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Chemical risk assessment checklist: sources and guidance

A task-by-task chemical risk assessment for US general industry, built on OSHA's hazard communication standard, which applies to chemicals present in a way that employees may be exposed [3], and on the PPE hazard assessment in 29 CFR 1910.132 [32]. Exposure limits come from the relevant OSHA standard or Section 8 of each safety data sheet [20].

How often: Set by your organization. Review the assessment when a new chemical hazard is introduced into the work area, since employees are trained again at that point.[27]

Purpose

Use this chemical risk assessment checklist to look at one task or work area where hazardous chemicals are used and record the hazards, who could be exposed, the controls in place and what still needs doing. It is written for US general industry workplaces and follows OSHA's hazard communication standard, 29 CFR 1910.1200, which covers any chemical present in a way that employees may be exposed [3]. For protective equipment it follows the workplace hazard assessment in 29 CFR 1910.132 [32].

The checklist does not give exposure limits. Where a limit applies, it comes from the relevant OSHA standard, such as the Table Z-1 limits in 29 CFR 1910.1000 [1], or from Section 8 (exposure controls and personal protection) of the safety data sheet [20].

Who should use it

Supervisors, safety staff and employers who plan or review work with hazardous chemicals, together with the employees who do the task. Because mistakes with chemicals can cause serious harm, a competent person should check the finished assessment.

How often

Your organization decides how often to review each assessment. A sensible trigger is any new chemical hazard in the work area, because employees must be trained again when one is introduced [27]. Review it also after an incident, a change in the process or a new safety data sheet.

How to use this checklist

  1. Pick one task or work area and list every chemical used or produced, by the product identifier on its safety data sheet.
  2. Check the written program and the safety data sheets first; you need them for the rest of the assessment.
  3. Record the hazards from Section 2 of each safety data sheet, the ways people could be exposed and who could be exposed.
  4. Walk the area to check labels, controls, PPE and emergency eyewash.
  5. Talk to the employees who do the task about their training.
  6. Rate the remaining risk with your organization's method, then record actions, an owner and a review date.

The PPE condition check is marked critical because damaged or defective PPE must not be used [35].

What the rules say

  • Written program. Employers develop, implement and maintain a written hazard communication program at each workplace [4], including a list of the hazardous chemicals present [5] and how employees are told about the hazards of non-routine tasks [6].
  • Safety data sheets. Employers have a safety data sheet for each hazardous chemical they use [17] and keep them readily accessible to employees during each work shift [24].
  • Labels. Each container of hazardous chemicals in the workplace is labeled, tagged or marked [11], and labels are legible, in English and prominently displayed [10].
  • Training. Employees get effective information and training on the hazardous chemicals in their work area at initial assignment [26].
  • Controls. For airborne contaminants, the first aim is to prevent contamination with engineering controls such as enclosure, ventilation or substitution [37]; respirators are used when effective engineering controls are not feasible or while they are being put in place [38].
  • PPE. The employer assesses the workplace for hazards needing PPE [32] and has affected employees use PPE that protects against the hazards identified [33]. That assessment section does not apply to respirators, which have their own standard [36].
  • Eyewash. Where eyes or body may be exposed to injurious corrosive materials [41], quick-drench or flushing facilities are provided within the work area [40].

What this checklist does not cover

  • Setting or measuring exposure limits. Limits come from the relevant OSHA standard or Section 8 of the safety data sheet, and air sampling needs a competent person.
  • Substance-specific OSHA standards that add their own exposure assessment, monitoring and medical surveillance rules.
  • The details of a respiratory protection program, such as respirator selection, fit testing and medical evaluation.
  • Laboratory chemical hygiene plans, process safety management and hazardous materials emergency response, which have their own OSHA standards.
  • Classifying chemical hazards, writing safety data sheets and labeling shipped containers, which are duties of chemical manufacturers, importers and distributors.
  • Construction work and the rules of State Plan states that differ from federal OSHA.
  • Environmental permits and hazardous waste rules.
  • Rules outside the United States, such as COSHH in Great Britain. This page follows US federal OSHA rules only.

Questions

What does OSHA require for assessing chemical hazards?

Several OSHA rules call for parts of one. The hazard communication standard requires a written hazard communication program [4] with labels, safety data sheets and training. For PPE, the employer assesses the workplace for hazards [32] and verifies it through a written certification [34]. Substance-specific standards can add their own exposure assessment; the lead standard, for example, starts with an initial determination of whether any employee may be exposed at or above the action level [2]. This checklist brings the general pieces together for one task; check whether a substance-specific standard also applies.

Where do I find the exposure limit for a chemical?

