How Outdated SDSs Increase the Risk of Chemical Fires, and How ChemAlert Helps Prevent Them

Outdated Safety Data Sheets (SDSs) are anoften-overlooked contributor to chemical fire risk across U.S. workplaces,despite being a core requirement under OSHA’s Hazard Communication Standard.While many organizations focus on physical controls such as fire suppressionsystems and emergency response plans, the accuracy of chemical hazardinformation is just as critical. An SDS is not simply a compliance document; itis the primary source of information on a chemical’s flammability, reactivity,storage requirements, and appropriate firefighting measures. When thisinformation is inaccurate or no longer current, the likelihood of unsafehandling and storage practices increases significantly, creating conditionswhere chemical fires are more likely to occur.

One of the most serious risks posed byoutdated SDSs is incorrect hazard classification. Chemical formulations,scientific understanding, and regulatory classifications evolve over time, andolder SDSs may understate flammability, omit reactivity concerns, or fail toreflect updated ignition or decomposition data. This can lead to chemicalsbeing stored under inappropriate conditions or near incompatible substances, increasingthe risk of combustion, violent reactions, or fire escalation. In many chemicalfire investigations, improper storage or unrecognized incompatibilities can betraced back to inaccurate or outdated hazard information.

Outdated SDSs also compromise emergencyresponse efforts. During a fire or thermal incident, employees and firstresponders rely on SDS guidance to determine appropriate extinguishing agentsand protective measures. If the SDS contains obsolete firefightingrecommendations, responders may use methods that are ineffective or, in somecases, dangerously reactive with the material involved. In fast-movingemergency situations, even small inaccuracies in chemical data can have seriousconsequences for worker safety and incident control.

From a regulatory perspective, maintainingcurrent SDSs is a legal obligation in the United States. OSHA routinely citesemployers for missing or outdated SDSs, and these deficiencies are oftenscrutinized more closely following a chemical fire. In the event of anincident, outdated SDS records can increase legal exposure, complicateinsurance claims, and weaken an organization’s ability to demonstrate duediligence in chemical risk management. As chemical inventories grow andmanufacturers issue updates more frequently, manual SDS management becomesincreasingly unreliable, allowing outdated documents to persist unnoticed.

ChemAlert helps address these risks byproviding a centralized and automated approach to SDS management that supportsboth compliance and fire prevention. By actively monitoring suppliers andmanufacturers for SDS updates, ChemAlert ensures organizations have access tothe most current hazard information without relying on manual tracking.Centralized, cloud-based access allows employees and emergency responders toquickly retrieve accurate SDSs when they are needed most, improving the qualityand speed of emergency decision-making. Enhanced visibility into chemicalhazards also allows safety and EHS teams to better identify flammable and reactivesubstances, review storage and segregation practices, and take preventiveaction before an incident occurs.

Preventing chemical fires requires morethan physical controls and training programs; it depends on the accuracy of theinformation that guides daily chemical use and emergency response. OutdatedSDSs can quietly undermine safety systems, introducing hidden risks that onlybecome apparent after a fire has occurred. By ensuring SDSs are current,accessible, and reliable, organizations can reduce the likelihood of chemicalfires, protect their workforce, and strengthen compliance with OSHArequirements. ChemAlert supports this proactive approach by transforming SDSmanagement from an administrative task into a critical component of effectivechemical fire risk prevention.