Adhesives and sealants manufacturing spans an unusually wide range of chemistry for a single site. Solvent-based, water-based, reactive polyurethane, silicone and cyanoacrylate systems can share a building, along with cement and mineral powder handling for construction chemicals. Each brings a different hazard, and the plant that handles them all is rarely designed as a whole.

Projex Solutions provides engineering design, process safety studies and project delivery for manufacturers of adhesives, sealants, grouts, mortars and construction chemicals.

What makes this work different

Moisture-sensitive and reactive chemistry. Isocyanate and silicone systems react with atmospheric moisture, which drives inerting, dry air supply and closed transfer requirements. That is a utility and design problem, not a procedural one.

Isocyanate handling has a specific exposure profile. Respiratory sensitisation makes exposure control and LEV design a primary requirement rather than a secondary one, with implications for vessel charging, sampling and cleaning.

Mineral powder handling at volume. Cement, silica, fillers and mineral powders are handled in large quantities in construction chemicals. Silica exposure control and dust explosion assessment for organic components have to be addressed together.

Solvent inventory persists. Despite the shift to water-based systems, most sites retain meaningful solvent inventory, which continues to determine COMAH position and area classification.

High-viscosity transfer is an engineering discipline of its own. Pumping, metering and filling of high-viscosity and thixotropic materials constrains equipment selection, line sizing and cleaning far more than a low-viscosity process would.

Filling lines are where the hazards converge. Cartridge, tube and pail filling brings flammable atmospheres, exposure risk and material handling together in one place, usually with the highest operator presence on site.

Where we help

  • DSEAR assessment and hazardous area classification to BS EN IEC 60079-10-1:2021 and EI 15 (5th edition), covering solvent and dust
  • Inerting and dry air system design for moisture-sensitive chemistry
  • Exposure control and LEV design, particularly for isocyanate and respirable silica
  • Dust explosion protection for organic powder handling, with venting, suppression and isolation
  • High-viscosity transfer, metering and filling design, including cleaning and changeover
  • HAZOP facilitation, LOPA and SIL determination to BS EN 61511
  • COMAH tier determination and safety report engineering support
  • Bulk storage, bunding and containment design
  • Feasibility, FEED, detailed design and EPCM delivery under ISO 9001:2015

Typical reasons clients get in touch

  • Moisture ingress is causing product quality problems that trace back to plant design
  • Isocyanate exposure control has been challenged at audit or by an enforcement visit
  • Powder handling needs dust explosion assessment and control
  • A filling line needs replacing, automating or bringing into compliance
  • Product range has widened and the DSEAR assessment no longer covers what is run
  • Changeover and cleaning are limiting throughput

Related

Part of our work across the chemical sector. Closely related to coatings, paints, inks and surface treatments, and to chemical formulation and blending.

Standards and regulations we work to

  • DSEAR 2002, with ACOP L138 (second edition, 2013)
  • BS EN IEC 60079-10-1:2021 for vapour, and BS EN 60079-10-2 for dust
  • EI 15 (5th edition, October 2024)
  • COMAH 2015, where solvent inventory crosses threshold
  • COSHH 2002, with ACOP L5 (sixth edition, 2013), particularly for isocyanates and respirable crystalline silica
  • HSG258, Controlling airborne contaminants at work, for LEV design
  • PUWER 1998, with ACOP L22 (fourth edition, 2014, amended 2018)
  • Environmental Permitting (England and Wales) Regulations 2016 (as amended)
  • CDM 2015 and ISO 9001:2015

Frequently asked questions

Our product quality problems seem to be moisture-related. Is that a plant issue?
Very often it is. Isocyanate and silicone systems react with atmospheric moisture, so dry air supply, inerting, closed transfer and vessel breathing arrangements all affect product quality directly. It is usually a design problem presenting as a quality problem.

How seriously should we take isocyanate exposure control?
Very. Respiratory sensitisation means there is no safe habituation, and control has to be engineered rather than managed through PPE alone. Charging, sampling and cleaning are the operations that need most attention.

We handle cement and mineral fillers. What applies?
Two things at once: respirable crystalline silica exposure control under COSHH, and dust explosion assessment where organic powders are also present. They need addressing together rather than as separate exercises.

Can our filling line be made faster and safer at the same time?
Frequently, yes. Filling halls tend to have grown incrementally, and a properly designed layout with closed transfer, correct ventilation and better container handling usually improves both throughput and exposure control.

We are moving from solvent to water-based systems. Does the DSEAR assessment still apply?
Almost certainly, at least in part. Most sites retain solvent inventory through the transition, and reduced quantity does not remove the duty. The assessment should be revised rather than retired.

Do you design LEV systems?
Yes, including capture design at charging, sampling and cleaning points, which is where isocyanate exposure typically occurs and where generic extraction rarely performs.

Talk to us about your site. Request a call