BlueSafe
Hazardous Chemical Storage Handling and Disposal Risk Assessment

Hazardous Chemical Storage Handling and Disposal Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
  • • Pre-filled Content – Ready to Deploy Immediately
  • • Customisable – Easily Add Your Logo & Site Details
  • • Includes 2 Years of Free Compliance Updates

Hazardous Chemical Storage Handling and Disposal Risk Assessment

Product Overview

Identify and control organisational risks associated with Hazardous Chemical Storage, Handling and Disposal through a structured, management-level WHS Risk Management framework that supports planning, policy, training and system design. This Risk Assessment helps demonstrate Due Diligence under the WHS Act, reducing operational liability and supporting defensible organisational compliance.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Governance, Policy and Legal Compliance: Assessment of organisational WHS responsibilities, chemical safety policies, consultation arrangements and verification of compliance with WHS and Dangerous Goods legislation.
  • Hazardous Chemicals Inventory and Lifecycle Management: Management of chemical registers, procurement controls, stock rotation, lifecycle tracking and elimination/substitution opportunities to minimise chemical risk at source.
  • Hazard Identification, SDS and Material Safety Data Management: Systems for identifying hazardous chemicals, ensuring current Safety Data Sheets are accessible, and integrating SDS information into risk controls, training and emergency planning.
  • Labelling, Signage and Hazard Communication: Protocols for compliant container labelling, GHS classification, storage area signage, and communication of chemical hazards to workers, contractors and visitors.
  • Storage System Design, Segregation and Dangerous Goods Management: Assessment of storage locations, racking, bunding, ventilation, segregation of incompatible substances and Dangerous Goods class controls across warehouses, workshops and laboratories.
  • Chemical Handling Systems, Transfer and Mixing Controls: Management of decanting, pumping, dosing, mixing and transfer systems, including selection of suitable equipment, engineering controls and procedures to prevent spills, releases and cross-contamination.
  • Health Risk Management, Exposure Controls and Monitoring: Evaluation of acute and chronic health risks, airborne and dermal exposure pathways, hierarchy of controls, PPE programs, health surveillance and atmospheric monitoring where required.
  • Training, Competency and Supervision for Chemical Management: Determination of competency requirements, induction content, refresher training programs and supervision arrangements for personnel involved in chemical storage, handling and disposal.
  • Waste Chemicals, Hazardous Material Removal and Disposal Systems: Management of hazardous waste segregation, containment, labelling, temporary storage, transport arrangements and engagement of licensed waste contractors in line with regulatory requirements.
  • Emergency Planning, Spill Response and Decontamination: Development of emergency procedures, spill control strategies, decontamination processes, first aid provisions and integration with site emergency response plans and external services.
  • Inspection, Maintenance and Hazardous Area Integrity: Programs for routine inspections, preventative maintenance of storage and handling equipment, integrity of bunds and tanks, and management of hazardous areas (including ignition source controls).
  • Contractor, Visitor and Third-Party Management: Controls for informing and managing contractors, transport providers and visitors who may be exposed to hazardous chemicals on site, including permit systems and interface coordination.
  • Change Management and Process Safety for Chemical Systems: Formal assessment of changes to chemicals, plant, processes or layouts, including Management of Change (MOC) procedures, pre-start reviews and process safety considerations.
  • Monitoring, Reporting, Audit and Continuous Improvement: Systems for incident and near-miss reporting, KPI monitoring, internal audits, corrective actions and periodic review of chemical risk controls to drive continuous improvement.

Who is this for?

