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Workers exposed to hazardous chemical

In 2024, two workers sustained chemical burns after being exposed to a hazardous chemical, liquid sodium hydroxide, which is commonly referred to as caustic soda.

Initial investigations indicate the workers had been transferring the sodium hydroxide between intermediate bulk containers using a hose and handheld electric drum pump. The hose appears to have dislodged from one of the containers, splashing the chemical on the workers.

Investigations are continuing.

Safety issues

Transferring hazardous chemicals generally presents a far greater risk than static storage.

Spills and leaks are most likely to occur during unconfined transfers of hazardous chemicals between containers by hand or using mobile pumping equipment.

When a spill, leak or uncontrolled release of hazardous chemicals occurs, appropriate actions must be taken to contain the hazardous chemicals within the workplace and provide for cleanup and disposal.

Processes or conditions in which spills, leaks and uncontrolled releases of hazardous chemicals may occur include but are not limited to:

  • dispensing or transferring of different chemicals without decontamination or cleaning of equipment such as transfer lines, pumps and storage containers.
  • using incompatible materials in transfer and storage equipment.
  • not maintaining equipment in accordance with manufacturer’s recommendations.
  • inadequate physical constraints on transfer piping such as clamps, connectors and or stabilising equipment.

Ways to manage health and safety

Effective risk management starts with a commitment to health and safety from those who manage the business. If an incident occurs, you will need to show the regulator that you have used an effective risk management process. This responsibility is covered by your primary duty of care in the Work Health and Safety Act 2011.

Use the hierarchy of controls to help decide how to eliminate and reduce risks in your place of work. The hierarchy of controls ranks types of control methods from the highest level of protection and reliability to the lowest.

It is a step-by-step approach to eliminating or reducing risks. You must work through the hierarchy of controls when managing risks, with the aim of eliminating the hazard, which is the most effective control.

Possible control measures to prevent similar incidents

The Work Health and Safety Regulation 2011 includes a number of duties for a person conducting a business or undertaking (PCBU) in order to manage the risks to health and safety associated with using, handling and storing hazardous chemicals at a workplace.

A risk assessment is not mandatory for hazardous chemicals under the WHS Regulation 2011. However, in many circumstances it will be the best way for PCBUs to determine the measures that should be implemented to control risks. It will help to:

  • Identify which workers are at risk of exposure.
  • Determine what sources and processes are causing that risk.
  • Identify if and what kind of control measures should be implemented.
  • Check the effectiveness of existing control measures.

PCBUs must understand the hazards workers are exposed to when storing, handling or using hazardous chemicals. Demonstrating how risk is managed includes reviewing information that identifies specific hazard and exposure identification that will inform the risk management process.

Sources of information that should be reviewed can include (but is not limited to):

  • Reviewing safety data sheets (SDS).
  • Reading and applying safe handling and storage procedures from SDS.
  • Understanding how to prepare, review and implement task-based risk assessments and standard operating procedures.

Additionally, there are a number of ways to control the risks associated with hazardous chemicals. Some control measures are more effective than others.

Transfer of hazardous chemicals

Transferring liquids from one container to another has the potential to release mists, vapours and leaks when not managed effectively. Open vessel transfers using hand pumps, flexible hoses and similar equipment can increase the likelihood of leaks or uncontrolled spills if equipment is not monitored effectively.

Control measures for manual liquid transfer operations can include but are not limited to:

  • Avoiding spillage or overflow, including overflow protection on equipment and receiving vessels and spill containment around vessels.
  • Securing flexible transfer hoses so that hose “whip” or movement of the hose is minimised so far as reasonably practicable, this can include fixed or temporary restraints such as hose clamps or plumbed fittings.
  • Providing emergency shut offs where appropriate to limit the amount of hazardous chemical released during a loss of containment.
  • Providing a spill containment system suitable to the hazardous chemical being transferred.
  • Ensuring transfer fittings are compatible and leak free during use.
  • Avoiding sources of ignition when transferring materials that can generate flammable atmospheres.

Plumbed eye wash stations and safety showers should be installed in areas where workers may be exposed in the event of a spill during transfer operations. Water supplied to safety equipment should not introduce additional hazards, when installing eye wash stations and safety showers PCBU’s should review the Managing risks of hazardous chemicals in the workplace Code of Practice 2021 (PDF, 1.21 MB)

Preventative maintenance

Systems for the storage and handling of hazardous chemicals generally require on-going maintenance and testing to ensure that they continue to be safe for the intended use and that they maintain their operational integrity. Such systems include, but are not limited to, storage tanks and vessels, chemical transfer lines, pumps, spill bunding and associated plant and/or equipment.

To ensure that the integrity of hazardous chemical handling systems is preserved, planned maintenance programmes should be designed and carried out at regular intervals, consistent with manufacturer's instructions or advice provided by other competent persons. If this is not reasonably practicable, inspections and maintenance should be carried out annually.

Examples of preventative maintenance include:

  • Checking bund walls for cracks or other signs of wear to ensure that, in the event of a spill, the bund remains watertight and will not leak or fail.
  • Checking for signs of corrosion or degradation on tanks and pipework (including flexible hoses).

Safe System of Work

Risks can be further minimised by implementing a safe system of work associated with the storage, handling and transferring of hazardous chemicals. This can include, but is not limited to, the following examples:

  • Providing and maintaining the current safety data sheet (SDS) for hazardous chemicals from manufacturers. The SDS must be easily available to all workers.
  • Ensuring a hazardous chemicals register is kept at the workplace for use by workers. A hazardous chemicals register is a list of hazardous chemicals stored, handled or used at a workplace (subject to any exclusions). The current SDS for each of the hazardous chemicals listed must be included with the register.
  • The information, training and instruction to workers, should be easily understood by vulnerable worker groups including young workers and workers with English as a second language.
  • Developing safe work procedures for the use, handling, storage, clean up and disposal of hazards chemicals. This should include any arrangements in place to deal with emergencies, including evacuation procedures, containing and cleaning up spills and first aid instructions.
  • Providing sufficient information, training and instruction for all persons who operate, test, maintain or decommission a hazardous chemical storage and handling system. Training may include safety features included in the design, required maintenance, instruction manuals, specifications and safe working parameters such as temperature and pressure.

Any remaining risk must be minimised with suitable personal protective equipment (PPE) which might include use of overalls, aprons, footwear, gloves, chemical resistant glasses, face shields, respirators and air-supplied respiratory equipment.

Administrative control measures and PPE rely on human behaviour and supervision. If used on their own, they are least effective in minimising risks. Suitable PPE is identified in the product’s SDS and should be applied based on a risk assessment for the task. The control measures you put in place should be regularly reviewed to make sure they are effective.

More Information

If this information has caused distress, there are services to help:

  • Lifeline – 24/7 crisis support service, including phone, texting and chat services.
  • Beyond Blue – information and support for anxiety, depression and suicide prevention for everyone in Australia.
  • Black Dog Institute – research and resources on mental health in the workplace.
  • SANE – helpline service, as well as resources on mental health.

Have you been affected by a workplace fatality, illness or serious injury?

For advice and support, visit our Facebook page or email ohs.coronialliaison@oir.qld.gov.au.

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Last updated 27 August 2025