Aircraft maintenance involves the use of various chemicals essential for effective upkeep. However, many of these substances can be highly toxic, and prolonged exposure may pose serious health risks to maintenance workers. To ensure safety, it is crucial for all aircraft maintenance facilities to educate their workers about the potential hazards and the toxic chemicals they handle regularly. 

Common chemicals used in the regular maintenance of aviation facilities include ammonia, acetone, and carbon monoxide. Improper exposure to these substances can result in serious health issues, such as dizziness, shortness of breath, or even physical injury. However, with timely action and proper safety measures, these risks can be effectively managed, ensuring a safer work environment. 

Keep reading this blog for a detailed guide on the chemicals commonly used in aircraft maintenance. You’ll also find practical tips on how to minimize unnecessary exposure and ensure a safer work environment. 

 

Why do Aircraft Maintenance Facilities Need Chemical Products?  

Aircraft maintenance relies on chemicals to keep the aircraft safe, reliable, and running smoothly. Cleaning agents are used to remove dirt, grease, and fuel residue from surfaces and parts. It helps ensure clear visibility and good aerodynamics. Degreasers and solvents help get rid of oil and grime from mechanical parts to prevent problems.  

Corrosion inhibitors stop metal parts from rusting. Paint strippers and primers are used during repainting to keep the aircraft looking good and strong. Disinfectants help keep the cabin clean and safe for passengers. Each chemical plays a key role in keeping the aircraft in great shape. 

 

List of Toxic Chemicals Used in Aircraft Maintenance Facilities 

 

1) Ammonia: 

  • Use: Cleaning agent for surfaces and equipment. It is specifically used in fuel cells. 
  • Hazards: Its fumes can irritate the eyes. Also, if inhaled it can irritate the mouth, throat, nose and lungs.  
  • Safe Handling: Use in a well-ventilated area, wear gloves, goggles, and a face mask. Avoid mixing with bleach as it can produce toxic fumes. 

First Aid: 

  • Inhalation: Move to fresh air immediately. Seek medical attention if breathing difficulties occur. 
  • Skin/Eye Contact: Rinse with water for 15 minutes. Seek medical help for severe exposure. 

 

2) Acetone 

  • Use: Solvent for cleaning tools, degreasing, and removing adhesives/paints. 
  • Hazards: Highly flammable, can cause skin irritation, dizziness, and respiratory issues if inhaled.  
  • Safe Handling: Use in a well-ventilated area away from heat or flames. Wear gloves and eye protection. 

First Aid: 

  • Inhalation: Move to fresh air and seek medical help if dizziness persists. 
  • Skin Contact: Wash thoroughly with soap and water. 
  • Ingestion: Do not induce vomiting. Seek medical assistance immediately. 

 

3) Asbestos

  • Use: Previously used for insulation and fireproofing but now restricted due to health risks. It can be found in the aviation brake linings, and friction components.  
  • Hazards: Carcinogenic when inhaled, leading to lung diseases like asbestosis and mesothelioma. 
  • Safe Handling: Avoid disturbing asbestos-containing materials. Only trained personnel with PPE should handle it. 

First Aid: 

  • Inhalation: Leave the area immediately and avoid further exposure. Seek medical evaluation for long-term effects. 

 

 4) Carbon Monoxide (CO)

  • Use: Byproduct of fuel combustion in engines and heaters. 
  • Hazards: Reports from the U.S. National Institute of Occupational Safety and Health (NIOSH) show that several workers have died in or near refueling trucks due to carbon monoxide (CO) poisoning. Inhaling high levels of CO can also cause unconsciousness. 
  • Safe Handling: Ensure proper ventilation, use CO detectors, and avoid running engines in enclosed spaces. 

First Aid: 

              Inhalation: Move the person to fresh air immediately and call emergency services. Administer oxygen if trained. 

 

5) Chlorofluorocarbon (CFC)

  • Use: It is used for cleaning metals and electronic assemblies. Smaller quantities are also used in aerosol propellants, coatings, and thermal stress testing. 
  • Hazards: Can cause dizziness, nausea, and long-term ozone depletion. 
  • Safe Handling: Use in ventilated areas with proper PPE. Avoid direct inhalation. 

First Aid: 

  • Inhalation: Move to fresh air. Seek medical help if breathing difficulties occur. 
  • Skin Contact: Rinse thoroughly with water. 

 

 6) Ethylene Glycol

  • Use: It is used primarily as a coolant and aircraft deicing agent. 
  • Hazards: Toxic if ingested, can cause kidney damage, dizziness, and nausea. 
  • Safe Handling: Avoid skin contact, use gloves and eye protection, and store securely. 

