A risk-based review of dangerous goods storage and handling at a manufacturing facility

The safe storage and handling of dangerous goods (DGs) remain critical to preventing accidents, protecting personnel, and ensuring regulatory compliance within industrial manufacturing facilities. This paper examines the storage practices of Classes 3, 8, and 9 hazardous materials at a process-based manufacturing site, highlighting key deficiencies in compliance with Australian standards such as AS 1940, AS 3780, and AS/NZS 3833. These standards outline essential controls, including separation distances, segregation, isolation, bunding, ventilation, and fire protection, vital to mitigating critical risks like fire, chemical reactions, and environmental contamination. A risk-based assessment identified significant gaps, including inadequate funding, insufficient separation of incompatible materials, and non-compliance with ventilation and fire protection requirements. Addressing these gaps is necessary, as failures in these areas could lead to catastrophes involving highly toxic releases, fires, or explosions. Recommendations include establishing clear maximum quantity limits for hazardous materials, implementing compliant bunding and spill containment systems, improving fire protection measures with feasible extinguishing supplies, and conducting thorough risk assessments to refine storage arrangements. This work emphasises the need for commitment to uncompromising standards and provides actionable strategies to advance process safety in manufacturing industries handling hazardous chemicals.