Product Overview

Summary: This Flammable Materials Handling Safe Operating Procedure provides clear, practical guidance for safely storing, decanting, transporting and using flammable liquids, gases and solids in Australian workplaces. It helps businesses control ignition sources, prevent fires and explosions, and demonstrate compliance with WHS and dangerous goods requirements across workshops, warehouses, laboratories and construction sites.

Flammable materials are widely used across Australian industries, from fuels, solvents and adhesives to aerosols and laboratory reagents. Without a structured procedure, everyday tasks such as decanting, transferring, mixing or storing these substances can quickly escalate into serious fire or explosion incidents. This Flammable Materials Handling Safe Operating Procedure sets out a clear, step-by-step method for managing these risks, ensuring that ignition sources are controlled, storage is compliant, and workers understand exactly how to handle flammable substances safely.

Developed with Australian WHS legislation and dangerous goods requirements in mind, this SOP helps you translate complex regulatory obligations into practical workplace controls. It covers the full lifecycle of flammable materials—from delivery and receipt, segregation and storage, through to use, spill response and disposal. By implementing this procedure, your business can reduce the likelihood of fires, protect workers and visitors, and provide evidence of due diligence to regulators, insurers and clients. It also supports consistent training, so new and existing staff follow the same safe system of work regardless of location or shift.

Key Benefits

• Reduce the risk of fire and explosion incidents by standardising safe handling, transfer and storage of flammable materials.
• Ensure alignment with Australian WHS and dangerous goods requirements, supporting regulatory compliance and due diligence.
• Improve worker awareness of ignition sources, ventilation needs and incompatible substances to prevent unsafe practices.
• Streamline inductions and refresher training with a clear, step-by-step procedure that can be easily communicated and audited.
• Minimise business disruption, property damage and insurance exposure through robust controls and documented emergency response steps.

Who is this for?

• WHS Managers
• Health and Safety Representatives (HSRs)
• Site Supervisors
• Workshop Managers
• Warehouse and Storepersons
• Laboratory Managers and Technicians
• Maintenance Supervisors
• Construction Project Managers
• Facilities and Operations Managers
• Dangerous Goods Coordinators

Hazards Addressed

• Fire and explosion from flammable vapours and gases
• Ignition from static electricity, hot work, open flames and electrical equipment
• Inadequate ventilation leading to accumulation of flammable atmospheres
• Chemical burns, inhalation and skin/eye irritation from flammable liquids and aerosols
• Spills and leaks of flammable substances creating slip, fire and environmental hazards
• Incorrect storage or segregation of incompatible chemicals
• Manual handling injuries when moving containers, drums and cylinders
• Exposure to combustion products and smoke during an incident

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Flammable Materials
• 3.0 Roles, Responsibilities and Training Requirements
• 4.0 Hazard Identification and Risk Assessment for Flammable Materials
• 5.0 Storage Requirements and Segregation of Flammable Substances
• 6.0 Handling, Decanting and Transfer Procedures
• 7.0 Control of Ignition Sources and Static Electricity
• 8.0 Ventilation, Engineering Controls and Hazardous Areas
• 9.0 Personal Protective Equipment (PPE) Requirements
• 10.0 Labelling, Safety Data Sheets (SDS) and Signage
• 11.0 Transport and Internal Movement of Flammable Materials
• 12.0 Spill Management, Leak Response and Waste Disposal
• 13.0 Emergency Response, Fire Extinguishers and Evacuation Procedures
• 14.0 Inspection, Maintenance and Housekeeping Requirements
• 15.0 Training, Induction, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Hazardous Chemicals and General Risk and Workplace Management
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 60079 series: Explosive atmospheres (for hazardous area considerations)
• AS/NZS 2243.10: Safety in laboratories – Storage of chemicals (where applicable)
• AS 4332: The storage and handling of gases in cylinders