Where Should Eyewash Stations Be Located in Facilities?

In 2020, the U.S. Bureau of Labor Statistics (BLS) reported 1.7 eye injury cases for every 10,000 full-time workers, with contact with objects or equipment accounting for the majority. Among those affected, construction trades workers reported 2,120 cases, and material moving workers followed with 1,860. In incidents like these, the ability to access an eye wash station within seconds is the single most effective measure to keep a temporary irritant from becoming a sight-threatening injury.

In one real-world example, a worker in a plastics facility was splashed with injurious corrosive materials while cleaning a valve. Thanks to a properly positioned eyewash unit just several feet away, they were able to flush their eyes immediately, avoiding permanent damage. In contrast, another facility located its station in a storage room, delaying response by over a minute and leading to long-term vision impairment for the employee involved.

Key Takeaways

• According to 29 CFR 1910.151(c), employers must provide suitable eyewash and emergency showers in areas where workers risk exposure to harmful substances.
• Eyewash stations should be located within 10 seconds' walking distance of hazardous materials, especially where injurious corrosive materials are handled.
• Placement should account for OSHA eye wash station clearance requirements, as well as floor traffic, visibility, and access during all shifts.
• Regular maintenance and staff training are essential for making eyewash stations effective in a real emergency.
  

What Are the OSHA Requirements for Eyewash Stations?

The Occupational Safety and Health Administration (OSHA) requires eyewash stations in areas where employees may be exposed to corrosive materials, as outlined in standard 29 CFR 1910.151(c). While this regulation specifies the necessity of such facilities for quick drenching or flushing, it does not detail the installation, operation, or maintenance requirements for safety showers and eye wash equipment units. 

Instead, OSHA cites the American National Standards Institute as a reliable guideline for emergency eyewash and shower equipment. According to the ANSI/ISEA Z358.1 standard, emergency eyewash stations must be:

Importance of Eyewash Stations in Industrial Facilities

I’ve spent years around manufacturing floors, from metal shops to chemical processing areas. One thing that’s been consistent across every facility I’ve visited or worked in: properly located eyewash stations cut the delay to irrigation, the single strongest modifiable predictor of final visual acuity after a splash or particulate injury. 

This safety equipment is often the only immediate control available in keeping several eye hazards from turning into life-changing injuries, including:

• • Splashes of injurious corrosive materials such as acids, alkalis, or battery electrolyte

  • Metal, glass, or wood chips are ejected by grinding and cutting

  • Hot oil, steam, and other thermal agents

  • Bio-hazard disinfectants and irritating solvents

A few seconds of delay during an emergency can mean the difference between a full recovery and permanent vision loss. As noted in a feature from Occupational Health & Safety (OH&S) magazine: “These stations are central to the safety of everyone around them.”

Where Should an Eyewash Station Be Located?

According to the ANSI/ISEA Z358.1 standard, eyewash stations must be located on the same level as the potential hazard and be reachable within a 10-second travel time, approximately 55 feet, along a clear and unobstructed path. This same accessibility requirement applies to emergency showers.

Eyewash station placement should ensure that a worker with impaired vision can access it without encountering steps, closed gates, or sharp turns. Ideally, there should be no doors between the hazard and the eyewash station, though a single outward-swinging, unlocked door is permissible. 

Ultimately, the most effective eyewash station is one that an exposed worker can access instantly—without any hesitation, obstructions, or wasted time.

Eyewash Station Installation Guideline

A well-planned installation accounts for daily operations, facility layout, and the specific hazards present in each work area. Here’s a step-by-step approach you can follow:

1. Evaluate Site Hazards and Layout

Begin with a thorough walkthrough of your facility. Identify work zones where there’s a potential for exposure to injurious corrosive materials, high-pressure systems, or eye-level hazards. Look closely at:

1. Risk Areas: Identify specific locations (labs, battery charging stations, manufacturing floors, etc.) where eye injuries could occur.

2. Hazards Present: Which processes involve acids, caustics, battery charging, or dusts that can harm eyes or skin?

3. Exposure Likelihood: Evaluate the probability and severity of eye exposure incidents. Is a single eyewash unit sufficient, or do you need multiple units of a portable eyewash station?

4. Facility Layout: Are there corners, pallets, forklifts, or mezzanines that could block the immediate emergency use path? Is there a straight, unobstructed line of travel with clear sightlines?

