Welding or cutting into flammable drums or fuel tanks

Background

WorkSafe has seen an increase in the number of serious incidents involving the modification of drums and tanks that have contained flammable or combustible dangerous goods.

Performing hot work such as welding, cutting and grinding on metal drums or tanks is an activity that carries significant risk. Even if containers appear empty, rinsed, or labelled “clean,” hot work can cause residual liquids and vapours to ignite, causing serious injury or death from explosion or fire.

Safety Issues

Fuel tanks and metal drums are used to store flammable or combustible liquid (eg. diesel, petrol, paint thinners, turpentine, solvents, oil-based paints, automotive transmission/engine oils, industrial lubricants, cooking oils). Residue and vapours can remain long after the contents have been emptied.

WorkSafe has seen an increase in the number of incidents of explosion and serious burn injuries after tools have been used to adapt tanks and drums for other purposes. Tools used have included angle grinders, plasma cutters, oxy-acetylene burners, welding equipment and common portable electric saws fitted with metal cutters. In some cases, bystanders have been injured by drums which have become projectiles following an explosion.

Recommended ways to control risks

• Eliminate hot work on drums and tanks.
• If hot work is unavoidable, ensure drums or tanks are fully decontaminated and certified gas-free by a competent person. Hire a specialist in cleaning, gas monitoring and destruction of used drums. Rinsing tanks and drums with water does not guarantee removal of residue or vapours.
• Keep the tanks and drums away from oxy-acetylene torches, naked flames or sparks from grinding and welding equipment. Tanks and drums are not suitable to be used as welding or work platforms.
• Always remove bungs and ventilate before commencing any work.
• Implement a safe system of work for the modification or repurposing of drums such as hot work permits, risk assessments and procedures.
• Ensure that all employees and persons at the premises are informed of the hazards associated with cutting or working near tanks and drums with heat producing tools and equipment.
• Ensure all tanks and drums held on the premises are correctly labelled and (if applicable) a safety data sheet (SDS) is available for their contents.
• Ensure appropriate personal protective equipment (PPE), spill containment and fire protection equipment are available and accessible.

Before reusing a fuel tank or metal drum, ask yourself:

• What has the tank or drum been used for?
• Did it contain a flammable or combustible liquid, eg diesel or gas?
• Did it contain a chemical?
• Is there a hazard label on the tank or drum?

If you answered 'yes' or do not know the answer to any of these questions, follow the recommended ways to control risks and do not apply heat to the tank or drum.

Common Mistakes to Avoid

• Assuming drums are safe after rinsing or appearing empty.
• Performing hot work without confirming gas-free status.
• Keeping bungs or lids sealed.
• Removing labels or failing to confirm contents.
• Reusing drums without assessing the risks or understanding prior use.

Legal duties

Occupiers of premises where dangerous goods are stored and handled have duties under the Dangerous Goods Act 1985 and the Dangerous Goods (Storage and Handling) Regulations 2022. These include:

• Identifying any hazards associated with the storage and handling of dangerous goods at the premises, having regard to what the occupier knows or ought reasonably to know about the hazard.
• Ensuring that any risk associated with the storage and handling of dangerous goods at the premises is eliminated, or if it is not reasonably practicable to eliminate the risk, is reduced so far as is reasonably practicable.
• Ensuring that, so far as is reasonably practicable, ignition sources are not present in any hazardous area within the premises.

Employers also have duties under the Occupational Health and Safety Act 2004. These include:

• providing and maintaining for employees of the employer a working environment that is safe and without risks to health, so far as is reasonably practicable
• ensuring persons other than employees are not exposed to risks to their health and safety from the conduct of the undertaking of the employer, so far as is reasonably practicable.

Related information

AS 1674.1:2025 Safety in welding and allied processes, Part 1: Fire precautions