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Laboratory Safety Risk Assessment

Laboratory Safety Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
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Laboratory Safety Risk Assessment

Product Overview

Identify and control organisational risks associated with Laboratory operations using this comprehensive Laboratory Safety Risk Assessment, focused on governance, planning, systems and control measures at a management level. This document supports executive Due Diligence, alignment with the WHS Act, and the reduction of organisational and operational liability across all laboratory activities.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Governance, Responsibilities and Consultation: Assessment of leadership obligations, allocation of WHS responsibilities, consultation arrangements with workers, and integration of laboratory safety into organisational WHS governance frameworks.
  • Laboratory Risk Management and Change Control: Management of systematic risk assessment processes, introduction of new equipment or procedures, and formal change control for new experiments, technologies and research programs.
  • Laboratory Design, Layout and Infrastructure: Evaluation of facility layout, segregation of incompatible activities, traffic flow, utilities, and infrastructure suitability to minimise exposure to laboratory hazards.
  • Engineering Controls and Fixed Plant: Assessment of autoclaves, sterilisers, testing rigs and other fixed plant for guarding, interlocks, maintenance, validation, and compliance with relevant engineering and pressure equipment standards.
  • Laboratory Equipment Management: Management of routine apparatus, glassware and small equipment, including selection, inspection, calibration, maintenance, and safe decommissioning processes.
  • Hazardous Chemicals and Laboratory Substances Management: Controls for chemical procurement, SDS management, labelling and decanting, segregation and storage, handling of carcinogens and sensitising agents, waste disposal, and chemical inventory systems.
  • Gas Systems and Oxygen Cylinder Management: Assessment of compressed gas systems, cylinder storage and handling, regulator selection, leak management, emergency shut-offs, and oxygen enrichment or depletion risks.
  • Ventilation, Fume Cupboards and Fume Hoods: Management of local exhaust ventilation, fume cupboard performance, airflow monitoring, maintenance and certification schedules, and suitability for specific laboratory processes.
  • Thermal, Flame and High-Energy Processes: Risk controls for Bunsen burners, ovens, furnaces, lasers, UV sources, high-voltage equipment and other ignition or high-energy sources, including fire and explosion risk management.
  • Information, Training, Competency and Supervision: Systems for induction, competency assessment, refresher training, supervision of students and visitors, and maintenance of training records for laboratory personnel.
  • Laboratory Access Control, Permits and Work Authorisation: Protocols for restricted access areas, visitor management, contractor controls, permit-to-work systems, and authorisation for high-risk or after-hours laboratory activities.
  • Personal Protective Equipment (PPE) and Laboratory Dress Standards: Selection, provision and enforcement of appropriate PPE, laboratory dress codes, fit-testing (where required), maintenance, and replacement policies.
  • Housekeeping, Storage and Manual Handling: Management of bench and floor housekeeping, storage of chemicals and equipment, manual handling of gas cylinders and heavy items, and prevention of slips, trips and falls.
  • Emergency Preparedness and Incident Management: Planning for spills, fires, gas leaks, exposures and equipment failures, including emergency equipment, drills, communication protocols and incident reporting and investigation.
  • Health Monitoring, Exposure Control and Ergonomics: Systems for exposure monitoring, health surveillance where required, ergonomic assessment of workstations and repetitive tasks, and management of fatigue and psychosocial risks in laboratory environments.

Who is this for?

