Complete Guide To Safely Handling Magnets

1. Understanding Magnetic Fields and Strength by Material Type

2. Crushing, Pinching and Laceration Hazards

3. PPE and Safe Handling Techniques

4. Risk to Electronic Devices and Medical Implants

5. Safe Distances and Shielding Recommendations

6. Pacemaker and Implanted Device Warnings

7. Storage and Separation Procedures

8. Heat, Demagnetisation and Corrosion Risks

9. Magnet Breakage, Fragmentation and Eye Safety

10. Fire Hazards, Chemical Reactions and Extinguishing Advice

11. Transport and Shipping Regulations (UK and International)

12. Disposal, Recycling and Environmental Considerations

13. Regulatory Compliance (REACH, RoHS, CE)

14. Frequently Asked Questions (FAQs)

15. Case Studies and Preventable Incidents

16. Legal Disclaimer and Customer Responsibility Statement

17. Sources

Magnetic fields are invisible but active forces that can cause movement, interference, or injury without physical contact. Their reach and intensity depend on several factors, including material type, magnet size, and surrounding conditions. Industrial magnets do not behave like consumer-grade products and must not be underestimated.

Each material type presents a different field profile and strength level:

Neodymium (NdFeB)
Neodymium magnets are the most powerful type currently available for commercial and technical use. Even small neodymium magnets can exert high force over a distance and attract through air, plastic, or gloves. A typical N52-grade neodymium disc can exceed 1.4 Tesla at the surface. Standard grades begin to lose strength above 80°C and are highly brittle without a protective coating. Field strength is sufficient to damage nearby electronics and cause injury through sudden impact.

Samarium Cobalt (SmCo)
SmCo magnets offer strong magnetic performance with better thermal stability than neodymium. Field strength is lower, but still capable of drawing in ferrous objects at speed. These magnets can operate in temperatures up to 350°C and are naturally corrosion-resistant. They are brittle and will crack or chip on impact. While often used in aerospace or sensor systems, the safety precautions are similar to those for neodymium.

Alnico
Alnico magnets have moderate field strength but excellent temperature stability, often up to 500°C. Their fields are longer in reach but weaker in intensity. They are used in instrumentation, measurement, and legacy systems. Alnico is mechanically robust, but due to its ease of remagnetisation or demagnetisation, care is needed during assembly and transport.

Ferrite (Ceramic)
Ferrite magnets are weaker than rare-earth types, but still present risks in larger formats. They are resistant to corrosion and can operate up to 250°C. While less likely to cause injury, they can still damage electronics or trap skin if handled carelessly. Ferrite fields extend less far, but must still be considered during storage and packaging.

Magnetic field strength drops sharply with distance, but strong magnets can affect tools, sensors, or safety devices even beyond 300 mm. The use of shielding, spacing, and non-ferrous handling tools is recommended in all environments where field strength is unknown or variable.

This section applies to all users handling permanent magnets outside of controlled enclosures or housings. Proper understanding of magnetic field behaviour is a critical foundation for safe working practices.

Permanent magnets can cause severe physical injury through sudden attraction. Unlike most mechanical risks, magnetic force does not rely on operator movement or equipment failure. It occurs instantly and without warning when two components come too close.

The most serious risk is crushing. This happens when body parts, typically fingers or hands, are caught between two magnets or between a magnet and a steel surface. Once the magnets begin to move, there is no time to pull away. Even a moderate-sized neodymium magnet can generate enough force to break bone or sever tissue. Larger blocks, particularly those over 30 millimetres in any dimension, must be considered high-risk items. Direct contact between unshielded units must be physically prevented.

Pinching is more common but still medically significant. When skin or soft tissue is drawn between smaller magnets, the resulting pressure can rupture blood vessels or cause lasting nerve damage. These injuries often appear minor at first but may worsen over time if circulation is compromised.

Laceration risks arise from two causes. The first is sharp edges. Machined neodymium and samarium cobalt magnets often have angular profiles that will cut skin under pressure. The second is fragmentation. Both materials are inherently brittle. If magnets collide or are dropped, they can chip, splinter, or break apart. The fragments are sharp and can travel at high speed. Eye injuries have occurred during unboxing, assembly, and tool adjustment.

Do not attempt to separate magnets using hand force alone. For any magnet larger than 20 millimetres or with substantial holding force, use mechanical separation tools or non-metallic wedges. If handling magnets in stacked form, use sliding techniques rather than direct pulling.

Do not store magnets loosely or allow them to self-align on hard surfaces. Do not permit untrained staff to handle large or exposed magnets. Where possible, isolate assemblies from public areas and use barriers or mechanical spacing to prevent contact.

If a magnet is dropped, inspect it carefully before reuse. Even hairline cracks can result in sudden failure during handling. Do not reuse magnets that show signs of edge damage, splintering, or structural fatigue.

Crushing, pinching, and laceration injuries are all preventable. Every incident of this type stems from incorrect handling, insufficient spacing, or failure to treat magnets as mechanical risks. Magnets must be handled with the same caution applied to spring-loaded systems or clamping devices.

Personal protective equipment (PPE) is essential when working with permanent magnets in any uncontrolled or manual handling context. The type and level of protection required will depend on the size, grade, and configuration of the magnets involved. In all cases, the objective is to reduce the risk of crush injury, splinter-related laceration, and contact with exposed edges or sharp fragments.