5. Lighting & Visibility: Will staff see the unit even on night shift?

6. Utility Supply: Is potable water available where the unit is needed, or do you need a self-contained unit?

7. Environmental Conditions: Will freezing, heat, or chemical vapors affect the unit? If outdoors, look at freeze-protected models.

Without that evaluation, you risk placing the unit too far away, behind a door that sticks, on a different level, or without warm water, any of which can prevent an injured worker from reaching full flushing fluid within the first 10 seconds.

2. Determine the Type of Eyewash Station

Once the site evaluation is complete and potential hazards are identified, the next step is to select the most appropriate type of eyewash station for the specific location. In permanent, high-risk environments such as laboratories, chemical handling areas, or industrial facilities with reliable plumbing, a plumbed eyewash station is often the best option. These are fixed units connected to a water supply, offering steady pressure and consistent flushing fluid temperature.

On the other hand, sites lacking direct access to plumbing or requiring temporary or mobile setups should consider a self-contained portable eyewash station. These units store flushing solution in built-in reservoirs that rely on gravity for flow. While portable stations are convenient and flexible, they require frequent maintenance, including regular refilling, cleaning, and monitoring of fluid expiration dates to ensure compliance and effectiveness during emergencies.

Now, if multiple eyewash units are needed but neither plumbed nor self-contained portable units are suitable for a specific location, personal wash units can serve as a supplementary first response tool for immediate flushing until the affected individual makes their way to a primary eyewash unit.

3. Install the Eyewash Station

Given that ANSI/ISEA Z358.1 outlines the installation standards for eyewash equipment, most manufacturers design their units to comply with these guidelines, resulting in generally similar installation processes across different brands.

Installation steps for plumbed eyewash stations:

1. Shut off the water supply.

2. Assemble and position the eyewash station, typically using wall or floor mounting hardware.

3. Connect to the water supply line, ensuring a steady flow of clean water.

4. Install a tempering valve (mixing valve) to maintain a tepid range and avoid scalding or cold shock.

5. Connect to a drain, or prepare for water management if draining to the floor.

6. Test the unit to see that the flushing fluid flows 0.4 gallons per minute (GPM) for 15 minutes.

7. Mark the station with clear, reflective eyewash signage and lighting.

Installation steps for portable eyewash stations:

1. Assemble the unit according to the manufacturer’s instructions.

2. Fill with water/saline (replace per manufacturer schedule, often every 3–6 months).

3. Place the unit in the chosen location.

4. Secure it (wall-mounted or on a stand).

5. Label the station clearly and ensure visibility.

6. Test regularly and replace fluid as needed.

If you have a qualified, experienced maintenance staff comfortable with commercial plumbing and safety standards, in-house installation can work. Otherwise, it’s best practice to hire professionals, especially for high-use, high-risk, or outdoor applications. Many equipment suppliers offer full-service packages, which include surveying your site, recommending the right stations, installing them, and then performing scheduled inspections, fluid changes (for self-contained units), dust cap replacements, and record-keeping. That ensures ongoing compliance without burdening your facilities team.

Other design and construction considerations:

• • Map forklift aisles and pallet flow to ensure no part of the eyewash station (or its “no-storage” zone) protrudes into a powered-industrial-truck aisle.

  • Clearly stripe a 34 × 34 in (86 × 86 cm) “no-storage” zone on the floor so temporary work-in-progress stacks never creep across the access path.

  • Grade the floor away from electrical equipment and workstations to avoid pooling or slip hazards.

  • Provide at least 34 in (86 cm) of clear space in front of the unit so users can easily reach the paddle without bumping into nearby equipment.

  • Place the water outlets 33 to 53 inches above the standing surface and at least 6 in (15 cm) from any wall or nearest obstruction to prevent rebound injuries.

  • For stations incorporating sinks or counters, follow the Americans with Disabilities Act (ADA) guidelines: maximum sink/counter height 34 in (86 cm) above the floor, with appropriate knee clearance.

  • Select corrosion-resistant materials (stainless steel, ABS, epoxy-coated steel) that are compatible with on-site chemicals.

  • For outdoor or unheated locations, install freeze-protection (heated valves or insulation jackets) to prevent line freezing.

  • Label each eyewash station and emergency shower with highly visible signs at about 7 ft height; in low-light areas, add LED beacon lights.