This Risk Assessment is designed for Business Owners, Laboratory Directors, WHS Managers and Safety Officers responsible for planning, governing and overseeing laboratory operations across research, education, healthcare or commercial environments.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Governance, Responsibilities and Consultation
  • • Unclear allocation of WHS duties for laboratory managers, supervisors, technicians, contractors and students
  • • Lack of documented laboratory-specific WHS policies aligned with the WHS Act 2011 and WHS Regulation
  • • Inadequate consultation with workers, health and safety representatives and students on laboratory risks and changes
  • • Poor integration of laboratory WHS governance into broader organisational WHS management system
  • • Failure to monitor and review compliance with internal procedures for activities such as autoclaving, dissection, material testing and chemical handling
  • • Insufficient oversight of specialist high‑risk plant (industrial autoclaves, compression testing rigs, centrifuges, sterilisers, fume cupboards and fume hoods)
  • • Absence of formal laboratory safety committee or governance forum
2. Laboratory Risk Management and Change Control
  • • Inconsistent or informal risk assessments for laboratory activities such as science lab chemical handling, compression testing, material strength testing and mutual induction experiments
  • • Failure to identify hazards associated with new or modified plant such as industrial autoclaves, sterilisers, centrifuges and testing rigs
  • • Inadequate review of risk controls when introducing new substances, apparatus (e.g. spectrum discharge tubes, microscopes, incubators) or experimental methods
  • • No formal management of change process for refurbishment, new installations, or reconfiguration of benches, gas services or fume cupboards
  • • Reliance on generic risk documents not tailored to specific laboratories, class groups or research projects
  • • Poor documentation and version control of risk assessments, leading to outdated controls being applied
3. Laboratory Design, Layout and Infrastructure
  • • Poor laboratory layout causing congestion around fume cupboards, Bunsen burners, autoclaves, sterilisers and compression testing rigs
  • • Insufficient segregation of incompatible activities such as dissection, science lab chemical handling, destructive testing and microscopy work
  • • Inadequate bench space leading to cluttered work areas and unstable placement of laboratory glassware, microscopes, incubators and mutual induction apparatus
  • • Insufficient or poorly positioned emergency exits, safety showers, eye wash stations and fire equipment
  • • Inappropriate flooring or inadequate spill containment increasing slip and chemical exposure risks
  • • Insufficient ventilation or incorrectly designed airflows around fume cupboards, fume hoods and autoclaves
  • • Inadequate provision of secure storage for chemicals, gas cylinders and sensitive equipment
4. Engineering Controls and Fixed Plant (Autoclaves, Sterilisers, Testing Rigs)
  • • Industrial autoclaves and sterilisers lacking appropriate interlocks, pressure relief, guarding or automatic shut‑off, leading to explosion, scalding or crush injuries
  • • Failure of compression testing and material strength testing equipment resulting from inadequate engineering controls or maintenance
  • • Centrifuges operating without appropriate imbalance detection, lid interlocks or containment, causing ejection of rotors or samples
  • • Laboratory incubators, ovens and temperature resistance test rigs without over‑temperature protection or fail‑safe controls
  • • Use of non‑compliant electrical and mechanical equipment in wet or corrosive laboratory environments
  • • Inadequate calibration and verification of safety features, gauges and control systems on pressure and temperature equipment
5. Laboratory Equipment Management (Routine Apparatus and Glassware)
  • • Poorly maintained general laboratory equipment such as microscopes, mutual induction apparatus, spectrum discharge tubes and incubators leading to electric shock, burns or exposure to UV or high voltage
  • • Unsystematic management of laboratory glassware causing frequent breakages, sharps injuries and contamination
  • • Use of damaged or unsuitable glassware in temperature resistance tests, testing material strength or compression rigs, leading to shattering under load or heat
  • • Uncontrolled proliferation of small electrical devices with no test and tag program, increasing fire and shock risk
  • • Improper cleaning, storage and segregation of sharp dissection tools and fragile apparatus
6. Hazardous Chemicals and Laboratory Substances Management
  • • Inadequate system for identification, labelling and classification of chemicals used in science lab chemical handling, dissection preservation, material testing and cleaning
  • • Lack of current Safety Data Sheets (SDS) readily accessible in all labs where chemicals and laboratory substances are used
  • • Poor segregation and storage of incompatible chemicals, leading to potential fires, toxic gas generation or violent reactions
  • • Uncontrolled decanting of chemicals into unlabelled secondary containers during experiments and routine lab work
  • • Insufficient management of laboratory waste streams including sharps, contaminated glassware, chemical residues and biological materials
  • • Failure to assess and control exposure to hazardous substances generated during Bunsen burner use, destructive testing, spectrum discharge tubes or fume cupboard operations
7. Gas Systems and Oxygen Cylinder Management
  • • Improper securing and storage of oxygen and other gas cylinders used in science labs, increasing risk of cylinder falls or valve damage
  • • Inadequate system for leak detection, inspection and maintenance of gas lines feeding Bunsen burners, fume cupboards and other apparatus
  • • Use of incorrect regulators, hoses or fittings on oxygen and fuel gas cylinders
  • • Lack of procedural controls for cylinder transport within buildings and between storage and laboratory use areas
  • • Insufficient segregation of oxygen cylinders from combustible materials and incompatible gases
  • • Unclear emergency isolation locations for gas supplies in laboratories and preparation rooms
8. Ventilation, Fume Cupboards and Fume Hoods
  • • Use of fume cupboards and fume hoods that are not commissioned, tested or maintained to required performance standards
  • • Undocumented processes leading to inappropriate use of open benches instead of fume cupboards for volatile, toxic or corrosive substances
  • • Overloading of fume cupboards with equipment such as Bunsen burners, autoclave discharge, spectrum discharge tubes or material testing rigs, compromising containment
  • • Blocked or altered ventilation ducts affecting performance of local exhaust systems
