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An aviation maintenance operator required support to assess and improve compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) at one of its UK based maintenance facilities.
EPIT was appointed to carry out a site-based assessment, review existing documentation, and provide practical recommendations to help the organisation align with regulatory requirements.
Challenge
The client operated a busy maintenance hangar environment where flammable liquids, fuels, gases, and hazardous substances were routinely handled. This created potential fire and explosion risks that required careful management under DSEAR.
Key challenges identified included:
- Lack of documented procedures for handling hazardous substances and equipment
- Limited evidence of training and competency records for staff
- Potential ignition risks within storage areas
- Incomplete maintenance and operational records for key equipment
- Reliance on informal or undocumented working practices
Although some controls were in place, there was insufficient documented evidence to demonstrate full compliance with DSEAR requirements.
Solution
EPIT delivered a structured consultancy approach tailored to the operational environment:
- Conducted a detailed site survey of the maintenance hangar and external storage areas
- Reviewed existing risk assessments, documentation, and working practices
- Identified gaps against DSEAR regulatory requirements
- Assessed potential ignition sources, storage arrangements, and ventilation conditions
- Evaluated the suitability of current control measures
Based on findings, EPIT provided clear, prioritised recommendations focused on:
- Developing documented safe systems of work
- Establishing maintenance and operational procedures
- Improving hazardous substance handling and storage practices
- Implementing training and competency records
- Reviewing storage areas for potential explosive atmospheres
Outcome
Following the assessment, the client gained:
- A clear understanding of current compliance status against DSEAR
- Identification of key risk areas and potential ignition sources
- A structured roadmap to achieve regulatory compliance
- Practical, actionable recommendations aligned with site operations
The project enabled the organisation to move from informal controls toward a more robust, evidence based compliance framework, supporting both safety improvements and regulatory assurance.
For more information on Supporting an Aviation Operator to Strengthen DSEAR Compliance talk to EPIT Group