This Risk Assessment is designed for Business Owners, Safety Managers, Operations Managers and HSE Advisors responsible for planning, approving and overseeing hazardous chemical storage, handling and disposal activities across their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Governance, Policy and Legal Compliance
  • • Lack of a documented hazardous chemicals policy aligned with WHS Act 2011 and WHS Regulations
  • • Failure to identify and classify all hazardous chemicals and dangerous goods held on site
  • • Inadequate awareness of Australian Standards and relevant Codes of Practice for hazardous chemical storage and handling
  • • No system to review legislative changes or updated exposure standards for harmful substances, including nano-materials and heavy metals
  • • COSHH-style controls not adapted correctly to Australian WHS framework and classification systems
  • • Poor integration of chemical safety into broader WHS management system and risk registers
2. Hazardous Chemicals Inventory and Lifecycle Management
  • • Incomplete or inaccurate hazardous chemicals inventory across all areas and properties
  • • Unrecorded storage of chemicals, heavy metals, nano-materials, or contaminated materials on remote or seldom-used sites
  • • Inability to track chemical quantities, locations, expiry dates and container status
  • • Uncontrolled introduction of new chemical products (including lab reagents, cleaning products and industrial chemicals) without prior assessment
  • • Failure to identify chemicals that become more hazardous with age (e.g. peroxides, degraded containers, unstable compounds)
  • • Poor visibility of waste chemicals, oil disposal streams, and decommissioned containers awaiting disposal
3. Hazard Identification, SDS and Material Safety Data Management
  • • Absence of current Safety Data Sheets (SDS) / Material Safety Data Sheets for hazardous chemicals on site
  • • Out-of-date SDS not reflecting current health hazard information or revised exposure standards
  • • Inadequate review of SDS information prior to use, mixing or storage of chemicals and toxins
  • • Failure to consider acute risks (e.g. accidental ingestion, inhalation, skin contact with irritants, corrosive burns) and chronic exposures (e.g. heavy metals, nano-materials)
  • • No documented process to assess hazardous substances detection equipment selection and calibration requirements
  • • Inadequate translation of SDS information into local procedures, signage, and emergency response plans
4. Labelling, Signage and Hazard Communication
  • • Unlabelled or incorrectly labelled chemical containers, including decanted substances and interim storage vessels
  • • Illegible or damaged labels on drums, IBCs or laboratory containers
  • • Inconsistent labelling standards between suppliers, leading to confusion over hazard classes
  • • Lack of clear signage for chemical stores, hazardous areas and waste chemical accumulation points
  • • Failure to provide warning information for hazardous area certified works and maintenance of hazardous area instrumentation
  • • Workers unable to quickly identify hazards associated with liquid nitrogen, dry ice, mercury, nano-materials and other specialised substances
5. Storage System Design, Segregation and Dangerous Goods Management
  • • Improper storage of dangerous goods onsite leading to fire, explosion or toxic release
  • • Inadequate segregation of incompatible substances (e.g. oxidisers with flammables, acids with alkalis, reactive metals with water)
  • • Inappropriate storage conditions for liquid chemical storage, storing harmful liquids and liquid nitrogen (ventilation, temperature, containment)
  • • Insufficient design of bunding and spill containment for bulk liquid storage and oil disposal handling
  • • Overcrowded storage areas making it difficult to keep hazardous substances secure and access emergency equipment
  • • Uncontrolled storage of hazardous substances on picking lines or within production equipment without risk-based layout
6. Chemical Handling Systems, Transfer and Mixing Controls
  • • Uncontrolled transferring of hazardous substances from one storage vessel to another without appropriate engineering controls
  • • Manual handling of harmful liquids and powders resulting in splashes, spills or inhalation exposures
  • • Unsafe mixing of chemical compounds due to inadequate procedures, leading to heat, gas generation or violent reactions
  • • Improper handling of dry ice, liquid nitrogen and other cryogens causing cold burns or asphyxiation
  • • Working with mercury, other heavy metals and nano-materials without appropriate containment and ventilation
  • • Use of non-hazardous area rated equipment in hazardous areas when handling volatile chemicals
7. Health Risk Management, Exposure Controls and Monitoring
  • • Exposure to harmful substances via inhalation, ingestion, skin contact or eye contact
  • • Workers handling potentially hazardous materials without appropriate protection or controls
  • • Underestimation of chronic health risks from long-term low-level exposures (e.g. solvents, heavy metals, nano-materials)
  • • Inadequate consideration of vulnerable workers or those with pre-existing health conditions
  • • Absence of health monitoring programs where required (e.g. lead, isocyanates, certain organic solvents)
  • • Failure to recognise or report early symptoms of chemical exposures
8. Training, Competency and Supervision for Chemical Management
  • • Lack of competency in dealing with hazardous substances at a property or across multiple sites
  • • Inadequate training in recognising chemical hazards, SDS interpretation and COSHH-style risk controls adapted to Australian context
  • • Supervisors unable to identify unsafe practices in handling chemicals and toxins or hazardous material removal
  • • Specialist tasks (e.g. inertisation process, hazardous area certified works, maintenance of hazardous area instrumentation, working with nano-materials) performed by unqualified personnel