First Aid: 

  • Inhalation: Move to fresh air. 
  • Ingestion: Seek immediate medical attention. Do not induce vomiting. 
  • Skin Contact: Wash with soap and water. 

 

 7) Methylene Chloride

  • Use: Paint strippers, degreasers, and cleaning solvents. It’s also used as a propellant in aerosol.  
  • Hazards: Carcinogenic, can cause dizziness, headaches, and respiratory issues if inhaled. 
  • Safe Handling: Use a respirator, gloves, and protective clothing. Work in a well-ventilated area. 

First Aid: 

  • Inhalation: Move to fresh air and seek immediate medical attention. 
  • Skin Contact: Rinse thoroughly with water. 

 

 8) Methyl Ethyl Ketone (MEK)

  • Use: Solvent for adhesives, paints, and cleaning. 
  • Hazards: Highly flammable, causes skin irritation, dizziness, and respiratory issues. 
  • Safe Handling: Use in a ventilated space, wear protective gloves and goggles, and keep away from heat sources. 

First Aid: 

  • Inhalation: Move to fresh air and seek medical help if breathing issues occur. 
  • Skin Contact: Wash with soap and water. 
  • Ingestion: Do not induce vomiting; seek medical help immediately. 

 

 

How to Ensure Chemical Safety in Aviation Maintenance Facilities?  

 

Here’s a detailed explanation of key practices to ensure chemical safety in aviation maintenance facilities: 

 

1) Safe Chemical Storage 

  • Store chemicals in well-ventilated areas with secure shelves and temperature control to prevent exposure and reactions. 
  • Keep chemicals separated based on their compatibility to avoid dangerous reactions (e.g., flammable materials should be stored away from oxidizers). 
  • Use clearly labeled containers with hazard warnings, expiration dates, and handling instructions. 

 

 2) Wear Proper Personal Protective Equipment (PPE) 

  • Provide the right PPE, such as gloves, safety goggles, face shields, coveralls, and respirators based on the chemical hazard level. 
  • Train staff on how to wear, inspect, and maintain PPE to ensure safety. 
  • Make PPE easily available wherever chemicals are stored or handled. 

 

 3) Ensure Proper Ventilation 

  • Install ventilation systems like exhaust fans and fume hoods to control airborne chemicals and reduce fume exposure. 
  • Regularly maintain air filtration systems for effective performance. 
  • Avoid working in confined spaces without proper airflow or specialized respiratory protection. 

 

 4) Provide Safety Training and Awareness 

  • Conduct regular training sessions on chemical hazards, safe handling, and emergency procedures. 
  • Use hands-on demonstrations and safety drills to reinforce learning. 
  • Ensure all staff know how to read and use Safety Data Sheets (SDS) for the chemicals they handle. 

 

5) Be Prepared for Chemical Spills 

  • Keep spill kits with absorbents, neutralizers, and PPE easily accessible. 
  • Develop a clear spill response plan with steps for containment, evacuation, and notification. 
  • Train staff on how to use spill kits and handle both minor and major spills safely. 

 

 6) Clear Labeling and Documentation 

  • Label all chemical containers with their name, hazards, and safety instructions. 
  • Maintain an updated list of all chemicals on-site, along with their SDS for safety guidance. 
  • Use a standardized labeling system, like the Globally Harmonized System (GHS). 

 

7) Safe Chemical Waste Disposal 

  • Follow local and international guidelines for the proper disposal of chemical waste. 
  • Use clearly labeled containers designed for hazardous waste collection and keep waste types separated. 
  • Partner with certified waste disposal companies for safe handling and proper disposal. 

 

8) Regular Safety Inspections 

  • Perform routine checks on chemical storage, PPE availability, and emergency equipment. 
  • Look for leaks, corrosion, or damaged containers and fix issues immediately. 
  • Keep records of inspections and corrective actions for compliance. 

 

9) Use Chemical Inventory Management Software 

  • Implement a digital system to track chemical quantities, storage locations, and expiration dates. 
  • Ensure the software provides easy access to SDS and safety guidelines. 
  • Use the system to streamline inspections, reporting, and compliance checks. 

 

Conclusion: 

Chemicals are crucial in aircraft maintenance by ensuring safety, performance, and longevity. Proper handling, storage, and disposal of these chemicals are essential to protect workers, maintain compliance, and prevent environmental harm. By following safety best practices and staying informed, aviation maintenance facilities can create a secure workspace while keeping aircraft in optimal condition.