Worker Protection in Data Center Expansion: The Critical Role of Emergency Safety Shower Equipment

Editor's note:James Hamilton is the Global Engineering Manager at Hughes Safety Showers. The views expressed in this article are solely those of the author.

More and more data center operators are striving to create "lights-out" environments with minimal on-site staff, but data centers still require technicians, engineers, and contractors for inspections, maintenance, and operational support. In these high-density, high-energy environments, operational focus naturally falls on availability, cooling performance, and power resilience. However, as systems scale up, the chemical and mechanical hazards facing on-site personnel also increase. When personnel come into contact with hazardous substances, every second counts. The faster a hazardous substance is flushed from the skin, the more effectively the severity of chemical burns can be reduced. This is precisely why appropriateemergency safety shower equipmentis indispensable.

Risks within data centers

In data centers, thousands of servers run continuously and rely on cooling infrastructure and backup power systems. Across the United States, investment in new capacity is growing rapidly to meet the demands of digital services, AI workloads, and cloud expansion.

Although automation helps, it does not eliminate risk. Battery rooms, cooling equipment, water treatment systems, and cleaning processes are all areas where workers may come into contact with hazardous substances that can cause harm upon skin or eye contact.

Facility operators may assume that small splash risks can be handled simply or addressed with a standard sink, but neither approach adequately addresses chemical exposure. For isolated hazard points, such as battery racks or water treatment dosing areas, portable emergency eyewash stations provide rapid, ANSI/OSHA-compliant decontamination without requiring installed plumbing. In small, high-risk areas within a facility, they are often the fastest and most practical option.

Below are some hazards that facility operators should seriously consider how to address.

Chemical hazards

• Lead-acid and lithium batteries in backup power systems.These units contain electrolytes that can cause immediate irritation or burns if they leak and come into contact with skin. Maintenance activities, such as replacing batteries or inspecting battery racks, present exposure risks. Lithium battery systems are increasingly common due to their performance advantages but also carry risks, including the potential for overheating. In both cases, technicians require immediate access to emergency safety shower equipment after splash or leak exposure.
• Hazardous refrigerants in cooling systems.Servers generate significant heat, making cooling systems essential. While some refrigerants are harmless upon contact, others, particularly ammonia, pose risks. Ammonia exposure requires flushing with water at a specific temperature range. Where such systems exist, emergency safety shower equipment must be installed nearby so workers can reach it quickly.
• Cleaning and water treatment.Data centers use chemicals in cleaning processes and in water treatment systems for cooling towers and humidifiers. Moreover, a major leak is not required to cause a problem. A single splash is sufficient to cause serious injury if not flushed immediately. These risks are often overlooked during facility design or retrofits.

Emergency preparedness

Data centers prioritize floor space for critical infrastructure, leaving limited room for emergency systems. In multi-story or retrofitted facilities, the distance workers must travel from a hazard point to the nearest safety shower may exceed best-practice limits. In an emergency, this brief delay can allow substances to remain on the skin too long, worsening the injury.

Certain areas cannot be covered by plumbed systems. For these locations, mobile emergency shower stations offer a practical solution. Providing continuous flushing via a water tank and featuring a durable, easily movable frame, they ensure workers still have access to emergency decontamination equipment where a fixed water supply is unavailable.

Another common issue is the assumption that a hygiene shower can double as an emergency safety shower. This is not the case. Hygiene showers are intended for routine cleaning of non-hazardous debris, not for flushing hazardous chemicals in an emergency. Confusing the two can delay effective decontamination when time is critical.

Emergency response

• The 10-second rule.According to the ANSI/ISEA Z358.1 standard, emergency safety showers and eye/face wash equipment must be located within a 10-second reach of any chemical hazard point. If hazardous substances are present, shower equipment should be adjacent to the hazard point. These facilities must be easily visible, unobstructed, and well-lit to ensure rapid use in an emergency.
• Enclosed safety showers.In space-constrained environments, enclosed safety showers with built-in catch basins provide a controlled, contained decontamination area. The catch basin prevents spray and contaminated water from coming into contact with sensitive electrical equipment. These units offer a dedicated emergency area within a compact space.
• Chemical compatibility.To ensure thorough flushing, users must remain under the shower for 15 minutes without experiencing discomfort or shock. Safety showers must provide tepid water, typically between 60-100°F. Tepid water encourages workers to remain under the shower for the full recommended duration. For equipment rooms containing refrigerants or chemicals that require precise water temperatures, temperature-controlled safety showers equipped with heated water tanks and thermostatic mixing valves can deliver ANSI-compliant tepid water throughout the entire 15-minute period, even in unheated areas or during water supply fluctuations.
• Hard-to-reach areas.Facilities may have areas with insufficient water pressure or limited plumbing access. Emergency tank showers and mobile shower stations address this by providing a self-contained water supply independent of building infrastructure.

Testing and training

Emergency safety equipment must be tested regularly to ensure it functions properly in an emergency. Safety showers need to be activated weekly to check water flow and flush stagnant water. A full inspection must be conducted annually to ensure everything still meets ANSI performance standards and remains accessible.

Workers also need training on the location of safety showers, how to use them, and why rapid action is key to mitigating the severity of injuries. They should also understand that hygiene showers or standard wash stations cannot provide assistance in an emergency.

Data centers are designed for resilience and round-the-clock operation, and emergency preparedness must receive equal attention. As facility size and complexity continue to grow, operators must ensure that emergency safety practices evolve in step.

By identifying hazard points, selecting appropriate emergency safety shower equipment, positioning it properly, and maintaining it in good working order through regular testing, data center operators can mitigate the severity of injuries when incidents occur.