Chemical & Petrochemical DSEAR, COMAH & Safety
From bulk storage terminals to processing plants — specialist DSEAR assessments, ATEX zone classification, COMAH support, COSHH compliance, dangerous goods consultancy and explosion risk modelling for chemical, petrochemical and pharmaceutical operations across the UK.
Compliance Services for Chemical & Petrochemical
Click each service to see how RADCaT supports your chemical, petrochemical or pharmaceutical operations.
DSEAR Assessments
Comprehensive DSEAR assessments for chemical and petrochemical facilities — identification of all dangerous substances, assessment of where and how explosive atmospheres form, ignition source mapping, consequence modelling for fire, explosion and toxic release scenarios, and practical control measure recommendations. We assess everything from small solvent stores to major process plants handling hundreds of substances across multiple hazardous areas.
Explore DSEAR ServicesATEX Zone Classification
Detailed ATEX hazardous area classification for your entire facility — Zone 0, 1, 2 for gases and vapours; Zone 20, 21, 22 for combustible dusts. We produce scaled zone drawings, equipment schedules specifying required protection levels (Ex d, Ex e, Ex ia), earthing and bonding specifications and gap analysis against existing electrical and mechanical installations. Essential for process plants, tank farms, filling lines, drumming operations and reactor areas.
Explore ATEX ServicesCOSHH & Occupational Hygiene
COSHH assessments for every substance on your site — raw materials, intermediates, finished products, by-products, cleaning agents, maintenance chemicals and waste streams. We assess exposure routes (inhalation, skin absorption, ingestion), evaluate against Workplace Exposure Limits (WELs), recommend engineering controls (LEV, containment, substitution), RPE selection and health surveillance programmes. We also advise on REACH and CLP classification obligations for manufacturers and importers.
Explore COSHH ServicesDangerous Goods & DGSA
Chemical manufacturers and distributors transporting dangerous goods require a DGSA (Dangerous Goods Safety Adviser) appointment. We provide full DGSA services covering ADR road transport, IMDG sea freight, UN classification and packaging, transport documentation, vehicle specification, driver training, compliance audits, annual reports and 24/7 emergency telephone support for incidents involving your products in transit or on site.
Explore DGSA ServicesExplosion & Process Safety
Explosion consequence modelling, blast overpressure calculations, thermal radiation modelling, toxic dispersion analysis and domino effect assessments for your hazardous installations. We help define safe distances, specify explosion relief systems, design emergency planning zones and inform your COMAH safety report major accident scenarios. Essential for facilities storing or processing large quantities of flammable or toxic substances above COMAH thresholds.
Explore Process SafetySite Health & Safety
Beyond DSEAR and COSHH, chemical facilities require comprehensive health and safety management — permit-to-work systems for maintenance activities, confined space entry procedures, hot work controls, isolation and lock-out/tag-out (LOTO) procedures, crane and lifting operations, contractor management and site-wide emergency response planning including chemical spill, fire and toxic release scenarios. We develop integrated safety management systems that tie everything together.
Explore H&S ServicesHR & Chemical Sector Employment
Chemical facilities face specific HR challenges — safety-critical worker competency frameworks, drug and alcohol testing policies, shift pattern management for continuous operations, occupational health surveillance obligations, contractor vs employee status for site-based personnel and managing disciplinary processes where safety breaches may have criminal implications. We provide employment contracts, safety-critical role specifications, handbooks and ongoing HR advice for chemical operations.
Explore HR ServicesTraining for Your Chemical Facility Team
Specialist courses delivered on your plant by trainers who understand high-hazard chemical operations.
DSEAR Awareness
Understanding explosive atmospheres, ignition sources, ATEX zones and safe working practices for chemical environments.
COSHH Awareness
Hazardous substance handling, SDSs, WELs, PPE selection, exposure routes and emergency spill response.
ADR / Dangerous Goods
Classification, packaging, labelling, documentation and emergency procedures for chemical transport.
Fire & Explosion Safety
Chemical fire risks, specialist extinguishing agents, flammable storage and emergency evacuation.
IOSH Managing Safely
Management qualification for plant supervisors and operations managers. Risk, legal framework, incident investigation.
Chemical First Aid
First aid for chemical exposure incidents. Burns, inhalation, eye contact, ingestion and decontamination.
Permit to Work
Permit-to-work systems, confined space entry, hot work controls, isolation and LOTO procedures.
Manual Handling
Drum handling, IBC movement, chemical container lifting and safe use of mechanical handling aids.
DSEAR Awareness
Understanding explosive atmospheres, ignition sources, ATEX zones and safe working practices for chemical environments.
COSHH Awareness
Hazardous substance handling, SDSs, WELs, PPE selection, exposure routes and emergency spill response.
ADR / Dangerous Goods
Classification, packaging, labelling, documentation and emergency procedures for chemical transport.
Fire & Explosion Safety
Chemical fire risks, specialist extinguishing agents, flammable storage and emergency evacuation.
IOSH Managing Safely
Management qualification for plant supervisors and operations managers. Risk, legal framework, incident investigation.
