I had posted in another thread about safety. I am not wishing to antigonize anyone with my opinions along those lines. However, I do have a question about what seems to be is issue in this thread. The original poster was concerned about minimizing all possible exposures. There has been some discussion about the severity or necessity or operating in a middle ground of accepting some level of exposure.
I feel this post is implying that a low level chemical exposure and a death are causally related. Perhaps the poster could correct me if my condensation of the post has altered the meaning of the post and to describe the manner in which the accident occurred.
My experience suggests that accidents pose a greater risk than low levels of exposure (depending on the chemicals). I am not advocating that it is okay to swim in a bathtub of acetone or any other common chemical. Organic chemicals always possess a danger that is similar to gas in the house or flour in a flour mill. I don't know of anyone being directly injured by a low level exposure to methane or flour, yet they can be lethal.
I understand your differentiation between lab accidents and protection from chemical exposure. Both are important pillars in laboratory safety, but there is a fair amount of overlap. From personal experience, people either have overall good safety habits or they don't. Slopiness in one area often extends into the other.
Hence, the first line of defense against chemical exposure, either acute or chromic, are appropriate and effective engineering controls. The second line of defense are good administrative procedures and training regarding chemical handling. The very last line of defense is PPE. If there is low level, chronic chemical exposure, it is necessary to make sure the airborn concentration is maintained below legal limits, depending on one's jurisdiction. For a research lab, and this is just my opinion, there needs to be increased sensitivity to chronic exposure because the biological effects of many of the materials are unknown. With today's technology, there is no reason proper ventilation cannot be engineered into laboratories and storage systems installed that do not vent into to lab.
To your specific point, low level chemical exposure in the lab can cause serious health effects. What is written on an MSDS as a hazard is there because it is a known effect, not a hypothetical argument. There is plenty of precident where low level, chronic expsosures have caused health problems, and, as you mentioned, depend largely on the chemicals involved. But it also depends on the individual and their sensitivity. I have worked with people that have become sensitized to acrylics from low level, chronic exposure. One wiff of fumes in the lab and he becomes covered in bright red rashes. Isocyanates, a common material used in bulk to make polyurethanes, has caused pulmonary problems from low level, airborn exposure. One other person I know lost a percentage of lung function from that because they had an unusually high sensitivity to that material and the airborn concentration was below legal limits. When I was a grad student, there was one professor that allegedly developed an allergy to platinum!
One of the administrative controls that I personally do not like where I'm at is that we have to maintain an annual list of all the chemicals I've handled and sign off saying I've read and understood the MSDS. It's a pain to have to do, but my employer does it to protect themselves from liability and can state that we were provided the information on how to safely handle the chemical.
I am aware that many chemists see it as a necessity that they will experience chemical exposure during their careers. However, that does not excuse them from trying to prevent exposure nor from cutting corners for the sake of an experiment. It also does not absolve their supervisors and their facilities from legal liability should chemical exposure cause health problems.