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Define Physical Hazard in OSHA’s Hazard Communication Standard

To define physical hazard under OSHA’s Hazard Communication Standard (HazCom), think of hazards that arise from a chemical’s physical or reactive properties—how it can burn, explode, react, or otherwise cause harm due to energy release or violent chemical change.

OSHA’s HazCom (29 CFR 1910.1200) requires chemical manufacturers, importers, distributors, and employers to classify chemical hazards and communicate them through labels, Safety Data Sheets (SDSs), and employee training. In this framework, the definition physical hazard matters because it determines:

  • Which hazard statements and pictograms appear on labels
  • What appears in SDS Section 2 (Hazard(s) identification)
  • Which controls and storage practices are needed to prevent fires, explosions, and dangerous reactions

In plain terms: a physical hazard is a chemical hazard that can cause injury or damage through combustion, explosion, pressure release, or reactive instability, rather than through toxicity pathways like inhalation or skin absorption.

OSHA’s Definition Physical Hazard (Regulatory Context)

OSHA addresses chemical hazard classification in 29 CFR 1910.1200(d) and communicates the required SDS format and content in Appendix D. While HazCom doesn’t define physical hazard in a single sentence the way a dictionary does, OSHA incorporates the GHS-aligned approach: physical hazards are hazard classes based on physical characteristics (flammability, oxidizing potential, reactivity, corrosivity to metals, etc.).

Practically, when you define physical hazard for HazCom purposes, you’re identifying whether the chemical fits one or more OSHA-recognized physical hazard classes and categories (severity levels). That classification must then be reflected on the label and SDS.

Physical hazards vs. health hazards

A common compliance mistake is to treat “hazard” as one bucket. HazCom distinguishes:

  • Physical hazards: fire, explosion, reactive events, pressure hazards
  • Health hazards: acute toxicity, carcinogenicity, sensitization, reproductive toxicity, etc.

A single product can have both. For example, a solvent blend might be highly flammable (physical hazard) and also cause central nervous system effects (health hazard).

Common OSHA/GHS Physical Hazard Classes (What Counts as a Physical Hazard)

Below are examples of physical hazard classes commonly encountered in workplaces. These are the kinds of classifications you’ll see in SDS Section 2 and on shipped container labels.

Fire-related hazards

  • Flammable gases, aerosols, liquids, and solids
  • Pyrophoric liquids/solids (ignite spontaneously in air)
  • Self-heating substances (heat up and may ignite)
  • Substances that emit flammable gas when in contact with water

These hazards drive controls such as ignition source control, ventilation, bonding/grounding, and flammable storage cabinets.

Explosion and reactive hazards

  • Explosives
  • Self-reactive substances and mixtures
  • Organic peroxides

These classifications often require stringent storage temperature control, segregation from incompatibles, and careful handling to avoid shock, friction, heat, or contamination.

Oxidizers and energetic reaction hazards

  • Oxidizing gases, liquids, and solids

Oxidizers may not burn themselves but can dramatically accelerate combustion. Storage segregation from fuels and organics is critical.

Gas cylinder and pressure hazards

  • Gases under pressure (compressed, liquefied, dissolved)

These hazards include cylinder rupture risk, rapid pressure release, and cold burn (cryogenic) hazards. Proper securing, caps, regulators, and transport practices are key.

Corrosive to metals

  • Corrosive to metals

This classification matters for container selection and facility integrity—incorrect storage can lead to leaks, releases, and secondary reactions.

If you’re unsure how to apply the definition physical hazard to a specific product, start with the SDS: Section 2 identifies classification and label elements, while Section 9 (physical and chemical properties) and Section 10 (stability and reactivity) explain the underlying behaviors.

How Physical Hazards Appear on Labels and SDSs

HazCom is built around communicating hazards clearly. Once a chemical’s physical hazards are classified, that information must flow to labels and SDSs.

