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Flammable Liquids, Solvents and Adhesives Risk Assessment

Flammable Liquids, Solvents and Adhesives Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
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Flammable Liquids, Solvents and Adhesives Risk Assessment

Product Overview

Identify and control organisational risks associated with flammable liquids, solvents and adhesives through a structured, management-level WHS risk management approach that supports safe planning, procurement, storage and use across your operations. This Risk Assessment helps demonstrate due diligence under the WHS Act, reducing organisational exposure to prosecution, insurance disputes and operational liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Governance, Policy and Compliance Frameworks: Assessment of organisational WHS responsibilities, chemical safety policies, roles, and verification of compliance with WHS legislation and relevant Australian Standards.
  • Hazardous Chemical Inventory & SDS Management: Management of chemical registers, GHS classification, Safety Data Sheet currency, accessibility and alignment with on-site products and processes.
  • Procurement, Substitution and Supplier Controls: Evaluation of purchasing practices, lower-risk substitution opportunities, supplier competence, and pre-approval processes for new flammable liquids and solvents.
  • Storage, Segregation and Inventory Control: Assessment of dangerous goods segregation, flammable and combustible liquid storage design, cabinet and store compliance, quantity limits and stock rotation systems.
  • Handling, Decanting and Transfer Systems: Management of decanting procedures, bonding and earthing, transfer equipment selection, spill containment and controls for ignition sources during liquid handling.
  • Ventilation, VOCs and Vapour Exposure Control: Evaluation of local exhaust and general ventilation, vapour accumulation risks, atmospheric monitoring and controls for volatile organic compound exposures.
  • Combustible Dust, Hot Work and Explosion Risk: Assessment of combustible residues, hot work permitting, hazardous area classification, and explosion prevention and protection strategies.
  • Plant, Equipment and Maintenance for Chemical Handling: Management of pumps, hoses, containers, dispensing systems, static control devices and preventative maintenance programs for chemical and fuel handling plant.
  • Worker Competency, Training and Supervision: Review of induction, task-specific chemical safety training, supervision levels and competency verification for personnel working with flammable liquids and solvents.
  • Work Procedures, Permits and Administrative Controls: Development and governance of documented work instructions, permit-to-work systems, access controls and scheduling to minimise concurrent high-risk activities.
  • Exposure Monitoring, Health Surveillance and Indoor Environment: Management of personal exposure monitoring programs, health surveillance requirements and indoor environmental quality where chemicals are used or stored.
  • Emergency Preparedness, Spill Response and Fire Protection: Evaluation of spill kits, emergency plans, fire protection systems, alarm and evacuation procedures, and liaison with emergency services.
  • Waste Management and Environmental Controls: Controls for solvent-contaminated rags, chemical waste segregation, storage and disposal, and prevention of environmental releases to air, soil and water.
  • Contractor and Visitor Chemical Safety Management: Assessment of contractor pre-qualification, inductions, permits and supervision for chemical-related tasks, and protection of visitors in hazardous areas.
  • Incident Reporting, Investigation and Continuous Improvement: Systems for capturing near misses and incidents, root cause analysis, corrective actions, and ongoing review of chemical risk controls and performance.

Who is this for?

