Safety Risks When Working with Industrial Adhesives and Sealants: How to Prevent Accidents and Health Complications

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Industrial adhesives and sealants are an essential part of many manufacturing processes, from the automotive industry to construction. While their effectiveness and versatility are undeniable, they often contain substances that pose a high risk to the health and safety of workers. Solvent vapours, reactive components, or mechanical hazards during application can lead to serious injuries, chronic health issues, or environmental accidents. This article focuses on the specific risks associated with handling, storage, and use of these materials and offers practical recommendations on how to prevent them. Safety is not just a matter of compliance with regulations, but also of proper techniques and employee awareness.

Hazardous properties of industrial adhesives and sealants: What you need to know

Industrial adhesives and sealants often contain chemicals with properties that may pose risks to the health and safety of workers. The most common hazardous properties include flammability, toxicity, corrosivity, and sensitization. For example, adhesives based on epoxy resins or polyurethanes may release volatile organic compounds (VOCs), which irritate the respiratory tract and, with long-term exposure, can damage the liver or kidneys. Some sealants contain isocyanates, which can trigger asthmatic reactions or allergies when inhaled or upon skin contact.

Another risk is the reactivity of certain components – for instance, cyanoacrylate adhesives (so-called instant adhesives) polymerize extremely quickly and release heat, which can lead to burns upon skin contact. Corrosive substances, such as acidic or alkaline sealants, can cause chemical burns. Therefore, it is essential to study the safety data sheet (SDS) before handling any product and to follow the manufacturer’s instructions, including recommended protective equipment and procedures.

Proper Storage: Key to Minimizing Risks and Extending Shelf Life

Improper storage of industrial adhesives and sealants can lead to product degradation, increased fire risk, or the release of hazardous substances. The basic rule is to store flammable and reactive materials separately from heat sources, sparks, and open flames. The storage temperature should be stable, ideally between 15–25 °C, unless specified otherwise by the manufacturer – extreme temperatures can cause component separation, loss of adhesive properties, or even container explosion.

It is also important to ensure proper ventilation in storage areas, especially for products releasing VOCs or isocyanates. Containers must be tightly sealed and stored in an upright position to prevent leaks. Some adhesives and sealants require specific conditions, such as protection from moisture (polyurethane systems) or light (UV-sensitive materials). Regular inspection of expiration dates and container conditions helps prevent the use of degraded products, which may fail or increase the risk of accidents.

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Protective Equipment and Safety Procedures for Handling

Using appropriate protective equipment is essential to minimize health risks when working with industrial adhesives and sealants. Basic equipment should include nitrile or butyl gloves, which resist chemicals and prevent direct skin contact. When working with volatile substances, a respirator with a suitable filter (e.g., against organic vapors or particles) is necessary, while safety goggles or a face shield protect the eyes from splashes or fumes.

Work procedures should include several key measures: carry out application in well-ventilated areas or under extraction to reduce the concentration of harmful fumes. When mixing two-component systems, follow the exact ratios and procedures specified in the technical data sheet to avoid unintended reactions. After completing work, thoroughly wash hands and exposed body parts with soap and water, even if gloves were used—some substances may penetrate the material or remain on the surface.

First aid and emergency plans: How to respond in case of an accident

Even when all safety measures are followed, accidents can still occur, so it is essential to have an emergency plan in place and know how to provide first aid. If skin is exposed to adhesive or sealant, immediately remove contaminated clothing and rinse the affected area with a stream of lukewarm water for at least 15 minutes. Do not use solvents or aggressive cleaning agents, as they could worsen the reaction. In case of eye exposure, rinse with sterile saline solution or clean water and seek medical assistance.

In case of inhalation of vapours, move the affected person to fresh air and monitor their condition. If breathing difficulties, coughing, or dizziness occur, call emergency services. Do not induce vomiting after ingestion unless explicitly recommended in the safety data sheet, and provide the affected person with plenty of water. Always keep emergency numbers for the poison information centre and local emergency services at hand. Regular first aid training for employees and emergency situation simulations help minimise the consequences of accidents and speed up response in critical moments.

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Ventilation and technical safeguards in the workplace

Industrial adhesives and sealants often release volatile organic compounds (VOCs) or other irritating fumes, which can cause health issues with prolonged exposure, ranging from respiratory irritation to chronic illnesses. Ensuring effective ventilation is therefore crucial for worker safety. Ideally, workspaces should be equipped with forced extraction systems featuring filtration to capture harmful substances before they spread into the air. For smaller operations, local extraction directly above work surfaces where adhesives or sealants are applied will suffice.

It is also important to regularly check the functionality of ventilation systems and measure the concentration of harmful substances in the air. According to current regulations, regular inspections and measurements should be carried out to ensure that exposure levels do not exceed hygiene limits. If limits are exceeded, immediate corrective measures must be taken, such as increasing extraction capacity, reducing exposure time, or using respirators with appropriate filters. Investing in quality ventilation pays off not only in terms of safety but also productivity, as workers are not exposed to fatigue or headaches caused by poor air quality.

Handling Packaging and Minimizing Contamination Risks

Proper handling of industrial adhesive and sealant packaging is often an underestimated but critical factor in accident prevention. Packaging should always be stored and transported in its original, undamaged containers, clearly labeled in accordance with CLP/GHS regulations. Any damage to the packaging, whether mechanical or chemical, can lead to substance leaks, contamination of surrounding materials, or even hazardous reactions. When decanting or transferring, appropriate tools such as funnels with closures or closed transfer systems should be used to minimize the risk of spills.

Workplace contamination can also occur due to improper handling of used packaging. Empty containers should be thoroughly cleaned using standard procedures, such as rinsing with a suitable solvent, and subsequently disposed of in accordance with hazardous waste regulations. They must never be reused for other purposes, especially not for storing food or water. In the event of a spill, immediate action must be taken according to the emergency plan, which includes neutralization, absorption, and safe disposal of contaminated material. Employees should be regularly trained in these procedures to know how to respond in emergency situations.

Employee Training and Safety Culture in the Workplace

Safety when working with industrial adhesives and sealants is not just a matter of technical measures, but also of the human factor. Regular employee training is crucial for minimizing risks and preventing accidents. Training should include not only theoretical knowledge about the hazardous properties of the substances used, but also practical demonstrations of proper handling, the use of protective equipment, and first aid procedures. Employees should be familiar with the safety data sheets (SDS) of individual products and know how to interpret them correctly.

A safety culture in the workplace is built through open communication and motivating employees to report potential risks. Mechanisms for anonymous reporting of deficiencies or hazardous situations should be established to prevent their recurrence. Regular safety audits and emergency situation simulations help maintain a high level of risk awareness. Investing in training and building a safety culture pays off not only by reducing the number of accidents, but also by improving overall work efficiency and employee satisfaction.

Need Expert Advice?

Every chemical raw material requires an individual approach to safety. GCG Group provides detailed Safety Data Sheets (SDS) and technical support for all supplied adhesives and sealants to help you select the appropriate protective equipment and procedures for your specific applications. Contact us – or browse our catalog of over 1,300 products.