Putting the station too far from hazard zones
When someone gets a chemical or irritant in their eye, they have seconds to react. If the Eye Wash Station is placed in a storage room, across the warehouse, or behind blocked access points, the delay could cause damage. One of the most common mistakes is putting the station in a low-traffic area or far from where spills and splashes happen. The station must be within reach—ideally no more than ten seconds from the main risk zones.
Blocking access with equipment or stock
Even if the station is close, it’s useless if a worker can’t get to it. Too often, boxes, forklifts, or tools are left in front of wall-mounted units. Free-standing setups get surrounded by trolleys or bins. If access requires climbing over things or pushing equipment aside, it’s too late. The area around any eye wash unit should be clear, easy to see, and kept open at all times.
Mounting units too high or too low
An eye wash station must match the average eye level of the people using it. Some installations are too high, forcing users to stretch. Others are so low that they require bending over awkwardly. In both cases, the response time is slowed and the flushing process becomes uncomfortable. The right height lets the user lean in naturally with no extra movement.
Not checking water pressure or flow rate
A common problem is low flow. If the water trickles out or sprays unevenly, it won’t flush the eye effectively. On the other hand, if the pressure is too strong, it can push contaminants deeper or even damage the eye. Regular testing ensures that the station delivers a steady, controlled stream that covers both eyes without force.
Ignoring temperature control in certain environments
In very cold or hot settings, water from the station can be uncomfortable or even dangerous. Ice-cold water can cause shock or make the injured person pull away too soon. In extreme heat, the water may scald. Temperature-neutral systems are available, and in environments with climate extremes, they’re worth considering.
Failing to label and sign the station clearly
Eye wash units must be marked clearly and visibly. Poor signage leads to confusion, especially in panic situations. Workers unfamiliar with the area may not know where to go or what the station is. Bold signs, bright colours, and visible instructions are part of good setup. Glow-in-the-dark signs can help in low-light or power failure conditions.
Not training workers to use the station properly
Some people assume the process is self-explanatory. It isn’t. Training matters. Workers must be shown how to activate the station, keep their eyes open under the stream, and flush for the right amount of time. Without training, people often rinse too briefly or touch the unit incorrectly. During an emergency, they forget steps or hesitate. Practice sessions reduce fear and improve speed.
Using outdated or expired solutions in bottle-based units
Bottle-style Eye Wash Stations rely on pre-filled saline or buffered solutions. These have expiry dates. Once expired, they may not be safe or effective. Some facilities forget to check these dates, especially if the station hasn’t been used in a while. Expired solution can cause irritation or deliver poor results. Logs and scheduled checks help avoid this.
Assuming one station is enough for the whole site
Larger workspaces or multiple hazard zones need more than one unit. It’s a mistake to assume one station in the corner covers the entire floor. Areas with chemicals, dust, or flying debris should each have a nearby station. The more spread out your work areas are, the more stations you need.
Failing to check drainage and surrounding floor conditions
Water has to go somewhere. In many setups, the eye wash area floods because there’s no drainage plan. Water pools on the floor, making it slippery. This creates a new safety risk. The floor around the unit must be graded or fitted with drains. Anti-slip mats may also help, but they must not block drainage.
Installing the unit without testing it first
Sometimes, the first real use of a station is during an emergency. That’s too late to find out the handles stick, the nozzles are clogged, or the water splashes everywhere. Every station should be tested during installation, with follow-up tests on a fixed schedule. Early checks reveal defects or installation errors before someone needs it.
Skipping regular inspections
Inspections keep the unit ready. This means checking the water source, expiry dates (if it’s a bottle type), nozzles, handles, and labels. A dusty or stained station sends a message: this isn’t used or maintained. Workers may ignore it or assume it doesn’t work. A simple check once a week is better than guessing.
Not accounting for power or water supply outages
In buildings where water is controlled by valves or linked to other systems, outages can shut down the unit. During maintenance or power failures, the station may not work. Backup systems or gravity-fed units help solve this. Always ask: will the unit work when the lights go out or when maintenance is underway?
Choosing the wrong type of unit for your setting
Some setups need wall-mounted stations. Others need freestanding models with foot or hand operation. High-risk zones may need stainless steel units with full drainage. Choosing based on price or appearance often leads to regret. Match the station to the work you do, the space you have, and the fluids you store.
Mounting the unit too close to moving machinery
Workers can’t use a station if a press or conveyor belt is next to it. Machines can leak, shift, or block the path. The station must be placed in a stable zone, away from vibration, movement, or anything that might obstruct use. If machinery moves or expands, make sure the station remains accessible.
Using shared water lines without checking pressure loss
In facilities where one water line feeds multiple outlets, activating other taps can drop pressure. If the eye wash unit shares a line with toilets, sinks, or process equipment, water flow might suffer. If a toilet flush reduces pressure, the eye wash stream may not be usable. This needs testing under full load conditions.
Over-relying on portable bottles as a substitute
Portable bottles are helpful for mobile workers or as a stop-gap, but they’re not a full solution. They run out quickly, don’t always flush both eyes, and may not last the full recommended rinse time. Relying on them instead of installing a proper station is a common setup mistake.
Poor lighting near the unit
Workers might need the station during a blackout, power dip, or in dim conditions. A station hidden in a shadowed corner is hard to use. Always install lighting directly above or near the unit. Emergency lighting or glow signage helps when regular lights go out.
Forgetting to include the station in emergency planning
Eye wash units must be part of evacuation and response plans. Workers should know when to go to the station versus when to exit the building. This is especially important in facilities with high-risk chemicals or production zones. Mixing the wrong response with the wrong moment leads to panic.
Letting the station get dirty or dusty
A dirty unit may not be used in time. Workers hesitate to place their face near rust, grime, or unknown residue. Cleaning should be part of daily or weekly checks. In dusty workspaces, covers or sealed designs protect the nozzles and bottles from build-up.
Not having a clear method for reporting faults
When someone finds an empty bottle or broken handle, they must know how to report it. If there’s no process, faults linger. A small tag, sign, or WhatsApp group helps flag the problem. This way, the next person doesn’t discover the problem too late.
Assuming people will speak up if they notice a problem
Some workers don’t report minor faults. Others assume someone else will fix it. This leads to broken stations sitting idle. Leaders must create a system where checks are routine, not reactive. Relying on memory or goodwill is a common mistake.
Leaving replacement parts out of reach
Some parts wear out bottle seals, covers, or even labels. If a part is missing, the unit might be skipped or forgotten. Keeping backup bottles or nozzles in a locked cabinet is helpful, but it must be accessible to the person doing the check. Don’t store spares so far away they’re never used.
Not checking expiry dates during shift handovers
Shifts change, but hazards stay the same. If no one checks the station during handovers, time-sensitive checks slip. Staff should include a visual inspection as part of every changeover. This doesn’t take long but adds a fresh set of eyes regularly.
Treating eye wash as just another tick-box item
When a station becomes part of compliance paperwork only, it fades into the background. Treating it like fire extinguishers checked, visible, and respected helps it stay useful. People won’t use what they don’t trust or see. Keeping the station front of mind means it’ll be used when it counts.