Look in Section 8 of the chemical's safety data sheet [20] and in the OSHA standard that applies. For substances in Table Z-1 of 29 CFR 1910.1000, exposure must not exceed the 8-hour time-weighted average given for that substance [1]. This page does not repeat limits because they differ by substance.

What has to be on a workplace chemical label?

Either the full shipped-container label information or the product identifier plus words, pictures or symbols giving at least general information about the hazards [12]. Labels must be legible, in English and prominently displayed [10].

Do secondary containers need a label?

Usually yes: every container in the workplace is labeled, tagged or marked [11]. The exception is a portable container filled from a labeled container [14] for the immediate use of the employee who filled it [15].

Can safety data sheets be kept electronically?

Yes, as long as there are no barriers to immediate employee access [25]. Employees must be able to reach them during each work shift while in their work area [24].

When do employees need chemical hazard training?

At the time of their initial assignment [26] and whenever a new chemical hazard they have not been trained about is introduced into their work area [27].

Sources

Each cited excerpt was found word for word in the official text on the date shown.

  1. [1]29 CFR 1910.1000 Air contaminants (a)(2) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  2. [2]29 CFR 1910.1025 Lead (d)(2) — eCFR (Office of the Federal Register). Retrieved September 25, 2026.
  3. [3]29 CFR 1910.1200 Hazard communication (b)(2) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  4. [4]29 CFR 1910.1200 Hazard communication (e)(1) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  5. [5]29 CFR 1910.1200 Hazard communication (e)(1)(i) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  6. [6]29 CFR 1910.1200 Hazard communication (e)(1)(ii) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  7. [7]29 CFR 1910.1200 Hazard communication (e)(1)(ii) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  8. [8]29 CFR 1910.1200 Hazard communication (e)(2)(i) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  9. [9]29 CFR 1910.1200 Hazard communication (e)(4) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  10. [10]29 CFR 1910.1200 Hazard communication (f)(10) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  11. [11]29 CFR 1910.1200 Hazard communication (f)(6) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  12. [12]29 CFR 1910.1200 Hazard communication (f)(6)(ii) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  13. [13]29 CFR 1910.1200 Hazard communication (f)(7) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  14. [14]29 CFR 1910.1200 Hazard communication (f)(8) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  15. [15]29 CFR 1910.1200 Hazard communication (f)(8) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  16. [16]29 CFR 1910.1200 Hazard communication (f)(9) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  17. [17]29 CFR 1910.1200 Hazard communication (g)(1) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  18. [18]29 CFR 1910.1200 Hazard communication (g)(2)(ii) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  19. [19]29 CFR 1910.1200 Hazard communication (g)(2)(vii) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  20. [20]29 CFR 1910.1200 Hazard communication (g)(2)(viii) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  21. [21]29 CFR 1910.1200 Hazard communication (g)(2)(x) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  22. [22]29 CFR 1910.1200 Hazard communication (g)(6)(iii) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  23. [23]29 CFR 1910.1200 Hazard communication (g)(8) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  24. [24]29 CFR 1910.1200 Hazard communication (g)(8) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  25. [25]29 CFR 1910.1200 Hazard communication (g)(8) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  26. [26]29 CFR 1910.1200 Hazard communication (h)(1) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  27. [27]29 CFR 1910.1200 Hazard communication (h)(1) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  28. [28]29 CFR 1910.1200 Hazard communication (h)(2)(iii) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  29. [29]29 CFR 1910.1200 Hazard communication (h)(3)(i) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  30. [30]29 CFR 1910.1200 Hazard communication (h)(3)(iii) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  31. [31]29 CFR 1910.1200 Hazard communication (h)(3)(iv) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  32. [32]29 CFR 1910.132 General requirements (personal protective equipment) (d)(1) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  33. [33]29 CFR 1910.132 General requirements (personal protective equipment) (d)(1)(i) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  34. [34]29 CFR 1910.132 General requirements (personal protective equipment) (d)(2) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  35. [35]29 CFR 1910.132 General requirements (personal protective equipment) (e) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  36. [36]29 CFR 1910.132 General requirements (personal protective equipment) (g) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  37. [37]29 CFR 1910.134 Respiratory protection (a)(1) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  38. [38]29 CFR 1910.134 Respiratory protection (a)(1) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  39. [39]29 CFR 1910.134 Respiratory protection (c)(1) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  40. [40]29 CFR 1910.151 Medical services and first aid (c) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.
  41. [41]29 CFR 1910.151 Medical services and first aid (c) — eCFR (Office of the Federal Register). Retrieved September 24, 2026.

Guidance, not legal advice. It does not replace the law, the manufacturer's instructions or your organization's competent people.