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Epoxy Resins Flooring Risk Assessment

Epoxy Resins Flooring 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

Epoxy Resins Flooring Risk Assessment

Product Overview

Identify and control organisational risks associated with Epoxy Resins Flooring through a structured, management-level WHS Risk Management process that focuses on planning, governance, and system design rather than task-by-task work instructions. This Risk Assessment supports compliance with the WHS Act, strengthens Due Diligence for officers, and helps protect your business from operational and legal liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance, Legal Compliance and WHS Duties: Assessment of officer due diligence, PCBU responsibilities, consultation duties, and the integration of epoxy flooring risks into the organisation’s WHS management system.
  • Procurement and Supply Chain Management of Epoxy Systems: Management of supplier selection, product specification, pre-qualification, and verification that epoxy resins, hardeners and additives meet regulatory and performance requirements.
  • Hazardous Chemicals Identification, SDS and Labelling Systems: Systems for chemical classification, Safety Data Sheet availability, decanting controls, container labelling and worker access to up-to-date hazard information.
  • Risk Management, Planning and Design of Epoxy Flooring Works: Strategic planning of work methods, substrate preparation, curing times, access controls, sequencing with other trades and environmental conditions to minimise WHS and quality risks.
  • Training, Competency and Supervision Systems: Frameworks for competency assessment, task-specific training, induction, supervision levels and verification of contractor and employee capabilities for epoxy flooring activities.
  • Ventilation, Air Quality and Exposure Control Systems: Evaluation of natural and mechanical ventilation, airborne contaminant monitoring, control of vapours and fumes, and engineering controls in enclosed or poorly ventilated areas.
  • Personal Protective Equipment and Respiratory Protection Programs: Selection, fit testing, maintenance and management of PPE and RPE suitable for epoxy resins, solvents and associated tasks, including storage and replacement protocols.
  • Health Monitoring, Medical Surveillance and Worker Health Management: Policies for pre-employment screening, ongoing health monitoring, management of sensitisation and dermatitis risks, and referral pathways for medical review.
  • Storage, Handling and Waste Management Systems: Controls for bulk and day-use storage, segregation of incompatible substances, spill management, waste classification, disposal arrangements and environmental protection obligations.
  • Contractor Management and Multi-PCBU Coordination: Systems for contractor pre-qualification, information sharing, interface risk management and coordination of epoxy flooring works where multiple PCBUs operate on the same site.
  • Emergency Preparedness, Incident Response and First Aid: Planning for chemical spills, fire, exposure incidents, eye and skin contact, including emergency equipment, evacuation procedures and first aid response protocols.
  • Monitoring, Review, Consultation and Continuous Improvement: Processes for inspections, audits, incident investigations, worker consultation, corrective actions and periodic review of epoxy flooring risk controls and policies.

Who is this for?

