Process Risk Assessments

Achieve DSEAR Compliance and Strengthen Workplace Safety, Faster

Let Sigma-HSE take away the stress of obtaining and maintaining DSEAR compliance. We’ll do the heavy lifting so you can concentrate on what really matters, delivering the best products in the safest possible environment.

Complete UK Coverage

10+ Years in Business

400+ DSEARs Completed

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BECOME DSEAR COMPLIANTNew to DSEAR? Start here

The safety of your employees from risk of fire and explosion is on you.

Dangerous substances can put people’s safety at risk. DSEAR legally requires employers and the self-employed to protect their employees and members of the general public who may be put at risk by work activity.

CLEAR RISK ASSESSMENT GUIDANCE

Have confidence in your DSEAR with our expert guidance

Our tailored approach to DSEAR will guide you and your workplace towards compliance while reducing your risk, improving operational efficiency, and ensuring workplace safety.

  • Lifetime guidance: from your preliminary questions to the implementation of report actions, you will receive expert guidance throughout your entire project lifecycle.
  • Cross-functional support: maintain project oversight by connecting specialist process safety testing or consultancy solutions from a single expert source.
  • Evergreen: DSEAR is as an evergreen document, so our consultants will help create a culture of continuous improvement so you and your DSEAR can dynamically adapt to future change.

Sigma-HSE is your authoritative source for DSEAR compliance, safety audits and long-term risk management.

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PROCESS EFECIENCY

Guarantee business continuity and accelerate your journey to DSEAR compliance

Your business continuity is our priority. Our DSEAR consultants focus on maximising business efficiency by working to your strict processing or regulatory deadlines.

  • Get a quote in days: waiting weeks to receive a quote isn’t sustainable for you, your project or your business. Get in touch and we’ll issue a bespoke quote in days.
  • UK Wide: our DSEAR experts and process safety engineers are based across the UK. This allows us to quickly respond to and meet your requirements, wherever you and your unit operations are based.
  • Internal processes: our DSEAR assessments are streamlined so you will seamlessly move from the quotation stage, to the physical assessment period and a peer-reviewed report in a matter of weeks.

Sigma-HSE will accelerate your journey to compliance by providing, validating or reviewing DSEAR documentation.

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PRICING TAILORED TO YOU

Delight the regulators and fulfil your legal obligations, no matter your budget

Not all DSEAR assessments are created equal. Incomplete or poor quality DSEAR assessments can lead to higher insurance premiums, the unnecessary purchasing of expensive ATEX-rated equipment or non-conformity fines.

  • Budget friendly: DSEAR compliance, like your business, is unique to you. That’s why we always generate custom quotes tailored to your business and budget.
  • Full package: we don’t treat DSEAR like a tick-box exercise. Our assessments go beyond the bare minimum to ensure that you achieve workplace safety and are legally compliant.
  • No hidden fees: your quote is your quote. We don’t believe in hidden fees or admin charges.

Sigma-HSE can guarantee DSEAR compliance and your peace of mind, no matter the size or scope of your business or budget.

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Align Your Workplace Procedures and Practices with our DSEAR Framework

Whether you have a new design or need a review of an existing process, our dedicated team of specialist engineers and DSEAR assessment consultants will cut through the noise, so you can obtain and maintain compliance without the exorbitant fees and delay to your operations.

400+ DSEARs Completed

Complete UK Coverage

10+ Years in Business

Identification of Dangerous Substances

Every site presents unique risks. A thorough analysis identifies hazardous substances such as combustible dusts, flammable gases, vapours, and mists. We'll assess their presence, quantities, and potential interactions in order to establish a foundation for effective risk management.

Assessment of Explosion and Fire Risks

Our assessments will identify locations where explosive atmospheres may form, and will classify them based on frequency and duration of exposure. Potential ignition sources from electrical equipment, hot surfaces, and mechanical friction will always be examined and shown in your report.

Equipment and Protective System Analysis

Equipment must meet stringent safety standards. Our inspections verify compliance with ATEX ratings, ensuring protective systems provide adequate mitigation against explosions or fires. This includes checking ventilation systems, intrinsic safety measures, and explosion relief mechanisms.

