8 Essential Lab Safety Rules to Maintain Compliance

Lab safety failures like the University of Hawaii accident are often preventable. While worldwide recording and reporting of laboratory accidents is notoriously poor, one recent study focusing on accidental breaches in laboratory biocontainment found that nearly 70% of the accidents captured in the research were due to avoidable human error. In labs where teams handle volatile materials and specialized equipment, unclear or inconsistently enforced lab safety rules increase the risk of serious incidents and compliance violations.

Putting the right lab safety rules in place is a practical step toward maintaining regulatory compliance and avoiding preventable setbacks. Let's explore the top lab safety rules organizations use to maintain compliance in complex R&D environments.

What Are Lab Safety Rules?

‍Lab safety rules are written procedures that define how lab work is conducted to reduce risk and maintain operational control. These rules specify how materials are handled, how instruments are used, and what steps are required before, during, and after experimental tasks.

Their purpose is to prevent injury, reduce variability in results, and support documented compliance with regulatory standards. In labs operating under formal oversight, safety rules also serve as a mechanism for accountability and audit readiness.

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Lab safety rules apply to anyone who works in or supports the lab environment. These rules are developed using requirements from regulatory organizations like the Occupational Safety and Health Administration (OSHA), the European Chemicals Agency (ECHA), or the Environmental Protection Agency (EPA). Internal safety policies are also used to address lab-specific risks and workflows. 

Enforcement relies on documentation of lab procedures, access restrictions, task-specific training, scheduled inspections, and internal or third-party audits. The combination of these controls ensures that lab safety rules are consistently applied and verifiable.

Benefits of Lab Safety Rules

Lab safety rules provide many benefits, including:

• Injury Prevention – Lowers the likelihood of physical harm caused by chemicals, equipment malfunctions, or unsafe procedures.
• Regulatory Compliance – Ensures that lab activities meet legal and industry-specific safety requirements.
• Operational Continuity – Reduces the chance of work stoppages or delays following safety-related incidents.
• Data Integrity – Supports consistent lab conditions that help produce reliable and traceable results.
• Audit Readiness – Maintains documented records that satisfy the requirements of internal and third-party audits.
• Team Accountability – Defines who is responsible for safety actions, training, and oversight at every level.
• Reputation Protection – Helps prevent public or stakeholder fallout following reportable safety violations.

8 Essential Lab Safety Rules

Here are the essential guidelines that regulated R&D labs must follow:

1. Label All Chemicals with Identity and Hazard Information

Accurate chemical labeling is a core requirement in regulated lab environments and a foundational safety practice. Under the Globally Harmonized System (GHS)—an internationally recognized framework for chemical classification and labeling—and the OSHA Hazard Communication Standard (29 CFR 1910.1200), which implements GHS in the U.S., all chemical containers must be labeled with essential information, which includes the chemical name, concentration, hazard classification, and relevant pictograms.

Labels allow lab personnel to handle substances correctly, reduce the risk of accidental mixing or misuse, and help emergency responders act quickly if an incident occurs. Proper labeling also supports traceability across storage, usage, and disposal workflows.

How to do it:

• Apply GHS-compliant labels that include chemical identity, concentration, hazard class, signal words, pictograms, and handling instructions.
• Label all containers, including diluted solutions and temporary secondary vessels.
• Maintain consistency by using standardized templates approved by your EHS or QA teams.
• Perform regular label audits to catch fading, peeling, or incorrect labels.
• Store label data centrally using a digital inventory system that reflects current classifications.
• Use MaterialsZone's Materials Knowledge Center to manage chemical safety data sheets (SDS) and chemical metadata, as well as standardize label formats across teams.

2. Store Incompatible Chemicals Separately According to Approved Guidelines

Improper storage of reactive chemicals is one of the most common causes of laboratory fires, explosions, and toxic releases. Regulatory frameworks such as the EPA's Resource Conservation and Recovery Act (RCRA), OSHA, and NFPA 45 require that compatible substances are stored according to established segregation rules to prevent dangerous interactions. 

Failure to follow chemical compatibility guidelines can turn minor oversights like a mislabeled bottle or shared shelf into major safety events. Even low-volume storage areas must adhere to separation standards since many chemical reactions can occur with small amounts of contact or vapor exchange. Preventing these incidents requires active, verifiable controls over how and where substances are stored.

How to do it:

• Use chemical compatibility charts to guide storage layout and inventory planning.
• Segregate chemicals by hazard class using color-coded cabinets or labeled shelving.
• Employ secondary containment bins and ventilated enclosures for volatile or reactive substances.
• Perform regular storage audits and correct violations immediately.
• Train lab personnel on the risks of incompatible storage and how to identify separation requirements.
• Employ an advanced materials informatics platform to track chemical properties and enforce rule-based storage compatibility logic during inventory updates or relocations.

3. Restrict Equipment Use to Trained and Authorized Personnel

Improper use of lab equipment is a common cause of safety incidents. Under the OSHA General Duty Clause and ISO 17025 Section 6.2, labs must ensure that only personnel with documented, role-specific training are allowed to operate complex or hazardous instruments. This includes tools with specific handling risks or technical calibration requirements, such as centrifuges or autoclaves.

Limiting access to trained users helps prevent operator injury, protects equipment from damage, and supports defensible lab practices. It also creates a traceable link between personnel and procedures, which is especially important during internal reviews or external audits.

How to do it:

• Define which equipment requires formal training and restrict use accordingly.
• Maintain role-based training records and link them to access privileges via IAM tools.
• Use physical sign-off sheets, digital logs, or workflow-based permission checks.
• Include training on safety features, calibration procedures, and emergency shutdown steps.
• Periodically review access lists to remove outdated authorizations.
• Use scientific data management systems (SDMS) to log training completions and enforce access restrictions within workflow steps.