This Risk Assessment is designed for Business Owners, Operations Managers, Safety Managers and WHS Advisors responsible for planning, approving and overseeing activities involving flammable liquids, solvents and adhesives across their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Governance, Policies and Legislative Compliance
  • • Absence of a documented WHS policy for hazardous chemicals including flammable liquids, solvents and adhesives
  • • Inadequate alignment of procedures with WHS Act 2011, WHS Regulations and relevant Australian Standards (e.g. AS/NZS 1940, AS 1940, AS/NZS ISO 45001)
  • • Lack of clear allocation of PCBU, Officer and Worker duties regarding management of flammable and combustible substances
  • • Inadequate process for identifying, assessing and reviewing risks associated with flammable liquids, solvents, sealants, hot-melt adhesives and combustible dusts
  • • Failure to consult workers and Health and Safety Representatives (HSRs) on chemical safety arrangements and changes
  • • Inadequate change management when new solvent-based materials, adhesives, fuels or vehicular fluids are introduced
  • • Poor integration of chemical safety with other management systems (quality, environment, procurement, maintenance)
2. Hazardous Chemical Inventory, Classification and SDS Management
  • • Incomplete or inaccurate inventory of flammable liquids, combustible liquids, solvents, adhesives, sealants, dyes, pigments and vehicular fluids
  • • Failure to identify chemicals that present fire, explosion, toxic, corrosive or environmental hazards (e.g. VOCs, alcohol-based solvents, polymer solutions, bonding agents)
  • • Lack of current Safety Data Sheets (SDS) accessible for all hazardous chemicals on site
  • • Use of decanted containers without proper labelling for solvent-based materials and chemical adhesives
  • • Inability to verify compatibility of stored chemicals, leading to possible violent reactions or ignition
  • • Uncontrolled introduction of new chemicals without prior hazard review
3. Procurement, Substitution and Supplier Management
  • • Procurement of highly flammable or toxic solvents, sealants, bonding agents and adhesives where safer alternatives exist
  • • Sourcing chemicals from suppliers who do not provide compliant SDSs or technical support
  • • Bulk purchasing causing storage of quantities that exceed design limits for flammable and combustible liquids
  • • Inadequate consideration of VOC emissions, indoor air quality and explosion risk in product selection
  • • Lack of purchasing controls leading to unauthorised or incompatible products entering the workplace
4. Storage, Segregation and Inventory Control of Flammable and Combustible Liquids
  • • Improper storage of inflammable substances including fuels, alcohol-based solvents, volatile organic compounds and solvent-based adhesives
  • • Overstocking of flammable liquids beyond cabinet or store room design capacity
  • • Inadequate segregation of incompatible chemicals (e.g. oxidisers, corrosives) from flammables and combustible dust sources
  • • Lack of spill containment and bunding leading to pool fires, vapour spread or environmental contamination
  • • Defective or non-compliant flammable liquid cabinets and outdoor stores
  • • Poor housekeeping around storage areas leading to accumulation of combustible packaging, solvent-soaked rags and dust
  • • Insufficient control of ignition sources in and near chemical storage areas
5. Handling, Decanting and Transfer Systems for Flammable Liquids and Solvents
  • • Uncontrolled manual decanting of solvents, fuels, brake fluid and vehicular fluids leading to spills, vapour release and fire risk
  • • Inadequate earthing and bonding creating potential for electrostatic discharge ignition during transfer of flammable liquids or polymer solutions
  • • Use of non-conductive, damaged or incompatible hoses, funnels and containers
  • • Insufficient procedures for handling solvent-based materials, sealants and bonding agents when mixing and applying
  • • Lack of equipment such as closed transfer systems and drum pumps, increasing splash and vapour exposure
6. Ventilation, Indoor Air Quality and Control of VOC and Vapour Exposures
  • • Inadequate ventilation when applying solvents, chemical adhesives, sealants, dyes, pigments and paints leading to build-up of VOCs and flammable vapours
  • • Failure to manage indoor air quality, particularly in enclosed or poorly ventilated areas, vehicle workshops and spray application zones
  • • Potentially explosive atmospheres arising from accumulation of vapours from alcohol-based solvents and volatile substances
  • • Relying solely on natural ventilation without assessment of adequacy for the volume and type of chemicals used
  • • Lack of monitoring for vapour concentrations where high-use solvents are present
7. Combustible Dust, Hot Work and Explosion Risk Management
  • • Accumulation of combustible dust from dried paints, pigments, polymer powders and other fine combustible materials
  • • Inadequate control of ignition sources in areas where combustible dust or vapours may be present, leading to potentially explosive atmospheres
  • • Lack of effective extraction systems to remove combustible dust from mixing, sanding or cutting processes involving coatings and sealants
  • • Poorly managed hot work (welding, grinding, cutting) near flammable liquids, combustible dust deposits or solvent vapours
  • • No documented process for managing risk of explosion in areas where explosive atmospheres may form
8. Plant, Equipment and Maintenance for Chemical and Fuel Handling
  • • Use of non-compliant or poorly maintained plant for handling fuels, vehicular fluids, brake fluids and industrial solvents