Common Locations of Eyewash Stations and Their Hazards

Recognizing the environments where emergency eye wash stations are crucial forms a key aspect of workplace safety. These stations are strategically located to offer immediate relief from hazardous exposures. Below is a checklist of common places and their corresponding hazards where emergency equipment is necessary:

Janitorial Closet

Common cleaning agents like bleach and ammonia contribute to roughly 125,000 eye injuries each year. According to the Bureau of Labor Statistics (BLS), janitors and cleaners had the third highest number of nonfatal injuries and illnesses in 2015, with 42,740 cases, and in 2020, the injury rate remained high at 2.8 cases per 100 workers. These numbers reflect daily exposure to hazardous materials and irritants, reinforcing the need for properly located eye wash stations in custodial closets.

The Occupational Safety and Health Administration (OSHA) has actively cited facilities for failing to install suitable eyewash stations in janitorial closets, as mandated by 29 CFR 1910.151(c). These citations are considered serious violations due to the high risk of injury from chemical exposure:

• • In 2015, a hotel in Georgia received a citation for failing to provide a properly functioning eyewash station in the housekeeping area, where employees were exposed to burns to the eyes from hazardous material, such as but not limited to silica or lime.

Janitorial staff frequently handle potent cleaning agents like phosphoric acid tile and grout cleaners, degreasers with high pH levels, and other chemicals that can cause severe damage upon contact. These substances, if mishandled or misapplied, can lead to eye irritation, burns, or even more severe ocular injuries.

Boiler Room

The boiler room, a critical area in many industrial and commercial facilities, necessitates stringent safety measures, including the fulfillment of eye wash station requirements. The nature of work in these environments often involves exposure to extreme heat, steam, pressurized water systems, and chemicals used in water treatment processes, all of which pose significant risks to eye safety.

The eye wash station in a boiler room is vital due to the potential hazards, such as:

• • Chemical Exposure: Boiler water treatments involve chemicals like scale inhibitors, corrosion inhibitors, and anti-foaming agents, which can be hazardous upon contact with the eyes.

  • Thermal and Steam Burns: The high temperatures and steam emissions in boiler rooms can cause severe eye injuries.

  • Particulate Matter: Small particles from fuel, ash, or scale can become airborne, posing a risk to eye health.

A friend of mine works in building maintenance and told me about a close call one of his technicians had during a routine boiler inspection. A steam line suddenly leaked, hitting the guy in the face with hot vapor; his eyes took the brunt of it. Luckily, there was an eye wash station nearby, and he was able to start flushing right away with tepid water. That fast response likely prevented a much more serious injury. Since then, my friend’s team has made it a point to check that every boiler room has a working, accessible eyewash station, because in high-risk areas like that, even a few seconds can make all the difference.

Battery Charging Station

At battery charging stations, particularly where forklifts and other industrial vehicles are powered, the potential for hazardous exposure necessitates the presence of an eye wash station. According to OSHA Standard 1926.441(a)(6), such stations must be within 25 feet of the battery handling area to ensure immediate access in case of chemical exposure.

To comply with OSHA regulations and ensure worker safety, eye wash stations near battery charging areas must meet specific criteria:

• • Placement: Position the station next to the charging area for quick emergency access.

  • Height: Mount flushing heads 33–53 inches from the floor for easy reach.

  • Clearance: Keep at least 6 inches of space from walls or obstructions.

  • Flow Rate: Must provide 3 gpm of tepid fluid for a full 15-minute flush.

  • Accessibility: Use a stay-open valve that activates within one second and stays on hands-free.

  • Contamination Protection: Shield nozzles and fluid from dust and airborne debris.

These specifications are designed to ensure that in the event of exposure to hazardous substances at a forklift charging station, employees have immediate and effective access to an eye wash station, mitigating the risks of serious injuries or chemical burns.

Laboratories

Laboratories, whether they are in educational, medical, or industrial settings, handle a myriad of substances that can pose significant risks to eye health. The common hazards in these environments necessitate stringent safety measures, including the availability of an eyewash station. Hazards in laboratories include:

• • Chemical Spills and Splashes: The use of acids, bases, solvents, and various reactive agents can lead to accidental splashes or spills, endangering eye safety.

  • Vapors and Fumes: Many chemical reactions generate vapors or fumes that can irritate or burn the eyes upon exposure.

  • Particulate Matter: Operations like grinding, cutting, or milling can release small particles that can cause eye irritation or damage.

