Product Overview

Summary: This Adhesive and Sealant Application Safe Operating Procedure sets out a clear, safe and consistent method for handling, mixing and applying adhesives and sealants across Australian workplaces. It controls chemical, fire and manual handling risks while lifting the quality and durability of finished work, helping you meet WHS obligations and manufacturer specifications every time.

Adhesives and sealants are used daily across construction, manufacturing, maintenance and fit‑out work, yet they often involve flammable, corrosive or sensitising chemicals that can create significant health and safety risks if applied incorrectly. This SOP provides a structured, step‑by‑step process for planning, preparing and carrying out adhesive and sealant tasks, from checking Safety Data Sheets (SDS) and ventilation through to surface preparation, application techniques, curing, clean‑up and waste disposal. It is written specifically for Australian workplaces and aligns with WHS legislation, helping duty holders demonstrate that they have implemented safe systems of work for hazardous substances.

By implementing this procedure, businesses can drastically reduce incidents such as skin and eye contact with chemicals, inhalation of vapours, fire and explosion from flammable products, and musculoskeletal injuries from awkward or repetitive application work. At the same time, the SOP drives consistent workmanship by standardising how substrates are prepared, how products are mixed and applied, and how environmental conditions (temperature, humidity, moisture) are checked and recorded. This gives supervisors a practical tool for training new workers, auditing current practices and evidencing compliance to regulators, principal contractors and clients across Australia.

Key Benefits

• Reduce chemical exposure risks by mandating correct PPE, ventilation and handling of adhesives and sealants.
• Improve installation quality and product performance through standardised surface preparation and application techniques.
• Ensure compliance with Australian WHS laws and hazardous chemicals requirements, supported by SDS‑driven controls.
• Minimise fire and explosion risks when using flammable or solvent‑based products in confined or occupied spaces.
• Streamline worker training and supervision with a clear, repeatable process that can be easily rolled out across multiple sites.

Who is this for?

• Site Supervisors
• Construction Project Managers
• Maintenance Supervisors
• Manufacturing Team Leaders
• Shopfitters
• Carpenters and Joiners
• Flooring Installers
• Glaziers
• Automotive and Marine Technicians
• WHS Managers and Advisors

Hazards Addressed

• Skin and eye irritation or burns from contact with adhesives and sealants
• Inhalation of hazardous vapours, mists or aerosols from solvent‑based or reactive products
• Fire and explosion risks from flammable or combustible adhesives and sealants
• Respiratory sensitisation and asthma from isocyanates and other reactive chemicals
• Allergic contact dermatitis from repeated skin exposure
• Slips, trips and falls from spilled or excess product on floors and access ways
• Manual handling and repetitive strain injuries from awkward application postures and heavy containers
• Environmental contamination from incorrect disposal of waste product and contaminated packaging

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Legislation and Applicable Standards
• 3.0 Definitions and Types of Adhesives and Sealants
• 4.0 Roles and Responsibilities
• 5.0 Hazard Identification and Risk Assessment
• 6.0 Required PPE and Safety Equipment
• 7.0 Product Selection, SDS Review and Storage Requirements
• 8.0 Pre‑Start Checks and Work Area Preparation
• 9.0 Surface Preparation and Compatibility Verification
• 10.0 Mixing, Decanting and Dispensing Procedures
• 11.0 Application Methods (Cartridge, Bulk, Spray and Two‑Part Systems)
• 12.0 Ventilation, Atmospheric Monitoring and Hot Work Controls
• 13.0 Curing, Setting Times and Protection of Work Area
• 14.0 Housekeeping, Spill Management and Waste Disposal
• 15.0 Health Monitoring and Exposure Reporting
• 16.0 Emergency Procedures (Exposure, Fire, Spills)
• 17.0 Training, Competency and Authorisation Requirements
• 18.0 Inspection, Monitoring and Continuous Improvement
• 19.0 Document Control and Record Keeping

Legislation & References

• Model Work Health and Safety Act and Regulations (as implemented in each state and territory)
• Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace Code of Practice
• Safe Work Australia – Labelling of Workplace Hazardous Chemicals Code of Practice
• Safe Work Australia – Preparation of Safety Data Sheets for Hazardous Chemicals Code of Practice
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 1337.1: Personal eye protection
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 4501 series: Occupational protective clothing
• AS/NZS ISO 45001: Occupational health and safety management systems – Requirements with guidance for use