Today, we’re going to talk about corrosive materials. Corrosives are hazardous chemicals that can cause serious health problems if you fail to take proper precautions.

Corrosives can also be safety hazards. Some are flammable and others can cause explosive reactions. Strong corrosives can react with all kinds of materials—even metal.

All corrosives share a common chemical property—they degrade other materials due to their aggressive nature. To prevent accidents and injuries, you need to know how to work safely with corrosives.

Session Objectives

The main objective of this session is to tell you about the hazards of corrosive materials and the precautions you need to take to prevent accidents and injuries. By the time this session is over, you should be able to:

• Identify corrosive hazards;
• Find hazard and protection information;
• Select appropriate personal protective equipment, or PPE;
• Store, handle, and dispense corrosives safely;
• Respond effectively to emergencies involving corrosives; and
• Dispose of corrosive wastes properly.

What Is a Corrosive?

Let’s begin the session by asking a key question. What is a corrosive?

• Corrosive chemicals are most often thought of as being liquids. But they can also be solids, such as granules or powders. Corrosive gases or mists are often released from concentrated corrosive liquids.
• Unprotected exposure to corrosives can cause irreparable harm to living tissue. Your skin and eyes can be burned by contact with corrosives in any form. Breathing corrosive gases can damage your throat and lungs.
• Corrosives also damage many materials on contact. They will “eat through” metals, wood, concrete, clothing, and many other materials.

Types of Corrosives

In addition to different physical forms (solid, liquid, gas), there are also different types of corrosives.

• Acids are a common type of corrosive used in many cleaning solutions and production processes. Common acids include hydrochloric acid, hydrofluoric acid, nitric acid, and sulfuric acid.
• Bases, caustics, or alkalis are also corrosives. Their names often end in “hydroxide,” “oxide,” or “amine.” They’re used in cleaning agents, fertilizers, and pharmaceuticals. Common bases include sodium hydroxide, potassium hydroxide, and ammonium hydroxide.
• Dehydrating agents are corrosive because of their strong affinity for water. When they react with water they generate a lot of heat. In addition to strong acids, such as sulfuric acid, and bases, such as sodium hydroxide, other dehydrating agents include phosphorus pentoxide and calcium oxide.
• Halogens and halogen salts include bromine, iodine, calcium chloride, and sodium hypochlorite. Halogens give off acid gases that are soluble in water and will damage your skin or eyes on exposure to body moisture. The halogen salts can also create aggressive solutions with water.

Think about the types of corrosives in the workplace.

Corrosive Hazards

• Corrosives can be very hazardous. The primary hazard is that corrosives will attack skin, eyes, and other tissue on contact.
• Corrosives will also attack other materials, which means you have to be careful when selecting materials to use with corrosive chemicals.
• Corrosives can also contribute to fire hazards. Many acids and corrosive salts, such as sodium hypochlorite, are oxidizers— chemicals that support combustion. Some, such as phenol, are flammable. Other corrosives are very reactive and can cause explosions.
• Hydrogen gas, which is highly flammable, is generated during many corrosive reactions.
• Heat is generated when corrosives react; this could result in splattering of corrosive material and fire.
• Finally, corrosives are also toxic. Inhaling high concentrations of corrosive gases or mists can cause serious lung injuries or even death. Corrosives can also generate toxic products when mixed together. For example, mixing cyanide or sulfide salts with strong acids can produce potentially lethal hydrogen cyanide or hydrogen sulfide.

Think about the hazards of the corrosives you work with on the job.

Warning Signs and Labels

To alert you to the hazards of corrosives, we use warning signs and labels.