SDS sections most relevant to physical hazards

Under OSHA’s standardized 16-section SDS format (29 CFR 1910.1200, Appendix D), physical hazards are most directly addressed in:

  • Section 2: Hazard(s) identification (hazard class/category, signal word, hazard statements, pictograms)
  • Section 5: Fire-fighting measures (suitable extinguishing media, specific hazards)
  • Section 7: Handling and storage (conditions to avoid, incompatibles)
  • Section 9: Physical and chemical properties (flash point, vapor pressure, etc.)
  • Section 10: Stability and reactivity (reactivity, hazardous reactions, incompatible materials)

Label elements that often indicate physical hazards

When you see these on a label, you’re likely dealing with a physical hazard:

  • Flame pictogram (flammables, self-reactives, pyrophorics)
  • Exploding bomb pictogram (explosives, organic peroxides, self-reactives)
  • Flame over circle pictogram (oxidizers)
  • Gas cylinder pictogram (gases under pressure)

These label elements support OSHA’s core HazCom requirement: employees must be able to quickly identify hazards and protective measures.

Why It Matters: Workplace Controls Driven by Physical Hazard Classification

Knowing how to define physical hazard is not just a paperwork exercise. Physical hazards often lead to sudden, high-consequence events. The classification informs practical prevention measures such as:

  1. Storage compatibility and segregation (oxidizers away from flammables; acids away from cyanides, etc.)
  2. Engineering controls (ventilation, explosion-proof equipment, temperature control)
  3. Administrative controls (hot work permits, safe transfer procedures, inspection schedules)
  4. Emergency readiness (spill/fire response guidance aligned with SDS Sections 5 and 6)

Misclassification or poor communication can lead to improper storage, inadequate ignition control, and incompatible mixing—common contributors to chemical incidents.

HazCom Compliance: Employer Responsibilities Related to Physical Hazards

OSHA’s HazCom standard (29 CFR 1910.1200) requires employers to implement a written hazard communication program and ensure that SDSs and labels are accessible and employees are trained. Physical hazards are a major part of that training—workers need to recognize what “flammable,” “oxidizer,” or “gas under pressure” means in day-to-day tasks.

Key employer duties include:

  • Maintaining an SDS for each hazardous chemical and ensuring employee access (1910.1200(g))
  • Ensuring containers are properly labeled (1910.1200(f))
  • Providing effective information and training (1910.1200(h))
  • Keeping a written HazCom program and chemical inventory (1910.1200(e))

Simplifying Physical Hazard Management with SwiftSDS

Managing physical hazards gets complicated quickly when SDSs are scattered across binders, shared drives, and email threads—especially if you have multiple sites, frequent chemical changes, or decentralized purchasing.

SwiftSDS helps organizations reduce HazCom friction by centralizing the information employees and safety teams rely on:

  • A Centralized SDS Library so the right SDS is available when a chemical is used or stored
  • OSHA HazCom support aligned with 29 CFR 1910.1200 expectations for access and consistency
  • Chemical inventory management to track what’s on-site and where physical hazards exist (e.g., flammable storage areas)
  • Mobile access so employees can pull up SDS Sections 2, 5, 7, 9, and 10 instantly during daily work or emergencies

You can also strengthen internal consistency by linking your inventory locations to the hazards most likely present there (e.g., oxidizers in one cage, flammables in another), making inspections and training more targeted.

For related guidance, see Safety Data Sheet management and Hazard communication program basics.

Call to Action

Want to reduce the risk of fires, explosions, and reactive incidents while staying aligned with OSHA’s Hazard Communication Standard?

Standardize how you define physical hazard across your chemical inventory, confirm each product’s classification in SDS Section 2, and make sure employees can access SDSs immediately. SwiftSDS makes this easier with a secure, cloud-based SDS library, inventory tracking, and mobile access.

Get started by reviewing your current SDS access process and explore how SwiftSDS can streamline your HazCom compliance workflow.