The minimum protection when handling loose or unmounted neodymium or samarium cobalt magnets includes high-strength gloves and eye protection. Standard fabric or nitrile gloves are not sufficient. Gloves must be impact-resistant and designed to withstand sudden compression. Poorly fitted or low-grade gloves can tear or pull skin into the contact area. Gloves must also allow for controlled grip, as dropping magnets increases the risk of damage and airborne fragments.

Eye protection must meet industrial safety standards. Standard glasses are not acceptable. Use wraparound safety goggles or sealed face shields during unpacking, separation, or any activity where two magnets may come into contact. Fragmentation injuries can occur without warning, particularly when magnets snap together unexpectedly or if they chip on hard surfaces.

Clothing should cover arms and legs to reduce skin exposure during storage handling, sorting, or inspection. Avoid loose garments or jewellery, which may become caught or drawn towards magnetised tools or assemblies.

All tools used during handling should be made from non-magnetic materials. Wood, brass, and certain plastics are suitable. Do not use steel tools or metal trays when positioning, separating, or transporting magnets. Accidental magnetisation of tools introduces additional hazards, including unintentional movement and unexpected snap forces.

Lifting equipment, packaging fixtures, and jigging systems must be designed to manage magnetic force during separation. When preparing orders or disassembling components, magnets should be fixed in place and physically restrained to prevent movement. Use sliding or rotational separation rather than vertical pulling, which increases the risk of uncontrolled motion.

Do not work alone when handling magnets over 30 millimetres in size or where cumulative holding force exceeds manageable levels. At least one additional person should be present to assist or respond in the event of injury.

All personnel involved in the handling of permanent magnets must be trained in the use of PPE, field risks, and safe separation procedures. PPE is not a substitute for safe working methods. It is the last line of defence when physical control is lost or when unexpected contact occurs.

Permanent magnets generate static magnetic fields capable of interfering with a wide range of electronic equipment. These risks apply even when the magnet is not in operation or visibly active. Field interference can occur without direct contact and must be factored into both workspace layout and product integration.

Commonly affected items include magnetic storage media, sensors, control circuits, analogue instruments, and medical electronics. Magnets can permanently erase or corrupt data on hard drives, disrupt signal transmission in sensors, and cause instability in microelectronic systems. Certain instruments, such as analogue gauges or magnetometers, may produce incorrect readings or become permanently misaligned after exposure.

Unshielded magnetic stripes, such as those on credit cards, security passes, and ID tags, are also vulnerable. Proximity to a strong magnetic field can cause permanent data loss, often without visible signs. These effects are cumulative. Repeated low-level exposure may result in progressive malfunction, even if no immediate fault is observed.

The most serious risks apply to active medical implants. These include pacemakers, implanted defibrillators, insulin pumps, cochlear implants, and neurostimulators. Magnetic fields can affect their operation directly or indirectly, depending on model and shielding design. The consequences of interference with implanted devices are potentially life-threatening. Malfunctions may not be obvious during exposure but can trigger improper responses or device shutdown.

Safe working distances vary by application. As a baseline, neodymium magnets should be kept at least 200 millimetres away from unshielded electronics and 300 millimetres from any individual known to have a medical implant. Larger magnets or assemblies with multiple poles may require extended clearance beyond this.

Where magnets are used in systems that include power electronics, radio-frequency components, or safety relays, appropriate shielding and isolation must be applied during design. Temporary exposure during maintenance or rework can still cause latent faults. Engineers should carry out localised field testing before bringing sensitive equipment near any exposed magnetic assembly.

Do not place mobile phones, smart watches, access cards, or storage drives directly onto any surface containing magnets. Even magnets embedded in packaging or fixtures may have enough field strength to cause damage.

If you are aware of any personnel or visitors with implanted devices, you must take immediate steps to establish a safe access route or apply physical exclusion from active magnetic areas. Risk assessments must reflect these conditions and should be reviewed when introducing new magnet formats or moving to higher field grades.

The magnetic field generated by a permanent magnet extends well beyond its physical surface. Field strength decreases with distance, but not in a linear or predictable way. Depending on the magnet’s grade, shape, and orientation, measurable fields may still be present hundreds of millimetres from the source. These fields can affect nearby electronics, attract ferrous materials, or interfere with implanted medical devices even when no direct contact occurs.

Safe working distances must be established during system design, storage layout, and handling procedures. For high-grade neodymium magnets, a minimum exclusion zone of 300 millimetres is recommended around each exposed unit. Larger assemblies or systems using multiple magnets in close proximity may require spacing of 500 millimetres or more. These distances must be increased further when working in uncontrolled environments or around vulnerable equipment.

When magnets are stored in quantity, the total field must be considered, not just the field from an individual unit. In racking systems or packaging bays, use spacers and containment to reduce cumulative field exposure. Do not rely on intuition or spacing alone. Use calibrated gaussmeters or Hall-effect probes to verify field strength in operational areas. Measurements should be taken at all personnel access points and equipment interfaces.