Safety Programme Development

Generic safety measures do not suffice. Workplace-specific procedures minimise risks by addressing operational nuances. From handling practices to emergency protocols, we'll ensure that every aspect of your DSEAR programme aligns with regulatory requirements and can be implemented practically.
Our DSEAR assessments always include the below as standard:
Full site inspection from our qualified consultants
Identification of dangerous substances that may apply under DSEAR
Hazardous Area Classification drawings (if required)
Guidance on equipment and protective systems intended to adhere with potentially explosive atmospheres regulations
DSEAR Risk Assessment Awareness
Advice on area signage, labelling requirements and control measures
A prioritised & realistic action plan to mitigate any risks
Basis of Safety for each site process
To support your DSEAR journey and overall process safety strategy, we can also offer the following:
Emergency Procedures
Permit to Work Systems
Management of Change
SOP’s (Standard Operating Procedures)
Relevant Safety Data Sheet Guidance
Electrostatic Hazard Analysis
Testing for the explosivity/flammability of your potentially dangerous substances
Emergency Relief Sizing
DSEAR management systems – maintenance & competence

Get a Free DSEAR Consultation

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We’ll be your guide throughout your DSEAR journey.

Turn your legal obligations into business showstoppers.

Infrastructure

Installation of Leak Detection Systems to Avoid Replacing Air Conditioning Units

Read Case Study
Food & Beverages

Project Cost Reduction through Re-Evaluation of Conservative Internal HAC

Read Case Study
Printing Industry

“Sigma-HSE completed DSEAR assessments for multiple chemical inventory sites around the UK with flawless execution.”

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DSEAR Assessment providers for your industry

DSEAR applies to workplaces where substances classified as hazardous are present, stored, or used in processes. Our expertise and knowledge spans multiple industries and our solutions can be applied to your specific operations. This includes industries such as:
Aerospace
Agrochemicals & Pesticides
Pharmaceuticals
Paper Manufacturing
Wood Processing/Wood Workshops
Chemical Manufacturing
Machinery Manufacturing
Commercial/Residential Buildings
Textiles Manufacturers
Food & Beverages
Transportation & Logistics
Paints & Solvents
Warehousing & Storage
Mining, Oil & Gas
Animal Products
Research & Development

Move From Hazard to Harmony In A Few Simple Steps

Contact us

After you get in touch, a member of our team will reach out to discuss how DSEAR relates to your current workplace situation and how can we help you.

Inspection

Our consultants will visit your site in order to evaluate and verify the entirety of your safety procedures, equipment and control systems across your processes.

Documentation

Our consultants will issue a DSEAR report after their site visit. Although each report will differ, it will highlight everything you need for compliance.

Post-project support

We will follow up to make sure that our recommendations have been applied and that you have a clear understanding of the rationale behind your report.

Protect your employees.

Satisfy the regulators.

Drive growth.

Unlock DSEAR compliance clarity and process safety peace of mind with Sigma-HSE.

Frequently asked questions

DSEAR is, in effect, a risk assessment. As part of these assessments of risks, DSEAR requires that a hazard must be present – this is usually the presence of an explosive atmosphere and an effective source of ignition.

The key requirements for complying with the regulations revolve around the completion of a thorough risk assessment and the undertaking of a Hazardous Area Classification (HAC).

Ultimately, the assessment aims to provide a coherent focus for the identification and mitigation from:

Dangerous substances include a wide variety of materials present in the workplace that can be classified as flammable, explosive or corrosive to metals. This can include gases, mists, vapours and other combustible materials such as dust and powders.

Examples of potentially dangerous substances found at work include: 

We offer testing services for a variety of potentially flammable substances and other chemicals including combustible dust & powder testing, flammable gases & vapour testing and electrostatic testing.

The testing of these dangerous substances will aid in characterising, preventing, protecting and mitigating workplace hazards to help you comply with DSEAR regulations.

DSEAR defines hazardous zones as a place where a potentially explosive atmospheres may or may not occur.