This Risk Assessment is designed for Business Owners, Directors, Safety Managers and Project Managers responsible for planning, approving and overseeing epoxy resin flooring works within their organisation or on client sites.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, Legal Compliance and WHS Duties
  • • Lack of clear governance structure for epoxy flooring works leading to non-compliance with WHS Act 2011 and WHS Regulation
  • • Failure to identify and document epoxy resin works as hazardous chemical use in the PCBUs WHS management system
  • • Inadequate consultation with workers and health and safety representatives about epoxy flooring systems and associated health risks
  • • Absence of documented due diligence by Officers in relation to hazardous chemicals, airborne contaminants and respiratory sensitisers
  • • Poor integration of contractor management for epoxy installers into existing WHS governance systems
  • • No process to review legislative or standards changes relating to epoxies, isocyanates and silica dust
2. Procurement and Supply Chain Management of Epoxy Systems
  • • Procurement of epoxy resins, hardeners and solvents without WHS review, resulting in uncontrolled introduction of hazardous chemicals
  • • Selection of products with unnecessary levels of volatile organic compounds (VOCs), isocyanates or sensitisers due to cost-driven purchasing decisions
  • • Incomplete or missing Safety Data Sheets (SDS) from suppliers, or SDS not compliant with current Australian requirements
  • • Supply of incompatible or low-quality PPE, respiratory protection or ventilation equipment not suited to the selected epoxy system
  • • Inadequate consideration of curing times, off-gassing and ventilation requirements during product selection, leading to prolonged exposure risks
  • • No process to verify that suppliers and subcontractors have robust WHS and chemical management systems
  • • Bulk purchasing and storage of large quantities of epoxy systems without considering storage, segregation, spill containment and expiry dates
3. Hazardous Chemicals Identification, SDS and Labelling Systems
  • • Epoxy resins, hardeners, solvents and thinners not correctly identified or registered as hazardous chemicals
  • • Outdated, inaccessible or missing SDS for epoxy components at the point of use
  • • Inconsistent or non-compliant container labelling, including decanted or mixed products, creating a risk of misuse or incompatible mixing
  • • Workers and contractors not familiar with critical health hazard information such as sensitisation, carcinogenicity or chronic respiratory effects
  • • Failure to identify secondary hazards such as flammability, explosion risk in confined spaces and incompatible materials
  • • No centralised hazardous chemicals register covering all epoxy systems used across sites
4. Risk Management, Planning and Design of Epoxy Flooring Works
  • • Inadequate preliminary risk assessment for epoxy flooring projects, particularly regarding ventilation, confined spaces and adjacent occupancy
  • • Failure to consider design and planning options that could eliminate or reduce epoxy use or exposure durations
  • • Poor integration of epoxy flooring risks into project WHS plans and construction methodologies
  • • Overlapping activities and trades in the same area increasing exposure to fumes, vapours and sensitising agents
  • • Inadequate planning for segregation, exclusion zones and curing periods, resulting in building occupants or other workers being exposed
  • • No formal assessment of fire, explosion or electrical risks in areas where flammable epoxy solvents or vapours may accumulate
5. Training, Competency and Supervision Systems
  • • Workers and contractors applying epoxy flooring without adequate training in hazardous chemical handling, health risks and control measures
  • • Supervisors lacking competency to monitor compliance with ventilation, PPE and exposure controls
  • • Inconsistent induction processes leading to variable understanding of epoxy-specific risks across sites
  • • No verification of competency for specialised tasks such as respiratory protection use, fit checking and confined space work associated with some epoxy applications
  • • Informal, undocumented on-the-job training that fails to cover chronic health risks such as sensitisation and occupational asthma
  • • Limited understanding among workers of early signs and symptoms of epoxy-related health effects and required reporting pathways
6. Ventilation, Air Quality and Exposure Control Systems
  • • Inadequate general and local ventilation leading to accumulation of epoxy vapours and solvents above safe exposure levels
  • • No system for assessing and monitoring airborne contaminants, particularly in enclosed or semi-enclosed areas
  • • Reliance on natural ventilation without verification that it meets exposure control requirements
  • • Failure to consider interaction between ventilation systems and other building services, potentially spreading contaminants to occupied areas
  • • Insufficient planning for maintaining ventilation during curing phases when off-gassing continues
  • • No system to identify when respiratory protection must be upgraded due to inadequate ventilation
7. Personal Protective Equipment and Respiratory Protection Programs
  • • Inadequate or incorrect selection of gloves, coveralls, eye protection and respiratory protective equipment (RPE) for the specific epoxy system
