Chemicals and Flammable Materials

Many film productions use paints, solvents, adhesives, fuels, aerosols, cleaning products, and other hazardous materials. Even common household products can present serious fire, health, or environmental hazards if they are used or stored improperly. Always plan ahead and understand the risks before bringing any chemical onto a production.

Store all chemicals and combustible or flammable liquids in approved safety containers or flammable storage cabinets whenever possible. Never store chemicals near heat sources, electrical equipment, open flames, exits, or areas where they may be knocked over or damaged. Keep work areas clean and organized. Paints, solvents, oily rags, aerosol cans, and other combustible materials should never accumulate on stage floors, beneath platforms, inside studios, or in work areas.

Always ensure adequate ventilation when using chemicals, especially indoors. Wear the appropriate personal protective equipment (PPE) for the product being used, including gloves, eye protection, protective clothing, and respirators when required. Before using any hazardous material, identify the nearest eye wash station, emergency shower (if available), fire extinguisher, and emergency exit.

Every hazardous chemical used on a production must have a current Safety Data Sheet (SDS) available. SDSs provide important information about health hazards, personal protective equipment, first aid, storage requirements, spill cleanup, and fire response. Read the SDS before using any unfamiliar product.

Handling Hazardous Chemicals

Always follow these safety practices when working with chemicals:

• Assume any unfamiliar chemical is hazardous until you understand its properties.
• Read and follow all instructions on the container label and Safety Data Sheet (SDS).
• Never use chemicals from unlabeled or improperly labeled containers.
• Clearly label all secondary containers with the product name and hazard information.
• Date chemicals when they are received and when they are first opened, if recommended by the manufacturer.
• Never mix chemicals unless specifically instructed by the manufacturer. Mixing incompatible chemicals can create toxic gases, fires, explosions, or violent reactions.
• Treat any mixture of chemicals as being at least as hazardous as its most dangerous ingredient.
• Minimize exposure by avoiding unnecessary skin contact and inhalation of vapors, dust, or mists.
• Keep containers tightly closed when not in use.
• Wash your hands thoroughly after handling chemicals, even if gloves were worn.
• Dispose of hazardous waste properly. Never pour chemicals down sinks, drains, or onto the ground unless specifically authorized.
• Use the appropriate PPE for the chemical being handled.
• Never work alone when using hazardous chemicals. Use the buddy system whenever hazardous materials are being mixed, transferred, or used.

Handling Flammable Materials

Many production materials, including paints, thinners, adhesives, fuels, aerosol products, and certain cleaning solvents, are highly flammable.

When using flammable materials:

• Keep all flammable liquids and vapors away from heat, sparks, open flames, hot surfaces, smoking materials, and other ignition sources.
• Do not smoke or vape anywhere near flammable materials.
• Keep containers tightly closed except when actively dispensing the product.
• Store flammable liquids in approved safety containers and flammable storage cabinets whenever possible.
• Use only the minimum amount of flammable material necessary for the task.
• Maintain adequate ventilation to prevent the buildup of flammable vapors.
• Never use flammable chemicals near pilot lights, heaters, electrical sparks, generators, or operating lighting equipment unless specifically approved and controlled.
• Know the location of the nearest ABC fire extinguisher and understand how to operate it before beginning work.
• Immediately clean up spills using appropriate spill-control procedures and dispose of contaminated materials safely.
• Remove oily rags, solvent-soaked paper towels, and other combustible waste from the work area by placing them in approved metal containers with self-closing lids.

If you have questions about the safe use, storage, or disposal of hazardous chemicals or flammable materials, contact Production Services before using the material on your production.

Using Foamed Plastics

Foamed plastics are commonly used in film, animation, theater, and art production to create props, scenic elements, puppets, costumes, miniatures, and stop-motion characters. While these materials are lightweight and easy to shape, they present significant fire, dust, and health hazards if used improperly.

Common foamed plastic products include:

• Spray polyurethane foam
• Two-part rigid polyurethane foam (A/B foam)
• HSF 110 Pour Foam (Class 1)
• Expanded Polystyrene (EPS)
• Extruded Polystyrene (XPS)
• Polyurethane foam blocks

Because many foamed plastics are petroleum-based and combustible, they must be handled with care throughout fabrication, storage, transport, and disposal.

Fire Hazards

Foamed plastics can ignite rapidly when exposed to heat, sparks, open flames, welding, hot-wire cutting tools, pyrotechnics, or other ignition sources. Once ignited, these materials burn quickly and can produce dense black smoke along with highly toxic gases, including carbon monoxide, carbon dioxide, nitrogen oxides, and hydrogen cyanide.

Whenever possible:

• Use fire-resistant or fire-retardant foamed plastics that are approved for scenic construction.
• Keep all foam products away from heat sources, open flames, hot lighting instruments, generators, welding operations, and special effects.
• Never smoke or vape while working with or around foamed plastics.
• Keep an ABC fire extinguisher immediately available whenever foam is being fabricated.
• Maintain clear exit paths and do not allow large foam structures to block emergency egress.

If a foam product catches fire or you inhale smoke from burning foam, leave the area immediately and seek medical attention.

Health Hazards

Working with foamed plastics can expose users to dust, vapors, fumes, and uncured chemical components. Exposure may occur through inhalation, skin contact, or eye contact.

Possible symptoms include:

• Eye, nose, and throat irritation
• Coughing or difficulty breathing
• Headaches
• Nausea
• Skin irritation or dermatitis
• Asthma-like reactions in sensitized individuals

Some people can develop permanent respiratory sensitivity after repeated exposure to certain polyurethane products. Once sensitized, even very small exposures may trigger severe reactions.