Product Overview

Summary: This High-Risk Chemicals Safe Operating Procedure provides a clear, practical framework for safely purchasing, storing, handling and disposing of hazardous chemicals in Australian workplaces. It helps businesses control serious chemical risks, meet WHS and environmental obligations, and protect workers, contractors and the public from exposure, spills, fires and toxic releases.

High-risk chemicals are widely used across Australian industry – from laboratories and manufacturing plants to maintenance workshops and utilities – and they carry the potential for fires, explosions, toxic exposures and environmental harm if not managed correctly. This High-Risk Chemicals Safe Operating Procedure sets out a structured, step-by-step approach to controlling these risks, from initial procurement and risk assessment through to storage, handling, transfer, use, spill response and waste disposal. It translates complex WHS and environmental requirements into clear, workable instructions that can be followed on the floor, not just in the office.

The SOP is designed to help businesses demonstrate due diligence under Australian WHS legislation by standardising how high-risk chemicals are identified, labelled, segregated, stored and used. It supports integration with your Safety Data Sheets (SDS), chemical registers and permits-to-work, and provides guidance on ventilation, incompatible substances, decanting, PPE selection, emergency equipment and first aid. By adopting this procedure, organisations can reduce the likelihood and consequence of chemical incidents, improve worker confidence around hazardous substances, and provide inspectors, clients and insurers with clear evidence of a robust chemical risk management system.

Key Benefits

• Ensure consistent, compliant processes for purchasing, storing, handling and disposing of high-risk chemicals across all sites.
• Reduce the likelihood of chemical spills, fires, explosions and toxic exposures through clearly defined controls and responsibilities.
• Strengthen compliance with WHS and environmental legislation by aligning day-to-day practices with Australian standards and Codes of Practice.
• Improve worker competence and confidence around hazardous chemicals through clear instructions linked to SDS and training.
• Provide defensible documentation to demonstrate due diligence during regulator inspections, audits, incident investigations and insurance reviews.

Who is this for?

• WHS Managers
• Laboratory Managers
• Production Managers
• Maintenance Supervisors
• Site Supervisors
• Chemical Storepersons
• Laboratory Technicians
• Health and Safety Representatives (HSRs)
• Facilities Managers
• Environmental and Compliance Officers

Hazards Addressed

• Exposure to toxic, corrosive or sensitising substances via inhalation, skin contact or ingestion
• Flammable and combustible liquid and vapour fires
• Explosions from incompatible chemical mixing or confined vapour ignition
• Chemical burns to skin and eyes from corrosive substances
• Acute and chronic health effects from carcinogenic, mutagenic or reproductive toxic chemicals
• Environmental contamination from spills, leaks and improper disposal
• Pressure build-up and container rupture due to temperature or reaction
• Fume and vapour accumulation in poorly ventilated areas
• Reactivity hazards from oxidising agents and unstable substances
• Manual handling injuries associated with moving drums, cylinders and chemical containers

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Classification of High-Risk Chemicals
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Chemical Procurement and Approval Process
• 6.0 Safety Data Sheets (SDS) and Chemical Register Management
• 7.0 Risk Assessment for High-Risk Chemicals (including Hierarchy of Control)
• 8.0 Storage Requirements and Segregation of Incompatible Chemicals
• 9.0 Labelling, Signage and Container Management
• 10.0 Handling, Transfer and Decanting Procedures
• 11.0 Personal Protective Equipment (PPE) Selection, Use and Maintenance
• 12.0 Ventilation, Engineering Controls and Safety Equipment
• 13.0 Transport of Chemicals Within the Workplace
• 14.0 Spill Prevention, Spill Response and Decontamination
• 15.0 Waste Management and Disposal of High-Risk Chemicals
• 16.0 Health Monitoring and Exposure Management (where required)
• 17.0 Emergency Preparedness, First Aid and Incident Reporting
• 18.0 Training, Induction and Competency Verification
• 19.0 Inspection, Monitoring, Audit and Review
• 20.0 Recordkeeping and Document Control

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulations 2011 – Hazardous Chemicals (Part 7.1)
• Safe Work Australia – Code of Practice: Managing risks of hazardous chemicals in the workplace
• Safe Work Australia – Code of Practice: Preparation of safety data sheets for hazardous chemicals
• Safe Work Australia – Code of Practice: Labelling of workplace hazardous chemicals
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace (for chemical transfer and dosing systems)
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 2243.10: Safety in laboratories – Storage of chemicals
• AS/NZS 2243.1: Safety in laboratories – Planning and operational aspects
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 2161 series: Occupational protective gloves
• AS 3780: The storage and handling of corrosive substances