  • • Lack of clear criteria defining what work must be conducted in fume cupboards, leading to inconsistent practices between staff and student cohorts
9. Thermal, Flame and High-Energy Processes
  • • Uncontrolled use of Bunsen burners near flammable materials, solvents, oxygen cylinders or combustible waste
  • • Inadequate oversight of hot surfaces and steam from autoclaves, industrial sterilisers, ovens and temperature resistance test rigs
  • • Lack of system controls for high‑energy tests such as destructive and material strength testing, leading to projectiles, fragment ejection or equipment failure
  • • Insufficient policies restricting the use of open flames, hot plates and heaters in crowded teaching laboratories
  • • No documented criteria for safe operating envelopes for temperature resistance tests and high‑temperature material experiments
10. Information, Training, Competency and Supervision
  • • Workers, students and visitors performing laboratory tasks without adequate induction or competency‑based training
  • • Reliance on informal on‑the‑job instruction rather than structured training for use of autoclaves, centrifuges, industrial sterilisers and material testing equipment
  • • Insufficient supervision of inexperienced users during activities such as dissection, destructive testing, chemical handling and Bunsen burner work
  • • Training materials not updated to reflect current plant, procedures or legislative requirements
  • • No system to verify competency prior to granting access rights to specific laboratories or high‑risk equipment
  • • Lack of documented training records, making it difficult to demonstrate compliance with WHS Act 2011 due diligence obligations
11. Laboratory Access Control, Permits and Work Authorisation
  • • Unrestricted access to laboratories by untrained staff, students, visitors or contractors
  • • High‑risk work (e.g. after‑hours experiments, destructive testing, oxygen cylinder changes, industrial autoclave operation) conducted without formal authorisation or permits
  • • Contractors performing maintenance on autoclaves, sterilisers, fume cupboards or gas systems without adequate understanding of laboratory hazards
  • • Lack of a clear sign‑in, sign‑out or lone worker system for out‑of‑hours laboratory activities
  • • Inadequate management of visiting school groups or public tours entering operational science labs
12. Personal Protective Equipment (PPE) and Laboratory Dress Standards
  • • Overreliance on PPE in place of higher‑order controls for chemical, thermal and mechanical hazards
  • • Inconsistent PPE requirements across different laboratories leading to confusion and non‑compliance
  • • Inadequate provision, maintenance and replacement of PPE such as safety glasses, face shields, lab coats, gloves and thermal protection for autoclave work
  • • No system to enforce minimum laboratory dress standards (closed footwear, long pants, tied‑back hair) for students and visitors
  • • Insufficient guidance on glove selection and compatibility with chemicals, biological agents and temperature extremes
13. Housekeeping, Storage and Manual Handling
  • • Poor housekeeping leading to cluttered benches, blocked access to emergency equipment and increased risk of spills and breakages
  • • Unsafe storage of heavy items such as gas cylinders, large glassware, centrifuge rotors and material samples at height
  • • Inadequate systems for managing accumulated waste, including broken glass, off‑cuts from testing specimens and contaminated consumables
  • • Manual handling of heavy or awkward items such as autoclave loads, compression testing components and liquid containers without mechanical aids or procedural controls
  • • Uncontrolled storage of personal belongings and bags in laboratory work areas, creating trip hazards and contamination risks
14. Emergency Preparedness and Incident Management
  • • Lack of integrated emergency response plans for chemical spills, fires, gas leaks, electrical incidents and equipment failures in laboratories
  • • Inadequate drills or exercises for laboratory‑specific emergencies involving autoclaves, oxygen cylinders, Bunsen burners or destructive tests
  • • Unclear roles and responsibilities for first aiders, wardens and laboratory supervisors during incidents
  • • Insufficient access to and maintenance of first aid kits, spill kits and emergency decontamination facilities
  • • Under‑reporting of near misses and minor incidents, leading to missed opportunities for system improvement
15. Health Monitoring, Exposure Control and Ergonomics
  • • Failure to identify tasks requiring health monitoring under WHS Regulation, such as exposure to certain chemicals, biological agents or noise
  • • Inadequate systems to manage cumulative exposure to solvents, disinfectants, preservatives and combustion products from Bunsen burners
  • • Extended microscope use, repetitive pipetting and static postures at benches leading to musculoskeletal disorders
  • • Inadequate control of thermal stress for tasks involving autoclaves, ovens, incubators and high‑temperature test rigs
  • • Lack of confidential reporting mechanisms for early signs of overuse injuries or sensitivity to laboratory substances
16. Documentation, Records and Continuous Improvement
  • • Critical laboratory WHS documents such as risk assessments, procedures, maintenance records and training logs being incomplete, outdated or inaccessible
  • • Lack of systematic review of laboratory WHS performance metrics, audit findings and action completion
  • • Inconsistent application of lessons learned from incidents across different laboratories within the organisation
  • • Overly complex or poorly written procedures leading to non‑compliance or work‑around practices
  • • Failure to demonstrate due diligence and compliance during regulatory inspections due to poor recordkeeping

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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 safe chemical handling, storage and use.
  • Model Code of Practice – Labelling of Workplace Hazardous Chemicals: Labelling and identification requirements for hazardous substances.
  • Model Code of Practice – Managing the Work Environment and Facilities: Guidance on laboratory work environment, amenities and facilities.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines.
  • AS/NZS 2243 Safety in Laboratories (series): Standards for general laboratory safety, chemical safety, microbiology, and physical containment.
  • AS/NZS 2243.8: Safety in laboratories – Fume cupboards.
  • AS 4332: The storage and handling of gases in cylinders.
  • AS 1940: The storage and handling of flammable and combustible liquids.
  • AS 4775: Emergency eyewash and shower equipment.
  • AS/NZS 1715 & AS/NZS 1716: Selection, use and maintenance of respiratory protective equipment.
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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