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Two workers exposed to hazardous chemical

In late 2025, two workers suffered chemical burns after exposure to a corrosive chemical during a transfer process at a manufacturing workplace.

Initial investigations indicate one worker was transferring the chemical from an intermediate bulk container to a tank in an acid bay using a diaphragm pump system when the pump appears to have malfunctioned, spraying him, causing chemical burns. A second worker also suffered chemical burns while assisting the first worker.

Investigations are continuing.

Safety issues

Hazardous chemical transfers generally present a greater risk than static storage because spills, leaks and uncontrolled releases are more likely during movement between containers, particularly when using hand-operated or mobile pumping equipment.

Examples of situations that can lead to spills, leaks or uncontrolled chemical releases include:

  • transferring different chemicals without first decontaminating or cleaning equipment such as transfer lines, pumps and storage containers
  • using incompatible materials in transfer or storage equipment
  • failing to maintain equipment in accordance with the manufacturer’s recommendations
  • using inadequate physical restraints or supports on transfer piping, including clamps, connectors and stabilising equipment.

Managing the risk

Duty holders must identify hazardous chemical risks, implement effective controls and review those controls regularly. These obligations form part of the primary duty of care under the Work Health and Safety Act 2011.

When selecting controls, work through the hierarchy of controls and give priority to eliminating the hazard wherever reasonably practicable. If elimination is not possible, use the highest level of control available to reduce the risk.

Further guidance on applying the hierarchy of controls when managing risks is available.

Possible control measures to prevent similar incidents

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

PCBUs should understand the properties of the chemicals in use, how workers may be exposed, and what information is needed to assess and control the risk.

Transfer of hazardous chemicals

Liquid transfers can release mists, vapours and spills if they are not properly controlled. Open transfers using hand pumps, flexible hoses and similar equipment can increase the likelihood of leaks or loss of containment.

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

  • Providing overflow protection on equipment and receiving vessels, and spill containment around vessels.
  • Securing flexible transfer hoses to minimise hose movement or “whip”, including through 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 spill containment suitable for the type and volume of hazardous chemical being transferred.
  • Ensuring transfer fittings are compatible and leak-free during use.
  • Eliminating or controlling ignition sources when transferring materials that can generate flammable atmospheres.

Plumbed eyewash stations and safety showers should be installed wherever workers may be exposed during transfer operations. Water supplied to this equipment should not introduce additional hazards. When installing eyewash stations and safety showers, PCBUs should review the Managing risks of hazardous chemicals in the workplace Code of Practice 2021 (PDF, 1.21 MB). Consider including antidotes for specific chemical exposures in first aid kits.

Preventative maintenance

Hazardous chemical storage and handling systems require ongoing maintenance and testing to ensure they remain safe for their intended use and retain operational integrity. These systems may include storage tanks and vessels, transfer lines, pumps, spill bunding, and associated plant or equipment.

Planned maintenance programs should be carried out at regular intervals in line with the manufacturer’s instructions or advice from another competent person. If this is not reasonably practicable, inspections and maintenance should be carried out at least annually.

Examples of preventative maintenance include:

  • Checking bund walls for cracks or wear so they remain watertight and able to contain a spill.
  • Checking tanks, decanting containers (jugs, funnels, buckets etc), pipework and flexible hoses for signs of corrosion or degradation.

Safe System of Work

Risks can be further reduced by implementing a safe system of work for the storage, handling and transfer of hazardous chemicals. This may include:

  • Providing and maintaining a current safety data sheet (SDS) for each hazardous chemical and making it readily accessible to workers and others who may be exposed.
  • Maintaining a hazardous chemicals register at the workplace, including the current SDS for each listed chemical.
  • Developing safe work procedures for the use, handling, storage, clean-up and disposal of hazardous chemicals, including emergency arrangements, spill response and first aid instructions
  • Providing sufficient information, training, instruction and supervision for anyone who operates, tests, maintains or decommissions a hazardous chemical storage or handling system, including its design features, maintenance requirements and safe operating limits.
  • Information, training and instruction to workers and others should also include information that each part of the SDS provides, for example; exposure controls and personal protection.

Any remaining risk must be minimised by providing suitable personal protective equipment (PPE), which may include overalls, aprons, footwear, gloves, chemical-resistant eyewear, face shields, respirators and air-supplied respiratory equipment.

Administrative controls and PPE rely on human behaviour and supervision, so they should not be used as the sole means of risk control where higher-level controls are available. PPE should be selected using the product SDS and a task-specific risk assessment. All control measures should be reviewed regularly to ensure they remain 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:

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Last updated 16 June 2026