Worker burnt in gas explosion

In 2025, a worker suffered significant burns following a gas-related fire at a restaurant.

Initial enquiries indicate the worker had been preparing the kitchen and attempted to light a gas deep fryer using a BBQ-style lighter when, for reasons yet to be established, a fire occurred in the immediate area.

Investigations are continuing.

Safety issues

Fuel gases used in kitchens and cafes include natural gas (i.e. methane) and liquefied petroleum gas (LPG). Natural gas is supplied through reticulation pipeline networks whereas LPG is supplied through bottles and cylinders stored on-site in outdoor areas. Not every kitchen will have access to a natural gas pipeline.

Both fuel gases are highly flammable however, in terms of their ignition risks, they have some different physical characteristics. LPG is heavier than air whereas natural gas is lighter than air. This means LPG can accumulate in low points like drains, whereas natural gas will rise up towards the ceiling, if indoors. Both gases are odourised to assist in detecting leaks, with the chemical giving off a smell similar to “rotten eggs”.

Gas appliances have the potential to cause serious injury if not installed or used correctly.

While these gases are not poisonous or toxic, leaks can build-up in concentration which is a serious fire and explosion hazard if a lower explosive limit (LEL) is reached. The risk of a gas leak reaching its LEL is higher in areas with reduced ventilation (for example, indoors). Fuel gases can also displace the oxygen in air creating an asphyxiation hazard; however, the fire and explosion hazard is the more prominent risk.

An uncontrolled release of a flammable gas may lead to a fire or explosion, particularly in a confined area where potential ignition sources are present.

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 requires specific controls for prevention of fire and explosion risks associated with fuel gases. Effective risk management is often achieved using a combination of controls.

Safe system of work

A safe system of work should be implemented to manage the fire and explosion risks associated with ignition sources and fuel gases. This can include but is not limited to:

• In addition to the Work Health and Safety Act 2011, follow all relevant requirements from the Petroleum and Gas (Production and Safety) Act 2004.
• Only use gas appliances (e.g. burners and cookers) that are approved devices. Look for a gas certificate or gas approval label/badge.
• When moving gas appliances or any work associated with gas in a commercial kitchen you must use a licensed gas fitter.
• Store LPG gas bottles/cylinders outdoors in well-ventilated areas. Do not use a portable LPG burner designed for outdoor use, inside an indoor kitchen.
• Put gas appliances in a well-lit and draught-free area.
• Clearly identify all gas shut-off valves and ensure they are easily accessible.
• Label pipelines supplying gas appliances with the name of the fuel gas.
• Regularly inspect and maintain gas appliances and their fuel supply systems: further advice on inspecting and leak-testing fuel gas systems.
• Clean exhaust fans and hoods regularly to prevent build-up of oils and residue.
• Store combustible materials, clothes and paper away from heat sources.
• Fire safety installations (e.g. sprinkler systems and fire alarms) should be regularly maintained by qualified personnel.
• Provide firefighting equipment appropriate for the kitchen (e.g. fire blankets and correct fire extinguishers for fats and oils). Staff should be trained in the use of all fire protection equipment issued.
• Ensure worker training, experience and competency aligns with the requirements and complexity of the task (workers must be trained by a competent person and have the appropriate skills to carry out a particular task safely). Ensure specific gas appliance training occurs that includes:
  • the safety information from the appliance manufacturer, including warning labels, signage and instructions
  • the type of fuel gas used in the kitchen and whether it is lighter or heavier than air
  • approved methods for lighting a gas burner
  • what a fuel gas leak may smell like
  • emergency response actions
• Keep records of completed training and ensure training is always fit-for-purpose. Some examples might include:
  • how to access safety data sheets (SDS) and understand key information for storing hazardous chemicals at the workplace
  • storage and maintenance of personal protective equipment
  • what the emergency response actions are
  • where the gas isolation points are located and how to operate them.

Under the Work Health and Safety Regulation 2011, a person conducting a business or undertaking (PCBU) must prepare an emergency plan to reduce the effects of an emergency involving hazardous chemicals at their place of work. When preparing an emergency plan, a PCBU must consider all relevant matters including:

• the nature of the work being carried out at the workplace
• the nature of the hazards at the workplace
• the size and location of the workplace
• the number and composition of the workers and other persons at the workplace.

A PCBU must also ensure the workplace is provided with fire protection and firefighting equipment in response to the fire risk at a workplace. Firefighting equipment must also be compatible with the Queensland Fire Department’s (QFD) equipment. Ensure such equipment is properly installed, tested and maintained, and dated records kept of the testing and maintenance.