Fertigation and chemigation have scaled fast — a market nearing ~$50.3 billion in 2025 and projected to $64.2 billion by 2030 — but operator exposure to agrochemicals remains stubbornly high. A practical, facility‑first safety playbook reduces risk without slowing the work.
Farms that feed global supply chains increasingly deliver fertilizers or pesticides through irrigation. Market analyses peg fertigation/chemigation equipment at tens of billions of USD (e.g. ~$50.3 B in 2025, projected to $64.2 B by 2030, per mordorintelligence.com), underscoring how ubiquitous these systems have become.
But the human risk is not abstract. Globally, an estimated 18.2 pesticide poisonings per 100,000 agricultural workers occur each year (WHO; pmc.ncbi.nlm.nih.gov). In the U.S., the EPA/CDC estimates 10,000–20,000 physician‑diagnosed pesticide poisonings annually among ~3.38 million farmworkers (osha.gov).
Indonesia, which registers over 3,000 pesticide products for agriculture, sees high‑intensity use — often mixing multiple chemicals at once — making safe handling critical. Studies in Indonesian farmer populations show a strong protective effect of PPE: one trial found ~89% of PPE‑compliant farmers remained symptom‑free, whereas non‑users recorded significantly more health complaints (pmc.ncbi.nlm.nih.gov).
Exposure routes and acute risks
Agricultural chemicals enter the body via skin contact, inhalation, or ingestion during mixing and application (pmc.ncbi.nlm.nih.gov; osha.gov). Solvents in liquid formulations can volatilize or splash; dust formulations easily aerosolize. Operators face acute risks (chemical burns, poisoning) and chronic effects without protection. Extension literature experience ties a leading share of contamination and worker injury to improper storage or mixing, driving today’s emphasis on purpose‑built facilities and PPE.
PPE by chemical and formulation
Minimum protection when handling any concentrated agrochemical is long‑sleeved, chemical‑resistant clothing, chemical‑resistant gloves, boots, and splash‑proof eye protection (osha.gov; edis.ifas.ufl.edu). OSHA‑style guidance notes that “minimum protection when working with pesticides is long sleeves, long pants, shoes and socks, rubber gloves, and splash‑proof eye protection” (osha.gov).
Highly toxic pesticides (WHO Class Ia/Ib) require chemical‑resistant coveralls or an apron, chemical‑resistant gloves (nitrile, neoprene or butyl rubber) extending to forearms, chemical splash goggles or a full‑face shield, fully enclosed boots, and a respirator. For liquid sprays, a NIOSH‑approved respirator (NIOSH is a respirator certification standard) with organic‑vapor/acid gas cartridges is used, or SCBA (self‑contained breathing apparatus) for fumigants. For dry powders or dusts, a P100 (HEPA) filter mask or self‑contained respirator is needed. PPE selection must match hazards (e.g., synthetic polymer gloves vs. caustics; butyl rubber vs. solvents), and inner waterproof liners may be needed for extended exposure (edis.ifas.ufl.edu; osha.gov).
Herbicides and fungicides, including 2,4‑D and glyphosate formulations, can be moderately to highly toxic. Protocol aligns with insecticides: impermeable coveralls, chemical‑resistant gloves and boots, and eye protection. A respirator is advisable with high‑pressure sprays to avoid fine mists. Emulsifiable concentrates (oil‑based) are especially skin‑penetrating, so solvent‑resistant clothing and double layers of gloves are recommended.
Liquid fertilizers (ammonium nitrate, urea solutions, acidified nutrient mixes) are generally less acutely toxic than pesticides but can be corrosive or dusty. During mixing of concentrated liquid fertilizers or acid‑activated blends, acid‑alkali‑resistant PPE is used: heavy‑duty gloves (nitrile for moderate exposure, neoprene/butyl for strong acids), splash‑proof goggles, a face shield, and boots. Chemical‑resistant coveralls or aprons are prudent if splashing is possible. Extension guidance notes tanks for liquid fertilizers are often fiberglass or epoxy‑lined to resist corrosion (extension.uga.edu). For dry fertilizer dusts, P100 respirators plus gloves and goggles address inhalation and dermal contact with irritant particles.
Labels and Safety Data Sheets (SDS; hazard and handling instructions) are the legal reference for required PPE. If a label indicates “corrosive” or “fatal if inhaled,” PPE escalates to full respiratory protection and impermeable suits. Training and compliance boost effectiveness — farmers who consistently wear full PPE report far fewer symptoms (pmc.ncbi.nlm.nih.gov). PPE must fit and remain intact. After handling chemicals, decontamination includes removing gear and showering with water at 70–100°F to avoid thermal stress (edis.ifas.ufl.edu; osha.gov).
Mixing and storage infrastructure
Secondary containment defines safe mixing/loading and storage. A concrete pad with perimeter curbing and a sump contains spills and rinsewater, with capacity typically ≥110% of the largest container. Sumps pump to dedicated drums or “rinsate tanks” for later disposal (extension.uga.edu; extension.uga.edu). UGA Extension calls secondary containment “a form of insurance” to capture spills and rinsate for recovery (extension.uga.edu).
