Control Banding Tool | Exactus Labs

How to use this tool

Select the hazard band (from GHS classification or OEL range), quantity handled per task, dustiness or volatility, and the ventilation control in place. The tool applies the semi-quantitative control banding approach from COSHH Essentials (UK HSE) — the same approach underlying AIOH Simplified Occupational Hygiene Risk Management Strategies, 3rd ed. (Firth, Golec & Di Corleto, 2026), Table 3.10 — to determine the minimum recommended control band (CB1–CB5). Quantity and dustiness/volatility categories align directly with AIOH 2026 Table 3.10.

Hazard band — based on GHS classification or OEL range

Quantity — amount used or handled per task

Dustiness (solids) or volatility (liquids)

Ventilation control in place

Make selections above to determine the recommended control band.

This tool implements the semi-quantitative control banding approach described in UK HSE COSHH Essentials (HSG193). Quantity, dustiness/volatility, and ventilation categories align directly with AIOH Simplified Occupational Hygiene Risk Management Strategies, 3rd ed., Table 3.10 (Firth, Golec & Di Corleto, February 2026, Australian Institute of Occupational Hygienists Inc.). Control banding is a qualitative screening tool — it does not replace a full quantitative exposure assessment where one is practicable. Band E substances are subject to specific regulatory requirements under applicable WHS legislation and require specialist occupational hygiene advice regardless of the control band result.

Control band definitions

Control bands define the type and intensity of controls required based on the combined hazard band, quantity, dustiness/volatility, and ventilation already in place. They are substance-independent — the same band applies to any substance meeting the criteria.

Control band descriptions and control measures

CB	Control type	Typical measures	Examples
CB1	General ventilation	Natural or mechanical general ventilation. Good housekeeping. Standard PPE (gloves, safety glasses).	Dilute cleaning products, low-volatility lubricants, many food-grade substances
CB2	Engineering controls — LEV	Local exhaust ventilation (LEV) at point of generation. Enclosed process preferred. Respiratory protection as back-up only.	Solvent-based paints, moderate-hazard dusts (wood dust), most laboratory chemicals
CB3	Contained process / enclosure	Enclosed or near-enclosed process. High-efficiency LEV. Respiratory protection (half-face, FFP3 or higher) as supplementary control. Airborne monitoring required.	Isocyanates (limited quantities), fine respirable silica, high-volatility solvents with low OEL
CB4	Specialist advice required	Specialist occupational hygienist assessment required. Likely full enclosure with remote handling. Continuous monitoring. Stringent health surveillance.	Potent carcinogens (non-mandated), highly toxic materials (IDLH < 10 × OEL), radiotoxic substances
CB5	Mandatory specific controls	Specific statutory controls apply regardless of quantity or conditions. Prescribed measures, OEL compliance monitoring, and health surveillance are legally mandated.	Asbestos, respirable crystalline silica (construction/mining), lead, isocyanates (large quantities), vinyl chloride monomer

Hazard band (HB) criteria — GHS / OEL basis

HB	OEL range (vapours)	OEL range (dusts)	GHS classification triggers
A	≥ 500 ppm	≥ 10 mg/m³	No classification, or GHS08 Cat. 4 only
B	50–500 ppm	1–10 mg/m³	GHS07 (irritant), GHS08 Cat. 3–4 (narcotic), skin/eye irritant
C	1–50 ppm	0.1–1 mg/m³	GHS08 Cat. 1–2 (CMR), GHS sensitiser (skin/respiratory), GHS06 acute tox. cat. 3
D	< 1 ppm	< 0.1 mg/m³	GHS08 Cat. 1A (CMR), potent sensitiser, GHS06 acute tox. cat. 1–2
E	No safe threshold	No safe threshold	Mandatory specific controls — asbestos, respirable crystalline silica, lead, isocyanates, vinyl chloride monomer

Quantity bands — AIOH 2026 Table 3.10

Band	Liquids	Solids	Typical context
Minor	< 1 L	< 1 kg	Trace reagents, micro-scale laboratory, analytical sampling
Small	1–20 L	1–20 kg	Bench-scale synthesis, small batch mixing, laboratory chemical use
Medium	20–200 L	20–200 kg	Pilot-scale, workshop cleaning, coating operations
Large	200–1000 L	200–1000 kg	Batch manufacturing, industrial filling, large-scale mixing
Very large	> 1000 L	> 1000 kg	Bulk handling, continuous industrial process, large-scale transfer

Dustiness / volatility categories — AIOH 2026 Table 3.10

Level	Solids (dustiness)	Liquids (volatility)	Examples
Low	Low dusting — pellet-like solids that do not break up easily	Low volatility — boiling point > 150°C	Wax pellets, damp materials; mineral oils, glycerol, diethylene glycol
Medium	Dusty — crystalline or granular solids	Moderately volatile — boiling point 50–150°C	Crystalline solids, granular fertilisers; ethanol, toluene, xylene, MEK
High	Very dusty — fine light powder	Highly volatile — boiling point < 50°C	Flour, silica flour, fine pigments; acetone, DCM, diethyl ether, petrol

Primary reference: AIOH Simplified Occupational Hygiene Risk Management Strategies, 3rd ed. (Firth, Golec & Di Corleto, February 2026, Australian Institute of Occupational Hygienists Inc.) — Table 3.10 (quantity, dustiness/volatility & ventilation), Appendix 2 (GHS consequence rating), and Section 2 (hierarchy of controls). Table 3.10 is itself derived from UK HSE COSHH Essentials (HSG193). Additional frameworks: EMKG (Germany BAuA), Stoffenmanager (Netherlands). Control banding is a screening approach — it does not replace quantitative exposure assessment where practicable.