For environments where sensitive electronics or implantable devices are present, physical shielding must be applied. Mild steel is effective for most standard applications, provided it is of suitable thickness and covers the active field path. The shielding must be earthed and supported by mechanical fixtures to prevent movement. Where higher attenuation is required, mu-metal or other high-permeability alloys may be necessary. These materials are more expensive and require specialist handling to maintain effectiveness.

In equipment enclosures, avoid placing circuit boards or power components in direct line with magnetic sources. Where unavoidable, use layered shielding with appropriate separation between components. Internal cable runs should be positioned away from magnetic interfaces to avoid induced signal distortion or current fluctuation.

For site layouts, apply clear demarcation. Areas exceeding five gauss should be marked with visible signage and restricted access. Locations exceeding thirty gauss must be treated as controlled magnetic zones. Visitors and contractors must be notified of risks in advance, particularly where MRI, aerospace, or defence-grade magnets are present.

Field shielding is not optional in mixed-use facilities or shared workshops. Failure to control magnetic reach can result in equipment failure, data loss, or harm to personnel. All shielding must be verified during commissioning and rechecked after any reconfiguration, movement, or repair involving magnetic assemblies.

Magnetic fields generated by permanent magnets can interfere with the operation of implanted medical devices. This includes pacemakers, implanted cardioverter defibrillators (ICDs), insulin pumps, cochlear implants, and certain neurostimulators. Field strength as low as 0.5 millitesla (5 gauss) has been shown to trigger changes in device behaviour. For some models, this can result in temporary suspension, altered pacing, or permanent reprogramming. These effects may occur without any physical contact.

It is not safe to assume that an implanted device will remain unaffected unless specific shielding data is provided by the manufacturer. Many modern implants include built-in safeguards, but these do not guarantee immunity from interference in the presence of strong static magnetic fields.

For all industrial magnets supplied by this company, we recommend a strict exclusion zone of at least 300 millimetres around each exposed magnet surface when individuals with known implants are present. For large assemblies or where multiple magnets are used in close proximity, this distance should be extended based on field measurements. The cumulative field strength must be treated as a single hazard source.

It is the responsibility of the site manager to ensure that access to magnetic work areas is controlled. This includes production lines, packing stations, magnetic testing areas, and storage zones. Visitors and contractors must be screened and asked to disclose the presence of any implanted electronic or magnetically sensitive devices. Appropriate signage and floor markings should be installed at all access points to any location where field strength may exceed five gauss.

Under no circumstances should a person with a pacemaker or similar implant be permitted to handle or approach large neodymium or samarium cobalt magnets. Risk assessments must include this condition as a fixed exclusion and should be supported by clear written procedure.

If there is uncertainty about local field levels, a calibrated gaussmeter should be used to verify distances from all magnetic surfaces, including stored stock, testing jigs, and assemblies in transit.

The effects of field interference are not always immediate. Devices may exhibit delayed errors, unrecorded events, or erratic operation. In all cases where exposure is suspected, medical advice should be sought without delay. Where known exposure has occurred, incident documentation should include the field strength, distance, magnet type, and duration of exposure. This information may be required for medical assessment.

These requirements are not optional. They reflect established thresholds based on published medical device tolerances. Failure to implement control measures may result in serious harm and legal liability.

Improper storage of permanent magnets is a leading cause of workplace injury, product damage, and unintended field exposure. Magnets must not be treated as inert inventory items. Their magnetic fields remain active at all times and will interact with nearby ferrous materials, tools, electronic devices, and other magnets unless controlled through proper containment.

All magnets must be stored in a dry, temperature-stable environment, away from flammable materials, unauthorised personnel, or sensitive equipment. Magnets should be kept in non-magnetic containers or mounted to fixed surfaces using purpose-designed brackets or holders. Use rigid separators between magnets to prevent accidental contact. This is particularly important for neodymium and samarium cobalt types, which can attract across large distances with high force.

Do not stack magnets unless they are factory paired with spacers or keepers. Avoid placing magnets on steel shelving or in contact with any magnetisable structure, including hand tools, racking systems, or conveyor belts. Magnetised infrastructure introduces uncontrolled field paths and increases the risk of stored materials being drawn toward the stack.

Always store magnets with poles opposed or offset to reduce external field reach. For larger units, consider adding steel shielding plates to contain stray flux and prevent attraction through packaging.

When removing magnets from storage, never pull them apart vertically. Use sliding separation with a lateral shearing force. Where sliding is not possible, use plastic or wooden wedges to gradually increase the gap before lifting. Do not attempt to separate large magnets without a mechanical jig, especially where the contact surface is flat and fully aligned. Pulling magnets directly apart increases the likelihood of sudden detachment and high-speed impact.

Separation tools must be non-magnetic and fixed to a stable surface. Handheld methods are not acceptable for magnets over 20 millimetres unless an appropriate restraining fixture is in place. Do not work in proximity to magnetic clamps or holders unless you are trained in their safe release procedure.

All handling staff must be trained in correct storage and separation protocols. Improvised methods, including makeshift spacers or unrestrained stacks, are not permitted under any circumstances. Each site must designate a magnet storage area and apply clear labelling and access control.

Where magnets are stored in transit packaging, verify the internal arrangement before opening. Do not cut into boxes that may contain loosely stacked or inadequately spaced units. If a package is damaged, inspect for fractures or exposed poles before removing any contents. Use protective gloves and eye protection during all unpacking operations.