• Warning signs are posted in areas where corrosives are stored, dispensed, and used. Signs indicate hazards and required precautions.
• OSHA’s Hazard Communication Standard—now aligned with the Globally Harmonized System of Classification and Labeling of Chemicals (GHS)—requires manufacturer’s, importers, and distributors to provide a GHS-compliant label that includes a harmonized signal word, pictogram, and hazard statement on all hazardous chemical containers.
• Department of Transportation, or DOT, labels are found on shipping containers such as drums and as placards on tank trucks that transport corrosives.
• Hazardous Materials Information System®, or HMIS®, labels are often found on small containers. These labels use colors to represent different hazards. For example, blue for health hazard, red for fire hazard, and yellow for reactivity hazard. HMIS labels also use numbers from 1 to 4 to represent the degree of hazard—with 4 being the most severe.
• National Fire Protection Association, or NFPA, labels are similar to HMIS labels and may be found on containers or tanks of corrosives. The NFPA label has colors in the shape of a diamond and also uses numbers.
• Always pay attention to warning signs and read labels carefully to determine the hazards and the required precautions.

Do you always pay attention to warning signs and read labels to find out about corrosive hazards and precautions? You should.

SDS

The most important and complete source of information of about corrosive materials is the safety data sheet, or SDS.

The SDS provides you with essential information about safety and health hazards and the precautions you need to take when working with corrosives. For example, an SDS will provide:

• The product name, chemical name, and chemical formula;
• Safe exposure limits, such as the permissible exposure limit, or PEL, and the threshold limit value, or TLV;
• Reactivity, fire, and explosion information;
• Health hazards and symptoms of exposure;
• Required personal protective equipment and recommended first-aid procedures; and
• Storage requirements, as well as how to handle spills and leaks.

Do you know where to find SDSs for the corrosives you use and how to locate important safety and health information in the SDS?

First Aid

The first-aid procedures we’re going to discuss in this slide are appropriate for most corrosives. But you should always check the SDS in order to determine exact procedures.

• If corrosives splash in your eyes, go immediately to an eyewash station and flush your eyes with water for about 15 minutes. Then seek medical attention.
• If corrosives get on your skin, immediately wash the area with water. Use a safety shower if the exposure covers your face or a large part of your body. Remove clothing splashed with corrosives as well. See a doctor for follow-up evaluation and treatment.
• If you’ve been exposed to corrosive vapors, gases, mists, or airborne dusts, move into fresh air and then see a doctor for follow-up.
• If you accidentally swallow corrosives, seek medical assistance immediately. While waiting for emergency assistance, follow the first-aid recommendations in the SDS.

Do you know the first-aid procedures for medical emergencies involving the corrosive materials you handle on the job?

Corrosives: True or False?

Now let’s try a little true/false quiz to test what you remember about the information we’ve just discussed.

• Contact with corrosives can burn your skin and eyes. True.
• Corrosives are always liquids. False. Corrosives can also be solids or gases.
• If you get corrosives on your skin or in your eyes, you should move into fresh air immediately. False. First aid for eye or skin contact is flushing with water.
• Corrosives can contribute to fire hazards. True. Some corrosives are flammable, and some corrosive reactions generate a lot of heat. Corrosive reactions can also produce hydrogen, which is flammable.

The best source of information about corrosive hazards and precautions is a warning sign. False. The best source of safety and health information about corrosives is the SDS.

Corrosive Hazards

Now it’s time to ask yourself if you understand the information that has been presented so far.

• Do you understand what we’ve discussed about the types of corrosives and corrosive hazards?
• Do you understand the importance of warning signs, SDSs, and labels?
• Would you know proper first-aid procedures if you were exposed to a corrosive?

It’s important for you to understand all this information. Corrosives can be very hazardous, and you need to be aware of the risks.

Now let’s continue to the next slide and talk about engineering controls used to prevent harmful exposures to corrosives.

Engineering Controls

Engineering controls can reduce your exposure to corrosives. For example:

• Corrosives can be replaced with less hazardous materials whenever possible—or replace particularly hazardous corrosives with less hazardous corrosives;
• Operations that generate corrosive dusts, mists, or vapors can be reduced, or changed;
• Potential leak points in processes can be minimized with spill catch pans, splash shields, and exhaust ventilation; and
• Corrosives can be transferred through hoses or permanent piping systems, whenever possible, to avoid the possibility of exposure. The method of creating the ultimate product can be changed.

Engineering Controls (cont.)

