What GHS Labels Mean for Ammonia System Safety

Why Are Low-Charge Ammonia Systems Safer but Still Dependent on Strict Safety Protocols?

In refrigeration and HVAC, efficiency and safety go hand in hand. That’s why many facilities are transitioning from legacy refrigerant systems to modern, low-charge ammonia systems. These newer systems offer compact designs, increased efficiency, and lower operating costs—all while using just a fraction of the ammonia required by traditional systems.

But while low-charge systems reduce the volume of ammonia in use, they don’t eliminate the need for robust safety practices. Employers, contractors, and technicians must implement and maintain a comprehensive safety management process that includes risk assessments, GHS labels, and continuous training to stay compliant and protect workers.

Why Ammonia Safety Labeling Still Matters

Low-charge anhydrous ammonia systems are gaining popularity among manufacturers, suppliers, and end-users for their energy efficiency and operational savings. These systems use the smallest possible amount of ammonia to deliver effective cooling while reducing environmental impact and chemical risk.

Beyond cost and energy savings, another benefit of low-charge systems is improved worker safety. A reduced ammonia inventory means fewer hazards in the event of a leak or equipment failure. But reduced risk does not mean no risk. Ammonia safety labeling, emergency planning, and site-specific training remain essential for compliance and protection.

Visibility Is the First Line of Defense

Even in low-charge systems, ammonia remains a highly hazardous chemical. Visibility—through proper labeling, signage, and hazard communication—is a foundational step toward preventing accidents. Clear visual cues help technicians recognize potential danger zones, follow procedures precisely, and respond quickly in the event of an emergency. That’s why labeling systems play such a critical role in overall ammonia safety—and why GHS labels are a key part of any compliant visual communication program.

Chemical Compliance and Ammonia Hazards

Anhydrous ammonia is widely used in industrial refrigeration and HVAC systems due to its efficiency and cost-effectiveness. However, it remains a hazardous chemical that requires careful handling. Exposure to ammonia can cause severe health effects, including respiratory irritation, chemical burns, and, in extreme cases, fatalities.

Incidents involving ammonia releases can result from equipment failure, human error, or improper maintenance. For example, a worker suffered severe chemical burns at a beef processing facility in Nebraska due to an ammonia leak. The Occupational Safety and Health Administration (OSHA) issued 16 violations, including failures in lockout/tagout procedures and deficiencies in process safety documentation.

“When employers fail to properly document procedures and control highly hazardous chemicals, there is the potential for unintentional releases that can result in serious and fatal injuries,” said Jeff Funke, OSHA’s Omaha Area Director. “By implementing and sustaining workplace safety and health programs, employers can monitor their processes to ensure safeguards are in place to protect workers.”

To ensure safety and compliance, it’s essential for employees and contractors to understand ammonia's properties, associated hazards, and relevant OSHA regulations. Implementing comprehensive safety protocols and continuous training can significantly reduce risks and support chemical compliance.

Chemical Storage Signs and OSHA’s PSM Requirements

OSHA developed the Process Safety Management (PSM) standard to prevent catastrophic releases of hazardous chemicals, including ammonia. A well-executed PSM program includes hazard analysis, employee training, emergency response planning, and mechanical integrity evaluations.

Here are three key areas that support PSM compliance for facilities using low-charge ammonia:

1. Prioritize Clear Communication

Consistent, visual communication supports hazard awareness and safe behavior. Facilities can reinforce ammonia safety protocols with labels and signage that inform and instruct. For example:

• Use GHS labels on containers to identify chemical hazards at a glance.

• Mark ammonia storage areas with chemical storage signs to restrict unauthorized access.

• Apply ammonia pipe marking to indicate flow direction, contents, and pressure levels.

• Use floor marking to guide personnel and vehicles safely around refrigeration systems.

Simple, visual reminders help standardize responses across teams, especially when third-party contractors are involved.