Ventilation and fire safety standards apply. Storage/mixing rooms are well‑ventilated — at least two vents on opposite walls (~20×20 cm) or mechanical exhaust at 150+ CFM or 6 air exchanges/hour (extension.uga.edu). The facility is fireproof: non‑sparking lighting and switches, all heat sources UL‑rated for hazardous locations, and no open flames or smoking (extension.uga.edu). Explosion‑proof fans and electrics are required in cabinets used for flammables (extension.uga.edu). Note: “Temperatures should be kept between, be dust and explosion proof” (extension.uga.edu).
Structural materials favor impervious, non‑absorbent finishes. Sealed concrete floors sloped to a sump, concrete block or metal walls, and steel or plastic‑lined shelving are recommended; wood is avoided (extension.uga.edu). Tanks and containers are corrosion‑resistant: polyethylene, fiberglass, or lined steel (extension.uga.edu).
Site layout and regulatory controls
Location matters. Facilities are placed on high ground, away from wells, drainage ditches or streams, and outside flood zones. Distance from occupied buildings adds safety. Doors are lockable with clear hazard signage (“DANGER – Pesticides”) to restrict entry. Under Indonesian law (Government Reg. 7/1973), pesticide storage must be inspected by authorities for proper construction, labeling, and safety compliance (flevin.com).
Utilities and equipment align with rapid response. Eye‑wash fountains and emergency showers sit near mixing areas. Anti‑siphon/backflow prevention on any water intakes — required in many chemigation regulations — stops chemicals from flowing back into potable or source water (extension.umn.edu). Emergency lighting and fire extinguishers (ABC or as appropriate) are present.
Operational practices and documentation
Mixing is restricted to designated areas; no loading near edges or drains. Pesticides or rinsates go onto the pad, not ground soil. Equipment is cleaned over the pad — no wash‑off on bare earth — using dedicated tools (spatulas, buckets) kept in the facility. After filling sprayers, operators use double‑ or triple‑rinse, with washwater captured in the sump and managed as hazardous waste (extension.uga.edu; extension.uga.edu).
All containers are clearly labeled, inventories are current, and SDS sheets for each chemical are on hand (MSDS kept for reference) to guide emergency response (slf.co.id; extension.uga.edu).
Emergency response and first aid
Spill plans prioritize source control and containment. Personnel stop the source (shut valves, tip containers upright) and evacuate non‑essential workers if fumes are present. Absorbents such as activated charcoal, clay cat litter, vermiculite, or sawdust confine liquid spills (extension.uga.edu). Dry pesticide is swept and collected as hazardous waste; liquids are pumped to rinsate tanks or absorbed. Temporary berms manage large leaks. Supervisors and, where required, regulators are notified; under many laws (e.g., state pesticide regulations), spills must be reported and cleaned up promptly or penalties can apply (extension.uga.edu). Decontamination includes detergent washing of floors/slopes, with washwater captured in the sump and handled as hazardous waste (extension.uga.edu; extension.uga.edu).
First aid centers on rapid decontamination while protecting the rescuer with PPE. For skin contact, contaminated clothing is removed and the skin and hair washed immediately with soap and water or a safety shower, without vigorous scrubbing (which increases absorption) (edis.ifas.ufl.edu). For eyes, lids are held open and flushed continuously for 15–20 minutes (edis.ifas.ufl.edu). For inhalation, the person is moved to fresh air immediately; artificial respiration is administered if breathing stops (edis.ifas.ufl.edu). For ingestion, vomiting is not induced unless the product label or poison control directs it; if conscious, the person rinses their mouth with water (edis.ifas.ufl.edu).
Emergency contacts include a poison control center or emergency services, with the container or label available to provide active ingredients and registration numbers (edis.ifas.ufl.edu; edis.ifas.ufl.edu). Spill kits stock absorbents, neutralizers, clean‑up tools, and first‑aid supplies; a telephone or radio is accessible. After incidents, contaminated PPE and clothing are isolated and laundered or disposed of according to SDS guidance (edis.ifas.ufl.edu).
Outcomes and compliance metrics
Facilities designed with the above specifications, and PPE compliance, deliver measurable benefits: fewer injuries, fewer lost workdays, and lower liability. Research indicates farmers using full PPE have dramatically lower odds of poisoning symptoms (pmc.ncbi.nlm.nih.gov). Extension findings attribute over 80% of pesticide‑related groundwater pollution cases to poor storage or mixing; proper containment and equipment prevent nearly all such incidents (extension.uga.edu; extension.uga.edu).
The bottom line mirrors international and local codes: from WHO/FAO guidance to Indonesian storage rules, fertigation/chemigation safety blends PPE matched to hazard with engineered containment, ventilation, and documented response protocols (osha.gov; flevin.com).