Engineering controls can help prevent exposures in other ways as well:

• Corrosive operations can be designed so that they are enclosed to protect from exposure, or these operations can be guarded to prevent direct access to corrosives and avoid injuries.
• Ventilation and exhaust systems can be used to limit exposure to airborne corrosive vapors, mists, or dusts.
• Materials that are compatible with corrosive chemicals can be used when designing systems so that corrosives can’t corrode the materials, causing leaks and spills or releasing hazardous gases.
• Operating pressures and temperatures in corrosive systems can be minimized. Lower pressure means less likelihood of a leak, and lower temperature means a reduction in the amount of vapor and mists generated.

Think about the engineering controls we use to minimize the risk of hazardous exposures to corrosives.

Ventilation

Let’s take a closer look at ventilation—one of the key engineering controls used to prevent harmful exposures to corrosives.

• A well-designed, well-maintained ventilation system helps protect from corrosive vapors, mists, and airborne dust;
• The amount and type of ventilation we use to remove airborne corrosives is based on an evaluation of the kind of tasks being done, the type of corrosives used, and the size and layout of work and storage areas;
• We may also use air monitoring to check to make sure the ventilation systems are working properly and capturing airborne corrosives to keep exposure limits below the PELs set by OSHA and listed in the SDS;
• Where there are large quantities of corrosives being used or a number of workstations using corrosives, a system of hoods and ducts might be required to properly ventilate the work area; Remember that corrosives can be incompatible and can react vigorously or react to create very toxic materials, therefore co-mingling of ventilation systems may not be appropriate; and
• In other areas where only a small quantity of corrosives are used a single exhaust fan may be sufficient, as long as the corrosives and their concentrations are compatible.

Be sure to report any problems with ventilation immediately.

PPE

When engineering controls can’t fully protect you from corrosive hazards, PPE is required. PPE should be selected on the basis of the type of corrosive as well as the type of possible exposures.

• Safety glasses with full side shields provide minimum eye protection for use with small quantities that are not highly corrosive. But goggles provide better protection and must be used when handling highly concentrated corrosives or large quantities of corrosives. Goggles must also be worn when corrosives are heated, agitated, poured, or mixed.
• In case of splashing, you should also protect your face with a face shield worn over eye protection. A face shield alone is not adequate eye protection.
• You must wear chemical-resistant gloves, usually made of neoprene or rubber, when working with corrosives. Consult the SDS for the right type of glove. Other materials might also be acceptable.
• To prevent skin contact with corrosives, you might also need such protective clothing as aprons, boots, hoods, or other chemical-resistant clothing. Again, consult the SDS for recommendations.
• A respirator may be required for exposure to vapors, mists, or dusts. Air-purifying respirators with acid gas cartridges might be OK for low concentrations. For higher concentrations, an air-supplied respirator might be required. Check the SDS for complete information.

PPE (cont.)

In addition to selecting the right type of PPE, you also need to store it safely, inspect it before each use, and dispose of damaged PPE.

• It is essential to inspect each item of PPE you use before each use to make sure it is in good, safe condition. Look for cracks, tears, discoloration or fading, bubbling, peeling, or brittle spots. After remaining in storage, PPE may deteriorate for many reasons. Their inspection before use is critical.
• Dispose of damaged PPE right away. Never use any PPE that may be questionable. Get a replacement. Your health and safety depends on the protection your PPE affords.
• Replace used canisters/cartridges and worn valves, straps etc.
• After use and before storing PPE, be sure to wash it carefully and air dry it.
• Store all PPE away from corrosive operations to prevent contamination.

Storage

Now let’s talk about safe storage requirements for corrosives.

• Corrosives should be stored away from production and handling areas—and away from other potentially incompatible materials. Separate storage reduces the risk of fire or explosion. It also reduces the amount of damage done in the event of a fire or explosion.
• Storage areas for corrosives must have walls, floors, cabinets, and shelves made from materials that resist damage from corrosives.
• Corrosive liquids should also be stored in corrosion-resistant trays to contain spills or leaks. For large containers such as drums, dikes are provided around storage areas. Storage areas must also be equipped with emergency equipment, such as fire-fighting equipment, emergency showers, eyewash stations, and appropriate spill response and cleanup equipment.
• In addition, corrosive storage areas must be well ventilated and kept cool and dry. That means corrosives should be stored out of direct sunlight and away from steam pipes, boilers, hot equipment, or other sources of heat.