  • • Contractors and labour hire workers not inducted in site-specific chemical risks and emergency arrangements
  • • Insufficient refresher training leading to drift from established control measures
9. Waste Chemicals, Hazardous Material Removal and Disposal Systems
  • • Improper disposal of chemicals or other hazardous wastes leading to environmental contamination and regulatory breaches
  • • Uncontrolled accumulation of waste chemicals, contaminated material and oil disposal containers
  • • Inappropriate processing of contaminated material without prior risk assessment for unexpected contaminants
  • • Removal of hazardous materials (including asbestos by others, mercury, heavy metals, nano-materials) without competent contractors and controls
  • • Lack of traceability for hazardous waste consignments and disposal manifests
  • • Failure to segregate incompatible waste streams, increasing risk of reaction in waste storage areas
10. Emergency Planning, Spill Response and Decontamination
  • • Delayed or ineffective response to spills, leaks or chemical releases
  • • Lack of coordinated response to skin contact with irritants, accidental ingestion or inhalation of toxic vapours
  • • Insufficient planning for dealing with unexpected contaminants during maintenance or processing contaminated material
  • • Inadequate decontamination facilities and procedures for personnel, tools, vehicles and affected work areas
  • • Emergency plans not accounting for specific hazards such as cryogens, nano-materials, heavy metals and reactive chemicals
  • • Poor communication with emergency services and neighbours in the event of a significant chemical incident
11. Inspection, Maintenance and Hazardous Area Integrity
  • • Degraded containment systems (bunds, tanks, pipework, valves) increasing likelihood of leaks and spills
  • • Failure of hazardous area certified equipment leading to ignition of flammable atmospheres
  • • Inadequate maintenance of hazardous area instrumentation affecting detection and control of hazardous atmospheres
  • • Bypassing or disabling of safety interlocks, level controls and gas detection systems
  • • Lack of periodic inspection of emergency systems (detection, alarms, ventilation, inertisation systems)
  • • Corrosion, UV damage or wear of chemical storage infrastructure not detected in time
12. Contractor, Visitor and Third-Party Management
  • • Contractors conducting hazardous chemicals work without adequate understanding of site-specific risks and controls
  • • Insufficient oversight of third parties who bring hazardous substances onto site or remove hazardous materials
  • • Visitors inadvertently entering hazardous areas or chemical storage zones without awareness of risks
  • • Inadequate coordination between site and contractor emergency plans for chemical incidents
  • • Lack of clarity regarding legal duties and interfaces between PCBUs in shared workplaces
  • • Contractor work methods conflicting with site procedures for storage, handling and disposal of chemicals
13. Change Management and Process Safety for Chemical Systems
  • • Uncontrolled changes to chemical types, concentrations or suppliers leading to unforeseen incompatibilities or exposures
  • • Modifications to plant, piping or storage configurations without reassessment of hazardous area classification or containment capacity
  • • Introduction of new technologies (e.g. nano-materials, new reagents) without structured risk assessment
  • • Operational changes affecting inertisation processes or ventilation performance not formally reviewed
  • • Failure to revalidate risk controls following significant incidents or near misses related to chemical exposures
  • • Inadequate stakeholder consultation when changing waste management, chemical removal or decontamination methods
14. Monitoring, Reporting, Audit and Continuous Improvement
  • • Chemical incidents, near misses and exposures not reported or analysed, leading to repeat events
  • • Lack of performance indicators for hazardous chemicals management (e.g. spills, non-compliant storage, SDS gaps)
  • • Infrequent or superficial inspections failing to detect systemic weaknesses in chemical controls
  • • Complacency over time resulting in drift from procedures, especially in routine tasks on picking lines or laboratories
  • • No structured review of chemical risk assessments following organisational or regulatory changes
  • • Missed opportunities to adopt safer substitutes or improved engineering controls

Need to add specific hazards for your workplace?

Don't worry if a specific hazard isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom hazards at no extra cost. We take care of the hard work—creating the risk ratings and control measures for free—to ensure your document is compliant within minutes.

Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Managing Risks of Hazardous Chemicals in the Workplace – Code of Practice: Guidance on identifying, assessing and controlling risks from hazardous chemicals.
  • Preparation of Safety Data Sheets for Hazardous Chemicals – Code of Practice: Requirements and guidance for SDS content and availability.
  • Labelling of Workplace Hazardous Chemicals – Code of Practice: Requirements for GHS-compliant labelling of hazardous chemicals.
  • Managing Risks of Hazardous Chemicals in the Workplace (Safe Work Australia): National guidance on chemical risk management and control measures.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS 1940:2017: The storage and handling of flammable and combustible liquids.
  • AS/NZS 3833:2007: The storage and handling of mixed classes of dangerous goods in packages and intermediate bulk containers.
  • AS/NZS 2243 (Series): Safety in laboratories – requirements for chemical storage, handling and emergency facilities where laboratory environments are involved.
  • Australian Dangerous Goods (ADG) Code: Requirements for classification, packaging, marking and transport of dangerous goods by road and rail.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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Safe Work Australia Aligned