By defining an explosive atmosphere as a hazardous zone, special safeguards can be created in order to protect businesses, equipment, people, workplace and the environment.

A Hazardous Area Classification is used to identify risks in the places and areas of operation whereby control measures must be put in place i.e. intrinsically safe electrical equipment that conforms with the ATEX equipment directive (if necessary).

These classifications make up an integral part of the DSEAR risk assessment and is required by law – see DSEAR Regulation 7. 

Dangerous substances, as defined by DSEAR, is any substance in the workplace that could, if not properly controlled, lead to potential hazards when present in explosive atmospheres.

Compliance with DSEAR regulations, therefore, requires that the risks posed by such dangerous substances be removed or controlled to protect people from explosions and fire.

You will need a DSEAR if you deal with dangerous substances in the workplace. 

Take a our 2 minute DSEAR Quiz here

A DSEAR assessment should always be reviewed if you believe your current DSEAR may be invalid.

Although this could include the standardised 3-5 year time frame, it is recommended that a risk assessment review should occur if you have recently had a near miss or if you have made a minor change to your process.

The cost of a DSEAR assessment with Sigma-HSE will range depending on factors such as: 

  • Size of plant or facility
  • Type of DSEAR assessment (i.e., Review/Desktop/On-Site)
  • Specific compliance needs
  • Nature of your hazardous materials

You can get a free quote by filling in a form. Our team will get back to you asking for a couple of details and you will receive a quote in just a few days.

Each assessment targets different workplace hazards under specific regulatory frameworks.
A DSEAR (Dangerous Substances and Explosive Atmospheres Regulations) assessment focuses exclusively on identifying and mitigating risks related to flammable substances, explosive atmospheres, and potential ignition sources.

In contrast, COSHH (Control of Substances Hazardous to Health) assessments are concerned with the health effects of hazardous substances—like dusts, fumes, or chemicals—on workers. Fire Risk Assessments under the Regulatory Reform (Fire Safety) Order are broader, addressing general fire safety risks across premises, regardless of whether flammable substances are present.

At Sigma-HSE, we help clients navigate these overlapping but distinct regulatory obligations, ensuring each risk area is robustly covered and fully compliant.

The DSEAR Regulations require assessments to be carried out by someone with sufficient knowledge, training, and experience in managing explosive atmospheres and dangerous substances.

A competent person should understand not only the chemical and physical behaviour of hazardous substances but also be familiar with relevant engineering controls, protective systems, and regulatory compliance.

Sigma-HSE’s consultants are chartered professionals and sector specialists with years of experience delivering DSEAR compliance across high-risk industries. Our team ensures that your risk assessment stands up to regulatory scrutiny and is grounded in best practice.

Yes. While DSEAR is a regulatory requirement, it can and should be integrated with broader process safety methodologies.

At Sigma-HSE, we regularly align DSEAR assessments with HAZID (Hazard Identification), HAZOP (Hazard and Operability Study) and QRA (Quantitative Risk Assessment) techniques. This ensures a holistic view of potential risks across both routine operations and abnormal scenarios.

Our cross-disciplinary approach helps streamline compliance, prevent duplication of effort, and strengthen your organisation’s overall safety performance.

Although each site and set of unit operations will never be the same, we follow a structured methodology to ensure DSEAR compliance:

  1. Identification of Dangerous Substances
    Pinpoint all flammable gases, vapours, mists, and dusts used or generated onsite.

  2. Assessment of Explosion and Fire Risks
    Evaluate the likelihood of explosive atmospheres forming and the presence of ignition sources.

  3. Implementation of Control Measures
    Recommend suitable controls such as ventilation, inerting, zoning, and use of ATEX-rated equipment.

  4. Documentation and Reporting
    Provide a detailed report including zoning classifications, equipment inventories, and risk mitigation strategies.

  5. Review and Ongoing Monitoring
    Ensure regular updates to the assessment in line with process changes, incidents, or new substances introduced.

At Sigma-HSE, we delivers each stage with technical rigour, so your assessment meets both legal requirements and best-practice expectations.

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