  • • No formal respiratory protection program, leading to poor fit, maintenance and use of RPE
  • • Failure to manage facial hair, fit-testing and seal checks for tight-fitting respirators
  • • PPE policies not integrated with training, supervision and disciplinary procedures
  • • Insufficient supply, cleaning and replacement systems for contaminated PPE, leading to dermal exposure and cross-contamination
  • • No system for ensuring visitors or occasional workers entering epoxy work zones are appropriately protected
8. Health Monitoring, Medical Surveillance and Worker Health Management
  • • Lack of health monitoring for workers who may be exposed to epoxy sensitisers, solvents and respiratory irritants
  • • Delayed identification of occupational asthma, dermatitis or sensitisation related to epoxy exposure
  • • No formal process for assessing fitness for work for individuals with pre-existing respiratory or skin conditions
  • • Inadequate recording and follow-up of health complaints, symptoms or medical restrictions related to epoxy work
  • • Insufficient communication between the PCBU, treating medical practitioners and occupational health providers regarding epoxy-related risks
9. Storage, Handling and Waste Management Systems
  • • Inappropriate storage of epoxy components and solvents leading to leaks, spills, incompatible chemical reactions or fire risk
  • • No formal system for controlling access to epoxy storage areas, resulting in untrained personnel handling hazardous products
  • • Poor management of mixed but unused epoxy, contaminated containers and solvent waste
  • • Inadequate spill preparedness, including lack of spill response plans, materials and training
  • • Environmental contamination risks from incorrect disposal practices or uncontrolled wash-down of equipment
10. Contractor Management and Multi-PCBU Coordination
  • • Inconsistent control standards where epoxy flooring works are performed by external contractors under multiple PCBUs
  • • Lack of clarity regarding which PCBU controls specific risks such as ventilation, exclusion zones and after-hours access
  • • Inadequate exchange of information about epoxy products, SDS, health risks and site-specific conditions between host PCBU and contractors
  • • Contractors using unapproved products or methods that do not align with the host PCBU’s WHS management system
  • • Poor coordination of scheduling and access, leading to simultaneous occupancy and uncontrolled exposure of other workers or building users
11. Emergency Preparedness, Incident Response and First Aid
  • • Lack of specific emergency procedures for epoxy-related incidents such as large spills, acute inhalation exposure or skin/eye contact
  • • Inadequate first aid provisions, including eyewash facilities and skin decontamination resources in epoxy work areas
  • • Workers and supervisors unaware of appropriate responses to over-exposure, allergic reactions or respiratory distress
  • • No structured process for investigating and learning from epoxy-related incidents, near misses or health complaints
  • • Insufficient coordination with building management, emergency services and neighbouring tenants regarding potential epoxy emergencies
12. Monitoring, Review, Consultation and Continuous Improvement
  • • Static WHS management approach with no ongoing review of epoxy-related risks and controls
  • • Lack of worker consultation leading to under-reporting of health concerns, near misses and practical issues with controls
  • • Insufficient performance indicators and data analysis for epoxy exposures, incidents and compliance with controls
  • • Failure to incorporate lessons learned from internal and external incidents, audits and regulatory guidance into epoxy management systems
  • • No systematic review of the suitability of products and technologies as safer alternatives become available

Need to add specific hazards for your workplace?

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Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Model Code of Practice – How to Manage Work Health and Safety Risks: Guidance on systematic risk management processes.
  • Model Code of Practice – Managing Risks of Hazardous Chemicals in the Workplace: Requirements for storage, handling and use of hazardous chemicals including epoxy systems.
  • Model Code of Practice – Preparation of Safety Data Sheets for Hazardous Chemicals: Standards for SDS content and accessibility.
  • Model Code of Practice – Labelling of Workplace Hazardous Chemicals: Requirements for correct labelling of epoxy resins, hardeners and related products.
  • AS/NZS ISO 45001:2018: Occupational health and safety management systems – Requirements with guidance for use.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS 1319: Safety signs for the occupational environment, supporting hazard communication and emergency information.
  • AS/NZS 1715 & AS/NZS 1716: Selection, use and maintenance of respiratory protective equipment and performance requirements.
  • AS/NZS 2161 Series: Occupational protective gloves – Guidance on hand protection against chemicals and resins.
  • AS 1940: The storage and handling of flammable and combustible liquids, where applicable to solvent-containing epoxy systems.
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

$79.5

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