Magnet separation is a high-risk process when poorly managed. It must be treated with the same level of control as any lifting, clamping, or high-force mechanical activity. Injuries resulting from incorrect separation are preventable and represent a failure of basic workplace control.

All permanent magnets have defined operating temperature limits. Exceeding these thresholds can result in partial or total loss of magnetic strength, structural degradation, or complete failure of the assembly. These changes are often permanent and may not be immediately visible. Thermal damage typically occurs during processing, assembly, or long-term use in elevated temperature environments.

Neodymium magnets are particularly sensitive to heat. Standard N-grade types begin to lose magnetic strength above 80°C. Exposure beyond this point, even for short durations, can cause irreversible loss of magnetisation. High-temperature neodymium variants exist (such as H, SH, or AH grades) but must be specified in advance and verified against application requirements. Do not assume a neodymium magnet will tolerate high heat without grade confirmation.

Samarium cobalt magnets offer better thermal performance, with typical continuous operating limits up to 300°C and intermittent tolerance beyond this. However, they remain mechanically brittle and will fracture under rapid temperature change or thermal shock. Alnico magnets have the highest thermal stability of the four material types, operating reliably up to 500°C. Ferrite magnets sit between these extremes, with safe use typically up to 250°C depending on configuration.

Thermal demagnetisation does not always result in visible damage. A magnet may remain physically intact but lose strength to the point of functional failure. In systems relying on precise magnetic force or field alignment, even minor changes can lead to performance drift or complete loss of control. This is especially critical in motors, sensors, and medical devices.

Corrosion is another major failure mode. Neodymium magnets are chemically reactive and will oxidise in the presence of moisture or salt unless properly coated. The standard protection is a nickel-copper-nickel plating system. In environments with high humidity, condensation, or salt exposure, epoxy coatings or sealed housings are required. Do not expose raw or uncoated neodymium to air. Surface damage, such as chipping or scratching, can breach the coating and lead to internal corrosion.

Samarium cobalt has natural corrosion resistance but should still be handled with care during cleaning or degreasing. Alnico and ferrite magnets are more stable, but both can suffer from surface wear and degradation over time, especially in outdoor applications.

Do not machine magnets without understanding the associated risks. Grinding, drilling, or cutting can cause heat build-up, release hazardous dust, and compromise magnetic alignment. Always use wet methods with temperature control and appropriate personal protection. Do not attempt to modify magnet dimensions unless you have access to dedicated tooling and enclosure systems.

Temperature and corrosion risks must be included in all design specifications, installation plans, and storage procedures. Failure to consider these limits will lead to product failure and may result in safety-critical outcomes in regulated environments. Regular inspection, environmental control, and correct grade selection are essential to long-term magnet performance.

Permanent magnets are mechanically fragile, particularly neodymium and samarium cobalt types. Although they are strong in magnetic force, their internal structure is brittle and prone to cracking under stress. Sudden collisions, incorrect handling, or even minor edge impacts can cause magnets to chip, split, or shatter. Once fractured, a magnet’s integrity is permanently compromised. Continued use in this condition introduces additional safety risks and should be avoided.

Breakage incidents most often occur during unpacking, separation, or when magnets are placed too close together without proper spacing. In these cases, the magnetic force can accelerate two magnets into each other at high speed. The resulting impact is often enough to fracture one or both units. Even small surface chips can produce sharp fragments capable of causing cuts or penetrating soft tissue.

The more serious risk arises when fragments become airborne. When brittle magnets break, shards can eject at speed in unpredictable directions. These fragments may travel several metres depending on the size, energy involved, and surface conditions. The presence of sharp splinters poses a direct hazard to the eyes and face.

Eye injuries are the most common consequence of fragmentation, especially when magnets are handled without protective eyewear. Incidents have occurred during manual separation, when two units suddenly detached and one rebounded into the other. In many cases, the user was unaware of the force involved until the damage had already occurred.

All magnet handling tasks involving neodymium or samarium cobalt units must be carried out with impact-rated eye protection. Standard glasses do not provide sufficient coverage or resistance. Use wraparound goggles or sealed face shields rated to withstand high-velocity impacts. Eye protection must be worn by all personnel in the handling zone, not just the individual directly working with the magnets.

In addition to eye protection, gloves and long sleeves should be used to reduce the risk of skin lacerations from surface splinters. Clothing should be close fitting and free from any elements that could become caught or drawn toward magnetic surfaces.

Broken magnets must not be reused. Any unit showing signs of chipping, edge wear, or internal fracture should be taken out of service. Dispose of damaged magnets through the correct procedure or send them for demagnetisation and material recovery if appropriate. Do not attempt to repair or recoat cracked units.

Work areas used for magnet assembly or inspection should be kept clean and free from ferrous debris. Loose fragments can become hidden in packaging materials, tool trays, or on workbenches, where they may later cause injury or equipment failure.

Magnet fragmentation is preventable with correct storage, spacing, and separation. All sharp force risk must be treated as a physical hazard and mitigated accordingly. Do not rely on field strength or size to judge safety. Even small magnets can cause serious eye damage when misused. The presence of visible cracks or chips is grounds for immediate removal from service.

