A Chemical Hygiene Plan (CHP) is a mandatory written program required by the Occupational Safety and Health Administration (OSHA) for all employers engaged in laboratory use of hazardous chemicals. The plan establishes policies, procedures, and responsibilities designed to protect workers from health hazards associated with hazardous chemicals in laboratory environments. Since its implementation in 1990, the CHP requirement has been a fundamental component of laboratory safety compliance under OSHA’s Laboratory Standard (29 CFR 1910.1450). 

 

OSHA Chemical Hygiene Plan: Legal Foundation and Scope 

OSHA Laboratory Standard Requirements 

The CHP requirement stems from OSHA’s “Occupational Exposure to Hazardous Chemicals in Laboratories” standard (29 CFR 1910.1450). This regulation applies specifically to laboratory environments where chemical manipulations are carried out on a laboratory scale, multiple chemical procedures are used, and protective laboratory practices are commonly employed. 

The standard supersedes most other OSHA health standards for laboratories, with key exceptions including the requirement to maintain exposures below Permissible Exposure Limits (PELs) and prohibitions on eye and skin contact with hazardous substances. 

Applicable Workplaces 

CHPs are required for laboratories that meet specific criteria for “laboratory use of hazardous chemicals,” including research laboratories, teaching laboratories, and quality control laboratories. The plan must be easily accessible to all employees and can be maintained electronically as long as workers know how to access it.

 

8 Essential Elements of a Chemical Hygiene Plan 

  1. Standard Operating Procedures (SOPs)

The CHP must include standard operating procedures relevant to safety and health considerations for each activity involving hazardous chemicals. These procedures should address: 

Content Requirements: 

  • Specific handling procedures for each hazardous chemical or class of chemicals 
  • Amount and concentration of chemicals to be used 
  • Special handling procedures and precautions 
  • Engineering controls and personal protective equipment requirements 

Development Process: 

SOPs should be written by personnel who are most knowledgeable about the experimental process and associated hazards, with final approval from the laboratory supervisor. Laboratory-specific SOPs must be created for chemicals or procedures that pose unique hazards, particularly those meeting criteria for particularly hazardous substances. 

 

  1. Control Measures and Exposure Reduction

The plan must define criteria for determining and implementing control measures to reduce employee exposure to hazardous chemicals. This follows a hierarchical approach: 

Engineering Controls: 

  • Chemical fume hoods and ventilation systems 
  • Glove boxes and containment devices 
  • Local exhaust ventilation 
  • Administrative Controls: 
  • Work practice guidelines 
  • Training programs 
  • Access restrictions 

Personal Protective Equipment: 

  • Eye and face protection 
  • Respiratory protection when necessary 
  • Hand and body protection 

 

  1. Equipment Maintenance and Performance Verification

The CHP must establish procedures for ensuring the proper functioning of protective equipment. Key requirements include: 

Fume Hood Testing: 

  • Annual testing and inspection minimum 
  • Face velocity testing (typically 80-120 ft/min average) 
  • Flow visualization testing using smoke tubes 
  • Documentation of inspection results with visible labeling 

Safety Equipment Verification: 

  • Emergency eyewash and shower testing 
  • Fire extinguisher inspections 
  • Personal protective equipment maintenance 

 

  1. Employee Information and Training

Comprehensive training programs must address multiple components: 

Required Training Content: 

  • Contents of the Laboratory Standard and its appendices 
  • Location and availability of the CHP 
  • Permissible exposure limits for regulated substances 
  • Signs and symptoms of chemical exposure 
  • Location of safety data sheets and reference materials 

Training Methods: 

  • Detection methods for hazardous chemical releases 
  • Physical and health hazards of workplace chemicals 
  • Protective measures, including work practices, emergency procedures, and PPE use 

Training must be provided at the initial assignment and prior to new exposure situations, with frequency determined by the employer. 

 

  1. Prior Approval Requirements

The CHP must specify circumstances requiring prior approval from supervisors or designated personnel. Common situations include: 

High-Risk Operations: 

  • Work with particularly hazardous substances 
  • Unattended operations involving hazardous chemicals 
  • Working alone with dangerous materials 
  • Significant changes in chemical quantities (typically 10% or greater increases) 

 

  1. Medical Consultation and Examination

Provisions for medical surveillance must be established when appropriate. This includes: 

Triggering Conditions: 

  • Exposure above action levels for regulated substances 
  • Signs or symptoms of chemical exposure 
  • Emergency exposure incidents 

Medical Surveillance Components: 

  • Baseline medical examinations 
  • Periodic health monitoring 
  • Exposure history documentation 
  • Follow-up care for exposures 

 

  1. Personnel Designation and Responsibilities

The plan must designate specific personnel responsible for implementation: 

Chemical Hygiene Officer (CHO): 

The CHO serves as the technical resource for laboratory safety and must be qualified by training or experience. Key responsibilities include: 

  • Developing and maintaining the CHP 
  • Providing technical guidance on safety issues 
  • Managing particularly hazardous substance protocols 
  • Coordinating equipment testing and maintenance 
  • Conducting training programs 
  • Investigating incidents and recommending corrective actions 

The Chemical Hygiene Committee is only appropriate, if the establishment of a committee to provide broader oversight and guidance. 