4. Follow Approved Standard Operating Procedures (SOPs) for All Lab Activities

Standard Operating Procedures (SOPs) are the foundation of consistent and compliant lab work. ISO 17025 and FDA 21 CFR Part 11 both require that SOPs be documented, version-controlled, and followed exactly as written. These documents define the steps of a task or experiment and establish the approved method for conducting lab work safely and accurately.

Working outside of a current SOP can introduce preventable errors or create unrecognized safety hazards. It also weakens audit readiness, as regulators often request documentation showing exactly which procedure was used and whether it was followed correctly.

How to do it:

• Ensure all lab activities have a corresponding, approved SOP before work begins.
• Maintain SOPs in a version-controlled system with a clear review and approval history.
• Make SOPs easily accessible in digital and print formats.
• Train staff on any procedural updates and require acknowledgment of changes.
• Perform internal audits to confirm that SOPs are being followed as written.
• Embed SOPs directly into workflows within your materials informatics solution, with version tracking and discretionary access control tied to the task.

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5. Dispose of Hazardous Waste Using Approved Procedures

Hazardous waste disposal is tightly regulated and must follow specific procedures based on the type and classification of the waste. The EPA's Resource Conservation and Recovery Act (RCRA) and the Department of Transportation's Hazardous Materials Regulations require that hazardous waste be identified, stored, transported, and documented correctly.

Improper disposal can lead to environmental violations and exposure risks. These failures are frequently cited during inspections and may result in fines, shutdowns, or legal liability. Labs must treat waste handling with the same rigor as any other safety-critical activity.

How to do it:

• Categorize waste based on chemical composition, physical state, and hazard class.
• Use containers that are compatible with the waste material and meet regulatory standards.
• Label all waste containers clearly with content, hazard type, and accumulation start date.
• Keep incompatible waste types in separate secondary containment.
• Train staff on site-specific waste handling SOPs and update training as regulations evolve.
• Coordinate pickups only with licensed waste disposal vendors.

6. Document and Report All Incidents and Near Misses Immediately

Every lab safety event, regardless of outcome, must be reported and addressed. OSHA 29 CFR 1904 requires the recording of work-related injuries and illnesses, and most institutional EHS policies extend this to include near misses and equipment malfunctions. Prompt documentation supports investigation, corrective action, and compliance readiness.

Unreported incidents often signal deeper process failures that go uncorrected. Recording what occurred and how it was handled helps prevent recurrence and supports continuous safety improvement.

How to do it:

• Require reporting of all incidents and near misses, regardless of outcome.
• Use structured digital forms that capture time, location, personnel involved, and a narrative of the event.
• Assign follow-up responsibilities for root cause analysis and corrective action.
• Review incident data regularly to identify recurring problems or gaps.
• Reinforce a safety culture that encourages transparency over blame.
• Capture timestamped incident reports, route them to responsible parties, and track their resolution in a centralized system.

7. Complete Role-Specific Safety Training Before Lab Access

Before entering the lab or using equipment, every team member must complete safety training specific to their role and responsibilities. OSHA 29 CFR 1910.1200(h) and ISO 17025 Section 6.2 require that personnel are trained in the risks and procedures associated with their workplace, including hazardous materials handling and the correct execution of assigned tasks.

Allowing lab access without proper training increases the risk of non-compliance and safety violations. Training should reflect the actual conditions and tools used in the lab. It must be updated regularly to reflect updated procedures or regulatory changes.

How to do it:

• Define required training by role, task type, and risk exposure.
• Deliver detailed instructions and product demonstrations that include hazard communication, equipment use, SOPs, and emergency actions.
• Successful completion of training is required before granting physical or digital lab access.
• Maintain a centralized training log that tracks individual completion dates and required refresh intervals.
• Review training records during audits and after incidents to verify alignment with assigned responsibilities.

8. Conduct Routine Safety Inspections and Address Deficiencies Promptly

Routine safety inspections are one of the most effective tools for identifying issues before they cause harm or trigger regulatory findings. OSHA, FDA, and ISO 17025 all require regular oversight of lab practices and conditions, including PPE (Personal Protective Equipment) use, chemical storage, equipment readiness, and access to emergency stations. 

These checks confirm that procedures are followed correctly and that work areas remain in a safe and compliant state. Without scheduled inspections, minor lapses can go unnoticed, such as expired materials or blocked exits. Left uncorrected, these issues may compromise lab operations or result in citations during audits. Inspection findings must be logged and followed up until the issues are resolved.

How to do it:

• Establish an inspection schedule that aligns with lab activities, staffing, and risk level.
• Use standardized checklists reflecting regulatory and internal requirements.
• Assign specific individuals or roles to conduct inspections and report findings.
• Document issues in a centralized system with precise due dates and corrective actions.
• Follow-up confirmation is required before closing any inspection item.
• Use a platform like MaterialsZone to document inspections, assign resolution tasks, and track follow-up through collaborative workflows.

Make Lab Safety Rules Work for Compliance

Lab safety rules are essential to maintaining control in regulated lab environments. They support consistent procedures, protect research quality, and provide the documentation required for audits and reviews. For teams managing complex materials and high-throughput workflows, these rules are the foundation of sustainable compliance.

MaterialsZone helps labs apply and monitor safety rules by connecting them directly to operational systems. Its materials informatics platform links factors like chemical properties, workflow steps, and personnel roles to the safety protocols that govern them. This makes it possible to verify compliance at the moment the work is performed while automatically capturing documentation.

Request a demo to see how MaterialsZone helps enforce lab safety rules and manage compliance.