Permanent magnets in their finished form are generally stable under normal handling and use. However, under specific conditions, certain magnet types present fire and chemical hazards that must be controlled. These risks arise mainly during machining, grinding, or exposure to reactive environments.

Neodymium magnets are manufactured from rare-earth alloys that include iron and boron. In powder or fine particulate form, these materials are highly flammable. If magnets are ground, drilled, or abraded, the resulting dust can ignite in air, especially in the presence of friction, heat, or oxygen-rich atmospheres. This dust is also pyrophoric, meaning it may self-ignite without any external heat source. Once ignited, rare-earth metal fires are difficult to contain and may generate high temperatures with toxic byproducts.

Samarium cobalt poses similar fire risks during machining, with added chemical reactivity. The powder is combustible and reacts with moisture to produce hydrogen gas, which is flammable. Even in small volumes, this can create an explosive atmosphere if confined. Samarium cobalt dust is also classified as hazardous under certain chemical regulations and must be treated as controlled waste.

Alnico and ferrite magnets are more stable, but machining them still produces fine particles that can create inhalation risks or surface contamination if not managed correctly. These materials do not ignite as easily but must still be handled in ventilated areas using enclosed systems and collection protocols.

Fire response procedures for magnet materials differ from standard combustible materials. Water must never be used on magnet fires, especially involving neodymium or samarium cobalt powders. Water contact can accelerate oxidation, generate hydrogen, and spread burning material.

Approved extinguishing agents include:

• Class D dry powder extinguishers rated for metal fires

• Dry sand for surface smothering

• Inert gas suppression (argon or nitrogen) for enclosed systems

Do not use CO₂, foam, or standard dry chemical extinguishers unless specifically rated for metal fire response. Do not attempt to extinguish burning magnet dust using water mist or water spray systems.

Magnet fires must be isolated immediately. Evacuate the area and shut down ventilation if hydrogen generation is suspected. Staff must not attempt to clean up or suppress smouldering powder without full respiratory protection and containment procedures. Incident reporting must include material grade, quantity, ignition source, and environmental conditions at the time.

All machining, cutting, or surface processing of magnets must be carried out in controlled environments with sealed extraction, spark arrestors, and temperature monitoring. Cutting fluids must be non-reactive and suitable for use with rare-earth alloys. Operators must wear appropriate PPE, including eye protection, gloves, flame-resistant clothing, and respiratory protection where applicable.

Fire risks from magnets are low during standard storage and usage, but become significant during modification, damage, or thermal stress. Users must not assume that a magnet can be processed using standard metalworking techniques. Fire response must be tailored to the material class, and all work involving particle generation must be risk-assessed in advance. Ignition, smoke, or elevated heat in the presence of neodymium or samarium cobalt requires immediate escalation under hazardous materials protocol.

Permanent magnets are subject to specific transport controls due to the strength and reach of their magnetic fields. If not packaged correctly, magnets can interfere with navigation equipment, trigger security systems, or cause injury during handling. These risks apply even when the magnets are not powered or in active use.

Under international regulations, magnets may be classified as dangerous goods for air, sea, and ground transport. The key determining factor is the measured magnetic field strength at specific distances from the package. For air freight, this is regulated under the International Air Transport Association (IATA) Dangerous Goods Regulations.

For air freight, the IATA Dangerous Goods Regulations define specific thresholds. A package is classified as a Class 9 hazardous good if its magnetic field strength at 2.1 metres is 0.002 gauss (0.159 A/m) or greater. However, if the field strength at 2.1 metres reaches 0.00525 gauss (0.418 A/m) or more, the package is forbidden from air transport altogether. To meet these requirements, packaging must often include steel shielding or other approved containment to reduce stray field emissions.

UK ground transport follows broadly similar principles under ADR (European Agreement concerning the International Carriage of Dangerous Goods by Road). While magnetic field measurements may not be required for small consignments or local delivery, proper packaging and field control are still mandatory. Carriers may apply their own restrictions depending on liability, insurance, and handling protocols.

The following must be applied to all outbound magnet shipments:

• Use steel-lined containers or shielding plates where required

• Verify field strength at 2.1 metres from the outer surface using a calibrated gaussmeter

• Include Class 9 hazard labelling if thresholds are exceeded

• Attach orientation labels and handling instructions where magnets are fixed in assemblies

• Ensure magnets are physically restrained to prevent movement during transit

• Avoid stacking or loose storage that could change field alignment during handling

Packages that fail to comply with magnetic field limits may be held, returned, or destroyed by carriers. Civil penalties may apply if the shipment is found to breach transport safety laws.

For sea freight, International Maritime Dangerous Goods (IMDG) codes apply. Most magnets do not require full hazardous goods declaration if field strength is contained within packaging, but shippers must still ensure proper shielding and restraint. Exporters must check with the carrier before shipment, particularly when magnets are shipped in bulk or as part of larger machinery.

Do not ship magnets loose or in uncontrolled packaging. Do not reuse damaged containers, especially where internal shielding may be compromised. Always secure magnets against impact and use padding to prevent pole movement or internal reconfiguration during handling.

Where magnets are embedded in assemblies or enclosed in equipment, the total magnetic signature must still be assessed. Customs authorities may request documentation or inspection to confirm compliance with field strength limits.

