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Hazardous chemicals risk assessment

A chemical register tells you what is on site. A risk assessment tells you whether the way you use it is safe. Under the Work Health and Safety Act 2011 and its regulations a PCBU must manage the risks of using hazardous chemicals, which means assessing the task rather than the substance in isolation. This template does that, and pairs with the chemical register in this library.

Who it's for: Laboratory and workshop supervisors, cleaning and facilities managers, healthcare and aged care managers, agricultural and horticultural operators, and WHS managers anywhere chemicals are decanted, mixed, sprayed or heated.

Free to use and adapt · Last updated 2026-08-02 · No email required

Scope note

Workplace exposure standards, the triggers for air monitoring, and the requirements for health monitoring are set in the regulations and lists that apply in your jurisdiction, and they are substance-specific. This template does not state exposure figures. Record the standard for each substance from its safety data sheet and your jurisdiction's list, confirmed with Safe Work Australia and your state WHS regulator.

Assess the task, not just the product. The same chemical is low risk poured carefully into a bucket and high risk sprayed as a mist in an unventilated room.

Assessment details

Task assessed One assessment per task, for example spray application, decanting, mixing, cleaning a specific area
Chemicals used, as labelled Cross-reference the chemical register entries
Quantity used per task, and frequency
Location, and whether indoor, outdoor or enclosed
Workers doing the task, and anyone else nearby
Assessor, date and review date

Step 1 - Hazard information from the safety data sheet

Read the sheet for each product before assessing. Record the exposure standard where one exists.

  • Acute health effects identified, including corrosive and irritant effects
  • Chronic health effects identified, including carcinogenic, mutagenic and reproductive hazards
  • Sensitising substances identified, since a sensitised worker can react at very low exposures thereafter
  • Physical hazards identified: flammable, oxidising, corrosive to metals, gas under pressure
  • Incompatibilities identified, including mixtures created accidentally during cleaning
  • Decomposition products considered, including what is released when the substance is heated or burnt
ProductHazard classificationHealth effectsExposure standard, if anySDS datePhysical hazards
      
      
      

Step 2 - How exposure actually happens in this task

Duration and frequency of exposure per shift
Is any exposure likely to approach the exposure standard If yes, air monitoring by a competent person may be required
  • Inhalation: vapour, mist, aerosol, dust, fume, gas
  • Skin contact: splash, immersion, contaminated surfaces, contaminated gloves, contaminated clothing
  • Skin absorption, which can occur without any sensation
  • Eye contact: splash, mist, rubbing eyes with contaminated hands
  • Ingestion: hand to mouth, eating or drinking in the work area, contaminated containers
  • Injection: sharps, high pressure equipment, damaged skin
  • Exposure to others nearby, including people in adjacent areas and on later shifts
  • Exposure during non-routine moments: decanting, spills, cleaning, maintenance, disposal

Step 3 - Controls, strongest first

  • Eliminate: stop using the chemical, or stop doing the task
  • Substitute: a less hazardous product, or a less hazardous form such as a liquid instead of a powder, or a ready-diluted product instead of a concentrate
  • Isolate: enclose the process, use a fume cupboard or glove box, restrict access, work outside normal hours away from others
  • Engineering: local exhaust ventilation at the point of release, general ventilation, closed transfer systems, splash guards, dispensing equipment
  • Administrative: written procedures, training, reduced quantities, decanting into labelled containers, no eating or drinking in the area, hygiene rules
  • PPE: gloves of the correct material and breakthrough time, eye protection, respiratory protection fit tested, coveralls
Exposure routeControl chosenLevel in the hierarchyOwnerDue dateHow it is verified
      
      
      
      

Step 4 - Storage, spill and emergency

  • Storage complies with the safety data sheet, with incompatibles segregated
  • Quantities at the point of use kept to the minimum for the task
  • Decanted containers labelled with product name and hazard information
  • Spill kit suited to these chemicals, present, stocked, and staff trained to use it
  • Spill procedure written, including when to evacuate rather than clean up
  • Eyewash and safety shower available, unobstructed, and flushed on a schedule where required
  • First aid measures from the safety data sheet known to first aiders
  • Fire response considered, including the correct extinguishing media
  • Waste disposal route defined and compliant
  • Emergency contacts displayed, including 000 and the poisons information line for your country

Step 5 - Training and health monitoring

Health monitoring required for any substance in this task (Y/N) Check your jurisdiction's list of substances requiring monitoring
If yes, who supervises it, and the interval
  • Workers trained on the specific hazards, controls and emergency response for this task
  • Workers know where the safety data sheets are and can read the relevant sections
  • Correct PPE use, including glove selection, removal without self-contamination, and disposal
  • Respirator users fit tested, trained and medically assessed where required
  • Health monitoring requirement checked for each substance, since it is required for specified substances in many jurisdictions
  • Where health monitoring applies, a registered medical practitioner supervises it and workers receive their results
  • Records retained for the required period, which can be many years for substances with long-latency effects
How to use it

Getting the most out of this template

  • Assess the task, not the product. The same chemical carries very different risk depending on how it is used.
  • Look hardest at the non-routine moments. Decanting, spills, cleaning and maintenance produce most serious exposures.
  • Check glove material against the specific chemical. The wrong glove can be worse than none, because it holds the chemical against the skin.
  • Substitution is the most under-used control. A ready-diluted product removes the highest-exposure step, which is the concentrate.
  • Check the health monitoring list for every substance. It is substance-specific and easy to miss.

This template is general information, not legal advice. Requirements differ by jurisdiction and industry; check the guidance published by Safe Work Australia and your state WHS regulator and seek advice for your specific circumstances.

Questions

Frequently asked

What is the difference between the chemical register and this assessment?
The register lists what is on site with the safety data sheets, and is required in its own right. The risk assessment examines how a specific task uses those chemicals and what controls apply. You need both, and the register is the natural starting point for deciding which tasks to assess.
Do we need to assess every chemical?
Assess the tasks that create meaningful exposure, prioritising by hazard classification and by how the chemical is used. A sealed product used rarely with no exposure pathway needs little. A concentrate decanted daily, or anything sprayed, heated or used in an enclosed space, needs a proper assessment.
When is air monitoring required?
Generally where you cannot be reasonably certain that exposure is below the standard for a substance, or where you need to check that controls are working. It must be done by a competent person using appropriate methods. Confirm the trigger and the method with Safe Work Australia and your state WHS regulator.
When is health monitoring required?
Many jurisdictions require it for workers exposed to specified substances, with the list and the method set in the regulations. It must be supervised by a registered medical practitioner with the relevant experience, the PCBU pays, and the worker receives their results. Records often have to be kept for decades because some effects appear long after exposure.

The template covers the paperwork. Duress covers the response.