Eyewash units should be located as close as safely possible to where the hazard exists. Common pitfalls that lead to non-compliance include placing eyewash stations inside chemical storage rooms or behind closed doors that slow access. Units hidden behind lab benches, shelves, or equipment also reduce visibility and delay use during emergencies. Some labs rely on sink attachments that don’t meet required flow or activation standards. Cluttered areas, such as those blocked by carts or stools, can make stations hard to reach. These issues all compromise response time and put workers at greater risk.

Chemical Storage

In areas dedicated to chemical storage, the installation of an eye wash station is a fundamental safety requirement. These locations are filled with various chemicals, each with potential hazards that can cause severe eye injuries. The nature of stored chemicals, whether they are volatile, corrosive, or simply irritants, mandates the presence of an eyewash station to address potential eye exposure incidents effectively.

Common hazards in chemical storage areas include:

• • Chemical Spills: Even with stringent safety protocols, spills can occur, leading to the risk of splash injuries to the eyes.

  • Leaking Containers: Over time, containers may degrade, leak, or break, releasing harmful substances.

  • Fumes and Vapors: Many chemicals emit fumes that can irritate or damage the eyes, even without direct contact.

An OSHA report details an incident where a quality control technician in a laboratory was injured when a container of sodium hydroxide slipped and splashed the corrosive solution into his left eye. He struggled to activate the nearby eyewash station on his own and resorted to splashing water from a sink with his hand. A colleague eventually helped him turn on the eyewash unit, enabling him to flush his eye for 5 to 10 minutes.

This incident highlights the critical need for accessible eyewash stations in chemical storage areas. The capacity to quickly and effectively rinse the eyes can significantly lessen the seriousness of injuries resulting from chemical exposure.

How Are Emergency Eyewash Stations Maintained?

Maintaining an eyewash station isn’t complicated, but it does require consistency. Units should be tested weekly to confirm proper flow, clear access, and that the flushing fluid runs clean. Plumbed eyewash stations require their valves to be checked and nozzles to be cleared of debris or mineral buildup. As you can see in the image above, eyewash nozzles must be kept clean and corrosion-free to ensure they deliver a contaminant-free water flow for quick drenching or flushing when needed.

Self-contained portable units require regular fluid replacement depending on factors such as the ambient temperature and the potential for algae growth. In warmer environments, the solution may need to be checked and refilled more frequently to prevent microbial contamination.

Advanced Considerations for Modern Manufacturing

While basic eye wash stations meet regulatory requirements, forward-thinking workplaces are adding features that improve reliability, visibility, and worker response. One common upgrade is the integration of visual and audible alarms that activate when the eyewash is used. This alerts nearby staff that a chemical incident has occurred and may signal the need for additional emergency support. One industrial hygienist shared their experience on a forum:

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Some manufacturers are also incorporating smart monitoring systems into emergency equipment. These systems can track testing intervals, flow rates, and fluid temperature remotely, reducing the risk of non-compliance or unnoticed maintenance issues. In environments with multiple shifts or hazardous chemical zones, digital tracking ensures that each unit stays functional and ready.

FAQs on Eyewash Station Locations

Where should emergency equipment be installed?

Emergency equipment, including eye wash stations and emergency showers, should be installed within 10 seconds (about 55 feet) of areas where workers are exposed to injurious corrosive materials or other hazardous substances, with an unobstructed path for access.

What is the distance requirement for eyewash stations?

According to ANSI Z358.1 (referenced by OSHA), eye wash stations must be located within 10 seconds or roughly 55 feet from the hazard area.

Where is the eye wash station located in a lab?

In a laboratory, the eye wash station should be situated close to the areas where chemicals are handled or stored, typically within the immediate work area. This placement ensures quick access in case of a chemical splash or exposure, minimizing the time to commence flushing the eyes.

How close can an eye wash station be to an electrical panel?

Avoid placing eye wash stations directly next to or beneath electrical panels to reduce electrocution and short-circuit risks during use. Maintain safe separation based on facility layout and local codes.

Is a single centralized eyewash station sufficient for a manufacturing facility?

Usually not. A single station may be too far for multiple hazard zones. Facilities should install multiple stations close to each risk area to meet accessibility and safety standards.

How should temporary manufacturing operations handle eyewash requirements?

Temporary setups must still comply with 29 CFR 1910.151(c). Use portable self-contained eyewash units positioned within 10 seconds of any hazardous task, and ensure they are inspected regularly and fully operational.