  • • Failure of pumps, valves, hoses and seals leading to leaks, atomisation and ignition risk
  • • Inadequate inspection and maintenance of adhesive application equipment, hot melt systems and mixing vessels
  • • Lack of preventive maintenance on extraction systems, fire protection systems and emergency shut-off devices
  • • Use of inappropriate electrical equipment in areas where flammable vapours or explosive atmospheres are possible
9. Worker Competency, Training and Supervision for Chemical Safety
  • • Lack of competency in safe handling of flammable liquids, combustible liquids, volatile organic compounds and chemical adhesives
  • • Insufficient training on interpreting SDSs, labels and risk assessments for solvent-based materials and sealants
  • • Inadequate understanding of explosion risks associated with combustible dust and potentially explosive atmospheres
  • • Poor supervision of new or young workers when working with harmful substances, paints, hot melt adhesives and solvents
  • • No verification of competency for persons performing high-risk tasks such as solvent mixing, polymer solution preparation or brake fluid handling
10. Work Procedures, Permits and Administrative Controls
  • • Absence of documented procedures for applying solvents and chemical adhesives, including sealants and bonding agents
  • • Inconsistent practices across shifts and contractors, increasing likelihood of unsafe handling of volatile substances and harmful paints
  • • Lack of permits or formal controls for high-risk work such as hot work near flammable substances, confined space work involving solvents, or large-volume solvent extraction tasks
  • • Poor integration of chemical safety considerations into job planning and scheduling, leading to concurrent incompatible activities
11. Personal Exposure Monitoring, Health Surveillance and Indoor Environment Management
  • • Chronic exposure to VOCs, toxic adhesives, solvents, dyes and pigments due to inadequate monitoring
  • • Failure to identify health effects such as respiratory irritation, dermatitis or sensitisation from working near harmful substances and paints
  • • Insufficient control of indoor air quality where solvent and sealant use is frequent or prolonged
  • • No mechanism to track exposure histories for workers regularly handling hazardous adhesives and polymer solutions
12. Emergency Preparedness, Spill Response and Fire Protection
  • • Uncontrolled spills of flammable liquids, vehicular fluids, brake fluids, polymer solutions and solvent-based adhesives leading to fire or environmental incidents
  • • Inadequate emergency response procedures for solvent vapour releases, indoor air contamination and explosions
  • • Insufficient fire detection, fire protection systems and firefighting equipment for areas storing and using flammable liquids and combustible dusts
  • • Lack of worker training in spill response, emergency shutdown and evacuation for chemical-related emergencies
13. Waste Management, Solvent-Soaked Rags and Environmental Controls
  • • Improper storage and disposal of solvent-soaked rags leading to spontaneous combustion or ignition
  • • Inadequate segregation of chemical waste streams including adhesives, sealants, paints, dyes, pigments and fuel residues
  • • Uncontrolled discharge of solvents, brake fluids and vehicular fluids to stormwater or sewer systems
  • • Lack of documented procedures for managing contaminated absorbents, sludge and combustible dust waste
14. Contractor and Visitor Management for Chemical-Related Activities
  • • Contractors undertaking works such as painting, sealing, fuel system maintenance or extraction system installation without alignment to site chemical safety procedures
  • • Visitors entering areas where flammable liquids, solvents and adhesives are in use without awareness of the hazards
  • • Subcontractor activities introducing additional ignition sources or incompatible chemicals
15. Incident Reporting, Investigation and Continuous Improvement
  • • Under-reporting of spills, near misses, minor fires and exposures involving flammable liquids, solvents and adhesives
  • • Failure to investigate root causes such as system deficiencies, training gaps or maintenance failures
  • • Recurrent chemical incidents due to lack of learning and ineffective corrective actions
16. Consultation, Communication and Safety Culture for Chemical Risks
  • • Poor communication of chemical hazards, changes to products or procedures, and outcomes of risk assessments
  • • Limited worker involvement in identifying issues with solvent, adhesive and fuel handling practices
  • • Complacency or normalisation of deviance regarding shortcuts in chemical safety procedures

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
  • Model Code of Practice – Managing Risks of Hazardous Chemicals in the Workplace: Guidance on identification, risk management and control of hazardous chemicals.
  • Model Code of Practice – Managing the Work Environment and Facilities: Requirements for ventilation, amenities and safe workplace conditions.
  • Model Code of Practice – How to Manage Work Health and Safety Risks: Framework for systematic risk management and due diligence.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines for establishing, implementing and maintaining risk management systems.
  • AS 1940:2017: The storage and handling of flammable and combustible liquids.
  • AS/NZS 60079 (Series): Explosive atmospheres — Requirements for equipment and hazardous area classification.
  • AS 2865: Confined spaces — Where relevant to vapour accumulation and entry to tanks or pits.
  • AS 3745: Planning for emergencies in facilities.
  • AS 1851: Routine service of fire protection systems and 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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