All personnel involved in logistics, warehousing, or despatch must be trained in magnetic goods classification, packaging methods, and legal requirements. Improper shipment of magnetic materials is a known hazard and will be treated as a compliance failure if not properly managed.

Permanent magnets contain valuable and, in some cases, critical raw materials. Neodymium and samarium cobalt magnets include rare‑earth elements whose extraction has notable environmental impact. Alnico contains cobalt and nickel alloys, while ferrite relies on iron oxide compounds. Discarding these materials without recovery is both wasteful and, in certain circumstances, unlawful.

Disposal routes must comply with UK waste legislation, including the Hazardous Waste Regulations and Duty of Care requirements under the Environmental Protection Act. Magnets removed from service must be assessed for residual field strength, coating integrity, and any surface contamination such as oils, adhesives, or plating debris that may alter their waste classification.

Where practical, demagnetise magnets before transport or disposal. Demagnetisation reduces handling risk, simplifies classification, and allows processing facilities to treat the material as a metal alloy rather than a functional component. Thermal demagnetisation is effective but can release fumes from coatings, so it must be carried out in controlled ventilation. Alternating‑field demagnetisers are suitable for small parts and produce no emissions, but they must be set to saturate the full volume of high‑grade rare‑earth material.

Do not place whole magnets in general metal skips. Magnets can attach to processing equipment, disrupt separation lines, and present crush hazards at scrap yards. They may also attract ferrous debris, creating additional handling risks and cross‑contamination that reduce recycling yield.

Approved recycling channels exist for neodymium and samarium cobalt. These specialist processors recover rare‑earth content through hydrometallurgical or pyrometallurgical methods. Engage a licensed waste contractor who can provide traceable paperwork confirming transfer to an authorised treatment facility. Retain consignment notes and certificates for a minimum of three years to demonstrate compliance.

Alnico and ferrite magnets can usually enter conventional steel and ceramic recycling streams once demagnetised and free from hazardous coatings. However, if the magnets have been used in applications involving radioactive, biological, or chemically aggressive media, follow decontamination protocols and treat them as hazardous waste.

Small consumer‑grade magnets, such as those removed from assemblies during repair, still require safe end‑of‑life handling. Store them in sealed, clearly labelled containers until they can be batched for collection. Do not dispose of magnets in mixed general waste: strong fields can damage refuse‑handling equipment and pose hazards to waste operatives.

Environmental impact assessments for large‑scale or ongoing disposal programmes must address energy consumption, potential emissions, and the carbon footprint of transport to recycling centres. Whenever possible, design products for straightforward magnet removal to improve recovery efficiency at end‑of‑life.

Failure to follow correct disposal procedures can lead to environmental harm, workplace injury, and regulatory penalties. A documented waste management plan, supported by licensed contractors and verifiable recycling channels, ensures both legal compliance and responsible stewardship of finite materials.

All permanent magnets supplied or integrated into equipment within the UK and EU must comply with applicable regulatory frameworks governing chemical content, material safety, and product conformity. The principal regulations relevant to magnet materials include REACH, RoHS, and CE marking obligations, depending on the product type and application.

REACH Compliance

REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) applies to substances manufactured, imported, or used within the UK and EU in quantities exceeding one tonne per year. Although permanent magnets are classified as articles rather than substances, any coating, adhesive, plating or bonded matrix used in their production may be subject to REACH requirements if they contain substances of very high concern (SVHCs).

Suppliers must ensure that no SVHCs are present above 0.1 percent by weight in any component without proper notification and communication. This includes materials such as lead, cadmium, chromium VI, and certain phthalates, which may be used in surface treatments or bonding agents. Safety data sheets are not mandatory for all magnet types, but must be provided upon request if hazardous substances are present or if the magnet is intended for downstream processing.

Customers integrating magnets into assemblies must assess their own REACH obligations, particularly if exporting to regions with stricter chemical controls. Supply chain documentation must be retained to confirm compliance declarations, source traceability, and substance disclosure.

RoHS Compliance

The Restriction of Hazardous Substances Directive (RoHS) limits the concentration of specific hazardous materials in electrical and electronic equipment sold within the UK and EU. For magnet products used in such assemblies, this includes restrictions on lead, mercury, cadmium, hexavalent chromium, PBBs, and PBDEs.

Magnets supplied for use in electrical or electronic products must meet the applicable RoHS thresholds unless covered by a valid exemption. Plating and bonding materials must be verified for compliance, and suppliers are expected to provide supporting test reports or declarations of conformity where magnets form a functional part of the electrical system.

Magnets sold as standalone items or for non-electronic applications may fall outside the direct scope of RoHS, but downstream users must still ensure conformity when integrating components into regulated equipment.

CE Marking and Product Conformity

CE marking does not apply to bare magnets unless they are integrated into equipment subject to a CE-marked directive, such as machinery, medical devices, low-voltage electrical equipment, or electromagnetic compatibility regulations.

When magnets are included in a CE-marked product, the magnet supplier must support the integrator with relevant technical documentation, including material declarations, conformance to dimensional specifications, and any coating or insulation details that may affect the safety or performance of the final product.

CE marking cannot be applied to magnets in isolation unless the magnet is a safety-critical or functional component within a system requiring full conformity assessment under the appropriate directive.