  1. Particularly Hazardous Substances Protection

Enhanced protections must be provided for work with particularly hazardous substances (PHS). These include: 

Categories of PHS: 

  • Select carcinogens (OSHA-listed, IARC Group 1, NTP known carcinogens) 
  • Reproductive toxins 
  • Substances with a high degree of acute toxicity 

Required Protections: 

  • Establishment of designated work areas 
  • Use of containment devices (fume hoods, glove boxes) 
  • Procedures for safe waste removal 
  • Specific decontamination procedures

 

Annual Review and Updates 

OSHA requires that employers review and evaluate CHP effectiveness at least annually and update it as necessary. This review should assess: 

Performance Evaluation: 

  • Incident and exposure records 
  • Equipment performance data 
  • Training effectiveness 
  • Regulatory compliance status 

Update Requirements: 

  • New chemical hazards introduced 
  • Changes in work practices or procedures 
  • Equipment modifications or replacements 
  • Regulatory changes 

 

Annual Review and Updates 

OSHA requires that employers review and evaluate CHP effectiveness at least annually and update it as necessary. This review should assess: 

Performance Evaluation: 

  • Incident and exposure records 
  • Equipment performance data 
  • Training effectiveness 
  • Regulatory compliance status 

Update Requirements: 

  • New chemical hazards introduced 
  • Changes in work practices or procedures 
  • Equipment modifications or replacements 
  • Regulatory changes 

 

Chemical Inventory and Safety Data Sheet Management 

Inventory Management Requirements 

Effective chemical inventory management is essential for CHP implementation. Key components include: 

Documentation Requirements: 

  • Complete chemical inventory with locations 
  • Safety data sheets for all hazardous chemicals 
  • Proper labeling and identification systems 
  • Tracking from procurement to disposal 

Best Practices: 

  • Regular inventory audits to identify expired chemicals 
  • Compatibility assessments for storage 
  • Digital inventory management systems 
  • Documentation of all incoming and outgoing chemicals 

Safety Data Sheet Accessibility 

SDSs must be readily accessible to all laboratory personnel. Requirements include: 

Content and Format: 

  • 16-section GHS standardized format 
  • Hazard identification and classification 
  • Safe handling and storage procedures 
  • Emergency response information 

Accessibility Options: 

  • Physical copies in laboratory locations 
  • Electronic access via the internet or databases 
  • Mobile access capabilities for emergency situations 

 

Waste Management Protocols 

Laboratory Waste Disposal 

Proper waste management is integral to laboratory safety: 

Waste Categories: 

  • Hazardous chemical waste requiring special disposal 
  • Non-hazardous waste suitable for regular disposal 
  • Contaminated materials and PPE 
  • Sharps and broken glass 

Disposal Procedures: 

  • Proper segregation by chemical compatibility 
  • Appropriate container selection and labeling 
  • Storage requirements and time limits 
  • Coordination with licensed waste disposal contractors 

 

Recordkeeping and Documentation 

OSHA Recordkeeping Requirements 

While not specific to CHPs, laboratories must maintain records as required by OSHA standards: 

Required Records: 

  • Exposure monitoring results 
  • Medical surveillance records 
  • Training documentation 
  • Incident reports and investigations 

Retention Requirements: 

  • Medical and exposure records: Duration of employment plus 30 years 
  • Training records: As specified by individual standards 
  • Incident reports: Minimum 5 years 

 

Implementation Best Practices 

Effective Program Development 

Successful CHP implementation requires a systematic approach: 

Development Process: 

  • Comprehensive hazard assessment 
  • Stakeholder involvement in planning 
  • Clear assignment of responsibilities 
  • Regular program evaluation and improvement 

Integration with Other Programs: 

  • Coordination with institutional safety programs 
  • Alignment with regulatory requirements 
  • Integration with research planning processes 

 

Training and Communication 

Effective training programs enhance CHP success: 

Training Components: 

  • Initial comprehensive safety training 
  • Chemical-specific training for new materials 
  • Regular refresher training (typically annual) 
  • Hands-on emergency response training 

Communication Strategies: 

  • Clear documentation of policies and procedures 
  • Regular safety meetings and updates 
  • Accessible reference materials 
  • Feedback mechanisms for continuous improvement 

 

Conclusion 

The OSHA Chemical Hygiene Plan represents a comprehensive approach to laboratory safety that addresses the unique challenges of working with hazardous chemicals in research and educational settings. Through its eight essential elements—standard operating procedures, control measures, equipment maintenance, training, prior approval requirements, medical surveillance, personnel designation, and particularly hazardous substance protections—the CHP creates a framework for systematic risk management. 

Successful implementation requires ongoing commitment from all levels of the organization, from laboratory workers to institutional leadership. Regular review and updates ensure the plan remains effective as research activities evolve, and new hazards are introduced. By following these guidelines and maintaining compliance with OSHA requirements, laboratories can create safer working environments while supporting productive scientific research and education. 

The CHP serves not merely as a regulatory compliance tool but as a living document that promotes a culture of safety awareness and responsibility throughout the laboratory community. When properly implemented and maintained, it provides the foundation for protecting worker health while enabling the continued advancement of scientific knowledge and discovery.