Chemical First Aid
First aid for chemical exposure incidents. Burns, inhalation, eye contact, ingestion and decontamination.
Permit to Work
Permit-to-work systems, confined space entry, hot work controls, isolation and LOTO procedures.
Manual Handling
Drum handling, IBC movement, chemical container lifting and safe use of mechanical handling aids.
A Typical Chemical Facility Compliance Journey
Here's how we support a typical chemical or petrochemical client to achieve and maintain full regulatory compliance.
Substance & Process Review
We review every dangerous substance on your site — raw materials, intermediates, products, waste streams. We map your processes, storage arrangements, transfer operations and transport activities to understand your complete hazard profile.
DSEAR Assessment & ATEX Zoning
Full DSEAR assessment with ATEX zone classification, scaled zone drawings, ignition source identification and explosion consequence modelling. Equipment gap analysis identifying any non-compliant electrical or mechanical installations within classified zones.
COSHH & Exposure Assessment
COSHH assessments for every substance, exposure route analysis, WEL compliance, engineering control recommendations (LEV, containment), RPE specifications and health surveillance programme development for exposed workers.
DGSA & Transport Compliance
DGSA appointment if you transport dangerous goods, ADR/IMDG compliance audit, classification and packaging review, documentation templates, driver/staff training and implementation of 24/7 emergency telephone support.
Specialist Staff Training
On-site delivery of DSEAR awareness, COSHH, ADR, permit-to-work, confined space, chemical first aid and IOSH Managing Safely — all tailored to your specific substances, processes and site-specific hazards.
Retained Compliance Partner
Ongoing support: annual DSEAR and COSHH reviews, DGSA annual reports, management of change assessments, regulatory updates, incident investigation, HSE liaison, refresher training and 24/7 emergency DG support.
Chemical & Petrochemical Compliance FAQ
What is DSEAR and does it apply to my chemical facility?
DSEAR (Dangerous Substances and Explosive Atmospheres Regulations 2002) applies to any workplace where dangerous substances capable of creating a fire, explosion or similar energetic event are stored, handled, processed or transported. For chemical and petrochemical facilities this is virtually guaranteed — solvents, fuels, reactive chemicals, compressed gases, combustible dusts and intermediates all fall within scope. DSEAR requires a risk assessment, ATEX zone classification and implementation of control measures. RADCaT specialises in DSEAR for high-hazard chemical environments.
What is COMAH and does my site need to comply?
COMAH (Control of Major Accident Hazards Regulations 2015) applies to sites holding dangerous substances above specified thresholds. Lower-tier sites must produce a Major Accident Prevention Policy (MAPP) and notify the Competent Authority. Upper-tier sites must additionally produce a full Safety Report demonstrating identification and control of major accident scenarios, and develop an on-site emergency plan. RADCaT advises on COMAH threshold calculations, MAPP development and supports Safety Report preparation.
What does ATEX zone classification involve?
ATEX zone classification involves assessing every area of your facility where an explosive atmosphere could form and categorising it into zones based on the frequency and duration of the hazardous atmosphere. Zone 0/20 (continuous or frequent), Zone 1/21 (likely in normal operation) and Zone 2/22 (unlikely but possible in abnormal conditions). We produce scaled zone drawings, specify equipment protection levels for each zone and identify any non-compliant existing installations requiring upgrade or replacement.
Do we need a DGSA for transporting our chemical products?
If your facility manufactures, packs or consigns dangerous goods for transport by road, sea or air, you almost certainly need a DGSA appointment under CDG 2009. This applies whether you operate your own fleet or use third-party hauliers — the consignor has legal obligations regardless. RADCaT provides full DGSA services including ADR and IMDG compliance, classification, packaging advice, documentation, driver training, annual reports and 24/7 emergency support.
Can you deliver DSEAR training on our chemical plant?
Yes. We deliver all training on-site at your facility, tailored to your specific substances, processes and classified zones. DSEAR awareness training covers the regulations, recognising explosive atmospheres, ignition source control, zone restrictions, permit-to-work in classified areas and emergency procedures. We also deliver COSHH, ADR, permit-to-work, confined space entry, chemical first aid and IOSH Managing Safely — all contextualised to your chemical operations.
How often should DSEAR assessments be reviewed for chemical sites?
DSEAR assessments for chemical facilities should be reviewed whenever there are changes to substances, processes, equipment, building layout or ventilation. They should also be reviewed following any fire, explosion or near-miss incident. For active chemical plants with frequent process changes, we recommend a formal annual review cycle. RADCaT provides retained compliance packages with scheduled DSEAR review visits included.
How much does chemical facility compliance cost?
Costs depend on the size and complexity of your facility, the number of substances and processes, the extent of ATEX zoning required and whether COMAH obligations apply. We offer project-based pricing for individual assessments and retained annual packages for ongoing compliance management. All pricing is transparent with no hidden extras. Contact us for a free initial site discussion and we'll provide a detailed, no-obligation proposal.
Ready to Make Your Workplace Safer?
Get in touch for a free, no-obligation site visit. We'll review your facility, assess your hazard profile and recommend specialist compliance solutions.