Storage (cont.)

• Storage areas are marked with warning signs. Only trained and authorized employees should enter a storage area for corrosives. All containers should be clearly labeled also.
• These areas must be inspected regularly. Look for corrosion damage, leaking containers, or poor housekeeping. If you spot a problem, either correct it right away or report it if you can’t fix it yourself.
• Many corrosives can only be stored in glass containers. Be careful when handling these and other breakable containers. Make sure the shelves have restraints to keep these containers from falling and breaking. (Some, such as hydroflouric acid, need to be stored in plastic.)
• Remember, too, that some corrosives are incompatible with one another. For example, acids and bases react together violently. Make sure incompatible corrosives are stored separately. If incompatible corrosives are stored together in glass containers, they need to be stored so that if the container breaks, there will not be mixing of incompatibles.

Think about the way we store corrosives and how our storage requirements help prevent accidents and injuries.

Emergency Equipment

We mentioned emergency equipment in storage areas. The same type of equipment can be found in any other area of our facility where corrosives are handled or used.

• First-aid kits are provided and stocked with supplies you would need in the event of an accident involving the specific corrosive in use. Check first-aid kits regularly to make sure you have all the supplies you need.
• Also check spill-response supplies to make sure you have the appropriate items for the types of corrosives in your work area.
• Make sure you know the location of safety showers and eyewash stations and how to use them effectively to wash away corrosives. In addition, be sure access to the showers and eye wash stations are unobstructed.
• Fire extinguishers are also located around the facility. Make sure you know where they are so that you can get to them in a hurry. And also be sure you know how to use a fire extinguisher. Make sure that they are compatible with the fire hazard. Remember oxidizers can cause metals to burn.

Do you know the location of all emergency equipment and how to use it? You health, or that of a co-worker, might depend on this knowledge.

Handling Corrosives

Safe handling of corrosives is essential to prevent accidents.

• When handling drums of corrosives, use a hand truck designed to safely maneuver drums. Also make sure bung caps are closed tightly and that there are no corrosive materials encrusted or leaking on the outside of the drum.
• For carboy-size containers, use a carboy caddie to transport corrosives through the workplace. Make sure the lid is closed. Never transport or carry a corrosive container without a lid.
• Transport liquid corrosives in safety bottle carriers or suitable secondary containers.
• Self-closing portable containers can also be used for carrying, storing, and dispensing small amounts of corrosive liquids. Their spring-mounted spout caps close automatically.

Think about how corrosives should be handled and transported around the facility to ensure safety.

Dispensing Corrosives

• You must also be careful when dispensing corrosives to prevent accidents. For example, make sure you dispense corrosives in a way that avoids or reduces the creation of vapor, mist, or dust.
• Also use caution when pouring corrosives into smaller containers or laboratory equipment. You’re more likely to spill and be injured if you fail to take precautions when performing this task.
• When liquid corrosives are stored in drums, use a corrosion-resistant pump to transfer the liquid into other containers.
• Never transfer corrosive liquids by pressurizing a drum or other container with air or inert gas. Here’s another “never.” Never add water to acid. Always add acids to cold water, slowly, while stirring frequently.
• Transfer corrosive solids by using tools like scoops or shovels made of corrosion-resistant compatible materials.
• And always keep containers closed unless you’re actively removing material from or adding it to the container.

Good Housekeeping

Good housekeeping is important whenever any materials, including corrosives, are used.

• Clean up any drips, leaks, or small spills right away. Wipe down the outside of containers if corrosives have dripped down the outside when dispensing material.
• Dispose of unlabeled containers right away. Contaminated corrosives or off-spec materials should also be disposed of right away. Make sure you follow facility rules for proper disposal of these materials.
• Remove empty containers as well as materials that have not been used in a long time. Do not allow old corrosive materials to sit on the shelf.
• Ensure that all containers, as well as waste containers, are properly marked and labeled.