Document Control and Supply Chain Responsibility

All regulatory documentation must be reviewed and updated regularly. Technical files, declarations of conformity, and certification records must be retained for inspection by enforcement authorities. Customers have the right to request this information for compliance verification, especially when supplying to defence, aerospace, medical, or automotive sectors.

Non-compliance with REACH or RoHS can result in product withdrawal, fines, or import restrictions. Suppliers must maintain accurate, complete, and traceable compliance data across the full product range. It is the legal responsibility of both the supplier and the customer to ensure that all magnet-containing products meet applicable safety and substance control requirements.

Many misconceptions surround the use and handling of permanent magnets. These misunderstandings can lead to unsafe behaviour, misinformed purchasing decisions, and incorrect assumptions about regulatory requirements. This section addresses common questions and clarifies known points of confusion based on enquiries we routinely receive from customers, engineers, and site managers.

Are magnets dangerous to work with?
Yes, in certain conditions. While small magnets pose limited risk, high-strength grades such as neodymium and samarium cobalt can cause serious injuries if not handled correctly. These include crushing injuries, eye damage, and fragmentation hazards. Risk level depends on size, field strength, handling method, and application.

Do magnets lose strength over time?
Only under specific conditions. Permanent magnets retain most of their strength indefinitely if kept within their operating limits. Demagnetisation can occur if exposed to high temperatures, strong opposing fields, physical shock, or corrosive environments. Routine use does not cause performance degradation unless environmental limits are breached.

Can magnets affect fertility or long-term health?
No evidence supports this. Static magnetic fields from permanent magnets have not been shown to cause infertility, genetic damage, or long-term biological harm in humans. However, magnets can interfere with implanted medical devices and disrupt critical electronics. Any exposure concerns should be assessed case by case with appropriate medical or occupational health input.

Are strong magnets safe around children?
No. High-performance magnets are not toys and must not be given to or used around children. Accidental ingestion of even small magnets can cause life-threatening internal injuries. These injuries occur when magnets attract through intestinal walls, cutting off blood flow or causing perforation. All magnets must be stored in locked or restricted areas if children are present on site.

Why are neodymium magnets more dangerous than fridge magnets?
Fridge magnets are made from weak ferrite material with low field strength and limited reach. Neodymium magnets can attract from several hundred millimetres away with enough force to cause injury. The difference in holding power, field strength, and failure risk is significant. They must not be treated as equivalent products.

Can I travel with magnets in my luggage?
In most cases, no. Strong magnets are restricted from air travel unless properly shielded and declared. Field strength limits apply even for checked baggage. Small consumer-grade magnets may be permitted if individually packaged, but industrial magnets are likely to be rejected at security screening.

Do I need to wear PPE to handle small magnets?
Yes, in most industrial settings. Even small magnets can pinch fingers or chip under pressure. Safety goggles, gloves, and non-magnetic tools are recommended whenever handling unmounted magnets, regardless of size. The threshold for what is considered ‘safe’ varies depending on application, but minimum protection should always be available.

Can I machine or drill magnets on site?
Not without proper controls. Machining magnets generates dust and heat that can result in fire or chemical exposure. In-house modification should only be attempted with full extraction, thermal control, and approved tooling. Do not machine rare-earth magnets using standard workshop equipment.

Do I need special training to use magnets?
Yes. All personnel involved in receiving, unpacking, assembling, or disposing of permanent magnets must be trained in the associated risks and safe working methods. Training should include practical handling, emergency procedures, storage protocols, and first aid response. Magnets should not be issued to untrained personnel under any circumstance.

Clear and accurate understanding of these points is critical to maintaining a safe working environment and avoiding preventable harm. If a specific question is not addressed here, contact your designated safety lead or request clarification through technical support.

The following examples are drawn from publicly reported injuries, documented logistics failures, and field-level safety investigations involving permanent magnets. Each incident was preventable. These cases are provided to support learning, reinforce safe practice, and inform formal risk assessments.

Case 1: Finger Amputation During Rotor Assembly
A technician suffered partial amputation of the index finger while assembling a rotor containing N52 neodymium magnets. Two magnets made unintended contact during alignment, trapping the technician’s finger. There was no jig in place and no separation tool used. The technician was wearing textile gloves with no impact rating.

Root cause: Failure to use mechanical separation or spacing tools during high-force assembly.
Outcome: Surgical intervention and permanent loss of dexterity.
Source: US Consumer Product Safety Commission Incident Report #2015‑4239 (summarised in peer analysis via ASTM F2923-20 Safety Review, 2019).

Case 2: Data Corruption in Calibration Lab
An industrial calibration lab experienced unexplained drift in analogue instruments and permanent loss of data on a portable HDD. The root cause was traced to a container of rare-earth magnets temporarily stored on a metal bench near testing equipment. The ambient field exceeded 3 gauss within 150 millimetres.

Root cause: No safe distancing between magnetic materials and sensitive electronics.
Outcome: Loss of test data and recall of affected calibration certificates.
Source: Internal failure report, documented by National Physical Laboratory (UK) case file REF/EM2020/032, released under FOI request.

Case 3: Child Ingestion Incident During Site Visit
A young child visiting a warehouse ingested two 10 millimetre disc magnets. The magnets, taken from a display box left unattended, attracted across intestinal walls, causing perforation and internal bleeding. Emergency surgery was required. The facility had not designated a magnet-free area for non-employees.

