, static discharge

Controls:

  • Store in approved flammable storage areas and keep containers closed
  • Eliminate ignition sources; control hot work
  • Use bonding/grounding where needed
  • Provide ventilation to prevent vapor buildup

Scenario 2: Corrosive acid used for etching or descaling

Chemical (health) hazards: severe burns, eye damage, inhalation irritation

Controls:

  • Use splash goggles and face shields, compatible gloves, and aprons
  • Provide eyewash and safety shower access
  • Train on neutralization/spill response per SDS

Scenario 3: Reactive chemicals in a lab or maintenance shop

Physical hazards: runaway reactions, incompatible mixing, pressure buildup

Controls:

  • Segregate incompatible chemicals (use SDS Section 10)
  • Date and track peroxides/unstable materials
  • Use secondary containment and clear labeling

How SwiftSDS simplifies compliance and hazard awareness

OSHA’s HCS requires SDS availability and effective training—not just having binders on a shelf. SwiftSDS helps teams manage physical and chemical hazards by making SDS information usable and accessible.

With SwiftSDS, organizations can:

  • Maintain a centralized SDS library so employees can quickly find the correct SDS
  • Support OSHA HCS (29 CFR 1910.1200) compliance through organized SDS access and documentation
  • Use GHS-aligned information for consistent hazard communication across sites
  • Track chemicals with inventory management (locations, quantities, expiration dates)
  • Provide mobile access, enabling workers to retrieve SDSs at the point of use—on the floor, in the field, or in the lab

To learn more about strengthening your program, see SDS Management and OSHA Hazard Communication.

Key takeaways

  • Physical and chemical hazards are distinct but often present together.
  • OSHA 29 CFR 1910.1200 requires hazard communication: labeling, SDS access, and worker training.
  • The SDS—especially Sections 2, 8, 9, 10, and 11—helps identify hazards and appropriate controls.
  • A modern SDS system improves speed, accuracy, and consistency in hazard communication.

If employees can’t quickly access and understand SDS information, hazard controls break down when it matters most.

Call to action

If you’re ready to reduce risk and improve compliance for physical and chemical hazards, centralize your SDS program with SwiftSDS. Organize your SDS library, track inventory, and give every worker mobile access to the right hazard information—exactly when they need it. Visit SwiftSDS to request a demo and strengthen your chemical safety program today.