Do you know the rules for properly disposing of unlabeled containers or contaminated corrosive materials? If not, ask your supervisor.

Personal Hygiene

When working with corrosives, good personal hygiene is another way to protect yourself from hazards. Remember these important hygiene rules for working with corrosives:

• Wash hands before eating, drinking, smoking, or going to the restroom;
• Remove and clean contaminated clothing before wearing it again— or discard it;
• Do not eat, drink, chew gum, or smoke in any areas where corrosive chemicals are present, and don’t bring food, beverages, or tobacco products into these areas;
• Don’t touch your skin, eyes, nose, or mouth with contaminated gloves or clothing; and
• Wash thoroughly at the end of your shift, and change into your street clothes before going home. Do not bring contaminated clothing home.

Think about these hygiene practices. Do you always follow these important procedures?

Emergency Procedures

Now let’s briefly talk about emergency procedures in the event of an accident or spill involving corrosives.

• Evacuate the area immediately in the event of a large spill if you are not trained to handle the problem or it is clearly beyond your control.
• If splashed with corrosives, flush eyes and skin with water and remove contaminated clothes.
• Notify others of the emergency. Notify co-workers so they can evacuate, and notify your supervisor and the company’s emergency response team.
• Limit access to the spill area, and stay away until you’re told it’s safe to return.
• And remember, only trained and equipped personnel are to tackle authorized to clean up large corrosive spills. It’s simply too dangerous to tackle for anyone who is not properly trained and equipped.

Would you know what to do in the event of a workplace emergency involving corrosives?

Which PPE Is Required?

Now let’s test your knowledge about required PPE to protect against hazards from corrosives. Let’s say this worker is working with a strong corrosive that presents serious hazards, including skin and eye contact, and inhalation of vapors, gases, or mists. Take a moment to think about the kind of PPE he would need.

OK, time’s up. Did you select all the right PPE? Let’s find out. To be completely protected from all corrosive hazards, this worker would need the following PPE:

• Goggles;
• A respirator;
• Chemical-resistant gloves;
• Protective clothing; and
• A face shield.

How did you do? Did you keep this guy safe by choosing all the necessary PPE?

Remember, this scenario applies to all corrosives, including the most hazardous. Less corrosive chemicals may require less PPE. Always look at the chemical’s SDS to determine the right personal protective equipment.

Working with Corrosives

Now take a moment to think about the information presented in the previous slides:

• Do you understand what we’ve discussed about engineering controls, PPE, and storage, handling, and dispensing requirements for corrosives?
• Do you understand what we’ve said about good housekeeping, personal hygiene, and emergency equipment and procedures?

It’s important for you to understand all this information. Your life, or the life of a co-worker, might depend on your understanding of this information.

Now let’s continue to the next slide and talk about corrosive waste management.

Waste Management

Corrosive wastes are hazardous and must always be handled safely to protect people and the environment.

• Dispose of corrosives only in labeled corrosive-resistant containers appropriate for the type of corrosive waste.
• Don’t mix corrosive waste with other waste or other types of corrosive waste. There could be an explosive reaction.
• Dispose of empty corrosive containers properly. Empty containers might have residual materials inside, and should therefore be treated as if they are also corrosive wastes.
• Don’t pour corrosives down sinks or drains. Dispose of them only according to the company’s hazardous waste collection and disposal procedures.

Are you familiar with the company’s hazardous waste collection and disposal procedures? If not, find out what the rules are.

Now let’s wind up the session with some key points to remember.

Key Points To Remember

Here are the main points to remember from this session on working safely with corrosives:

• Learn about the hazards of the corrosives you work with by reading the SDS and container label;
• Follow safe storage practices;
• Use the engineering controls the company has made available;
• Always wear proper PPE to protect from corrosive hazards;
• Follow safe work practices when handling and dispensing corrosives; and
• Know the specific first-aid and emergency procedures for the corrosives you work with.

This concludes the working safely with corrosives training session.