Product Overview

Summary: This Chemical Risk Assessment and Control SOP provides a clear, step-by-step framework for identifying, assessing, and controlling chemical hazards in Australian workplaces. It helps businesses meet their WHS obligations, reduce exposure risks, and implement consistent, defensible controls across all chemical-handling activities.

This Chemical Risk Assessment and Control Safe Operating Procedure is designed for Australian workplaces that use, store, handle or generate hazardous chemicals, from manufacturing and laboratories through to maintenance workshops and service businesses. It provides a structured, repeatable method for identifying chemical hazards, assessing the level of risk, and selecting appropriate control measures in line with the hierarchy of control. The SOP guides users through reviewing Safety Data Sheets (SDS), understanding GHS classifications, evaluating exposure scenarios, and documenting risk ratings that stand up to internal and external scrutiny.

By implementing this procedure, businesses can move beyond ad‑hoc chemical handling practices and establish a consistent, organisation-wide approach to chemical risk management. The SOP helps you demonstrate due diligence under Australian WHS legislation, support safe work method statements (SWMS), and integrate chemical risk controls into day‑to‑day operations, procurement, storage, and emergency planning. It is particularly valuable for organisations looking to rationalise their chemical inventory, reduce reliance on high‑risk substances, and provide clear guidance for workers, supervisors and contractors who interact with hazardous chemicals on site.

Key Benefits

• Ensure a consistent, documented approach to chemical risk assessment across all work areas and sites.
• Reduce the likelihood of chemical exposures, spills, fires and health effects through well-chosen control measures.
• Demonstrate compliance with Australian WHS legislation and hazardous chemicals requirements during audits and inspections.
• Streamline the review of Safety Data Sheets and translation of technical information into practical workplace controls.
• Support informed decisions about chemical substitution, elimination and safer product selection at the procurement stage.

Who is this for?

• WHS Managers
• Health and Safety Representatives (HSRs)
• Laboratory Managers
• Production Supervisors
• Maintenance Supervisors
• Facilities Managers
• Site Managers
• Chemical Store Coordinators
• Laboratory Technicians
• Operations Managers
• Risk and Compliance Managers
• Small Business Owners handling hazardous chemicals

Hazards Addressed

• Exposure to hazardous vapours, mists, gases and fumes
• Skin and eye contact with corrosive or irritant chemicals
• Inhalation of toxic, sensitising or carcinogenic substances
• Flammable and combustible liquid and vapour risks
• Reactive and incompatible chemical mixing hazards
• Environmental contamination from chemical spills and leaks
• Improper storage leading to fire, explosion or container failure
• Chronic health effects from repeated low-level exposures
• Manual handling risks associated with chemical containers
• Inadequate labelling and unidentified decanted chemicals

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations (including GHS and key chemical terms)
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Chemical Inventory Management and Information Requirements (SDS, labels)
• 6.0 Chemical Hazard Identification Process
• 7.0 Chemical Risk Assessment Methodology and Risk Matrix
• 8.0 Selection of Control Measures (Hierarchy of Control)
• 9.0 Specific Control Measures for Storage, Handling and Use
• 10.0 Requirements for Decanting, Labelling and Transfer of Chemicals
• 11.0 Personal Protective Equipment (PPE) Selection and Use
• 12.0 Health Monitoring and Exposure Surveillance (where applicable)
• 13.0 Emergency Preparedness and Response for Chemical Incidents
• 14.0 Training, Induction and Competency Requirements
• 15.0 Consultation, Communication and Worker Involvement
• 16.0 Review, Monitoring and Continuous Improvement of Chemical Controls
• 17.0 Recordkeeping and Document Control (risk assessments, SDS, training)
• 18.0 Appendices – Sample Chemical Risk Assessment Form and Worked Examples

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variations)
• Work Health and Safety Regulations 2011 – Hazardous Chemicals (Parts 7.1 and 7.2)
• 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 2243.10: Safety in laboratories – Storage of chemicals
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 60079 series: Explosive atmospheres (where flammable vapours may be present)
• Globally Harmonized System of Classification and Labelling of Chemicals (GHS) as adopted in Australia