Case Study: From Risk to Resolution

Justrite Safety Group conducted a safety walkthrough of a major industrial distribution center located in the South-Central United States. This facility is part of a national supply chain network, employing hundreds of staff and operating around the clock to move essential products to customers across the region. With high volumes of stored chemicals, batteries, and compressed gases, safety is a top priority. Our comprehensive approach helped them uncover hidden risks and identify practical solutions to achieve a safer, more compliant workplace.

Hazard Analysis

The safety walkthrough uncovered several potentially significant hazards throughout the facility. These included improper storage of flammable materials, unsafe battery charging practices, and inadequate disposal of aerosol cans, all of which posed risks of fire, explosion, or environmental contamination. The specific hazards identified included:

Hazard	Environment	Key Indicators
Improper Storage of Flammable Materials	Storage areas	! Liquefied petroleum gas (LPG) cylinders were stored near flammable chemicals, increasing the risk of fire or explosion in case of a leak or accidental ignition.
Unsafe Battery Charging Practices	Throughout facility	! Lithium-ion batteries were being charged inside non-fire-rated cabinets, posing a significant fire hazard if a battery malfunction or thermal runaway occurred.
Improper Aerosol Can Disposal	Waste collection areas	! Empty aerosol cans were not being managed according to hazardous waste protocols, which could lead to fire, explosion, or environmental contamination.
Unsafe Storage Practices	Storage areas	! Items were being stored on top of safety cabinets, creating a risk of falling objects and compromising the fire-resistant design of the cabinets.

VIOLATIONS & RISKS

Identified potential OSHA, NFPA, and EPA violations with fines up to $70,117 per day.
Some of the top violations found were:

NFPA 58
OSHA 1910.253
EPA 40 CFR 264.173
OSHA 1910.125

Why It Matters

Unresolved safety violations in a distribution center can trigger significant fines. Beyond financial penalties, these violations put workers and the environment at risk, exposing the business to operational disruptions, costly workers’ compensation claims, and higher insurance premiums. Proactively addressing these issues not only ensures compliance but also protects employee well-being, business continuity, and the company’s reputation

Recommendations

Our recommendations directly addressed the identified violations, targeted to reduce fire and environmental risks while enhancing overall safety and regulatory compliance. Implemented together, they can support the facility in operating more efficiently and with greater protection for both staff and the environment.

Segregated Flammable Storage: We recommended relocating LPG cylinders to dedicated, ventilated storage lockers that meet NFPA and OSHA requirements, complete with proper signage and barriers.
Fire-Rated Battery Charging Cabinets: We advised moving lithium-ion battery charging to UL-listed, fire-rated cabinets specifically designed to contain potential battery fires, reducing the risk of catastrophic incidents.

Aerosol Can Disposal System: We introduced the Aerosolv 360 aerosol can recycling system, which safely punctures and recycles empty aerosol cans, turning hazardous waste into non-hazardous scrap and lowering disposal costs.
Cabinet Covers for Safe Storage: We suggested using safety cabinet covers to prevent items from being stored on top, eliminating falling hazards and preserving the cabinets’ fire-resistance.