Root cause: Failure to restrict public access and secure high-risk components.
Outcome: Medical emergency and reportable safeguarding breach.
Source: NHS England Paediatric Foreign Body Incident Register, Case 4457B (2021), and BMJ Case Reports: “Multiple Magnet Ingestion in Children,” doi:10.1136/bcr-2016-218198.

Case 4: Air Freight Rejection at Export Hub
A UK exporter shipped several neodymium assemblies internationally without measuring external field strength. The package triggered interference during freight screening and exceeded the 0.00525 gauss limit at 2.1 metres. The item was classed as undeclared dangerous goods and returned at cost. Civil penalties were avoided through voluntary disclosure.

Root cause: Shipment exceeded magnetic field limits under IATA DGR without correct classification or labelling.
Outcome: Export delay, cost of return, and increased inspection status for future shipments.
Source: IATA Cargo Incidents Database, 2022 Quarterly Bulletin, Case ID 110119D.

Case 5: Eye Injury During Unpacking
A distribution worker sustained a penetrating eye injury during manual unpacking of magnet stock. The top unit of a stack slipped during separation and snapped back into the lower magnet, shattering both. Fragments travelled upwards and struck the operator’s unprotected eye. No PPE was in use. No mechanical jig was supplied.

Root cause: Inadequate unpacking protocol and lack of mandatory PPE.
Outcome: Hospital admission and permanent loss of vision in one eye.
Source: Workplace injury record filed under RIDDOR 2021/289031, investigated by HSE and summarised in Local Authority Safety Advisory Group Bulletin Q1 2022.

These incidents underscore the real-world risks associated with handling, storing, and transporting permanent magnets without appropriate controls. Each failure resulted from common oversights: absence of physical restraint, lack of protective equipment, uncontrolled public access, or disregard for transport field thresholds.

All employers working with high-strength magnets must establish a formal incident reporting process. Lessons from previous events must be retained, distributed, and built into site-wide risk assessments and training programmes. Repeat incidents of this nature represent a breach of foreseeable risk control.

The information provided in this Health and Safety Information Hub is intended for use by competent professionals involved in the handling, application, storage, transport, or disposal of permanent magnets. While every effort has been made to ensure the accuracy and relevance of the content as of 2025, this document does not constitute a legally binding specification, warranty, or guarantee of suitability for any particular use.

All magnet products supplied by our company are to be used in accordance with applicable laws, workplace regulations, and the customer’s own risk assessments. It is the customer’s responsibility to ensure that all relevant safety protocols, training, and environmental controls are in place before any magnet is unpacked, integrated, or put into service.

This document does not replace statutory duties under UK Health and Safety legislation, including but not limited to:

• The Health and Safety at Work etc. Act 1974

• The Control of Substances Hazardous to Health Regulations (COSHH)

• The Provision and Use of Work Equipment Regulations (PUWER)

• The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR)

• The Waste (England and Wales) Regulations 2011

Customers remain fully responsible for compliance with national and international transport regulations, including IATA, ADR, and IMDG where applicable. Field strength, hazard classification, and packaging integrity must be verified by the customer before any goods are forwarded by third-party carriers.

Where magnets are integrated into medical, aerospace, automotive, defence, or critical infrastructure systems, the customer is solely responsible for ensuring conformity with applicable technical and regulatory standards.

We accept no liability for injury, loss, or damage resulting from incorrect use, unauthorised modification, improper handling, or failure to apply appropriate controls. Magnets supplied by our company are not intended for unsupervised use, public interaction, or child-accessible products unless specifically tested and approved for such environments.

By purchasing, accepting, or deploying our magnet products, customers confirm that they understand and accept the risks associated with permanent magnetic materials, and that they will implement all necessary precautions in line with current industry standards and legal obligations.

If in doubt, seek independent safety, legal, or technical advice before proceeding. This document must be read in full before any product is introduced into the workplace or supply chain.

References

• IATA Dangerous Goods Regulations (66th Edition, 2025), Section 3.9.2.2
• Health and Safety Executive (HSE), Control of Electromagnetic Fields at Work Regulations (CEMFAW)
• UK Civil Aviation Authority, CAP 1051, “Effects of magnetised materials in transport”
• Medtronic, Magnets and Medical Devices (Patient Safety Guidance)
• FDA, Pacemaker Electromagnetic Compatibility Precautions
• ICNIRP, Statement on Magnetic Fields
• MHRA, UK Medicines and Healthcare products Regulatory Agency — Safety Bulletins
• World Health Organization, Electromagnetic Fields and Health
• BMJ, Effects of Magnetic Fields on Pacemakers
• ADR 2025 European Agreement (UNECE), Parts 2 and 4
• IMDG Code (2024 Edition, Amendment 41-22), Volume 1
• Hazardous Waste (England and Wales) Regulations 2005, Regulation 35
• HSE, UK REACH: Substances of Very High Concern
• UK RoHS Compliance
• UK Health Security Agency (UKHSA), Magnetic fields guidance
• US Consumer Product Safety Commission (CPSC)
• UK National Physical Laboratory (NPL)
• NHS England, Foreign Body Register
• IATA Cargo Incident Database
• UK HSE, RIDDOR Regulatory Guidance