Many workplace accidents involving aerosols occur when the cans are left in the sun, in a car, or placed next to a hot machine. Two Australian workers were injured when they tried to use a can of spray paint which had been left in the sun. As one of the worker shook the can it exploded in his hand. Other workers have suffered burns and shrapnel injuries from exploding cans of cooking oil, adhesives, and electrical contact cleaner.

An aerosol can is a self-contained dispensing system where a substance is stored inside a small metal canister and pushed out as a fine mist, a spray, or a foam. This mini dispensing system consists of five key elements which work together to deliver a consistent product.

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Shaking the can mixes the active ingredient with the propellant and solvent. But it is also the combination of each of the five elements that compounds the risks and hazards of the cans. All of this stuff is going to be released if the can explodes. We’ll look at these next.

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Despite the small size, each aerosol can actually contains a complex ecosystem, and this is the reason that many aerosol cans need to be shaken before you can use them.

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Australians alone consume more than 250 million aerosol cans every year, and these little cans are used in homes and workplaces all over the world. Anti-septics, shaving cream, paints, industrial solvents, antibiotics, automotive sprays, insecticides… they’re so familiar to us. But what are aerosol cans really? And why are they dangerous? This blog serves to unpack these two frequently asked questions because many people (especially workers and their supervisors) don’t realise that all aerosol cans are Class 2 Dangerous Goods (even if it’s only whipped cream) and need to be included in your risk management processes.

A worker transferring unopened cartons of aerosol whipped cream was seriously injured when a can burst through the cardboard carton and hit him in the face. While it’s impossible to know what caused the metal canister to launch into a projectile, commercial warehouses and industrial worksites are rarely stable, temperature controlled environments. Aerosol cans (or bulk cartons) can be easily knocked over, dropped, or impacted by passing machinery and vehicles; potentially leaving the contents (active ingredients, propellant, and solvent) in a volatile state.

The most important thing to remember about aerosol cans in the workplace is to always treat them as you would treat other Dangerous Goods. Read the Safety Data Sheets (SDS) and conduct a risk assessment before introducing them into the workplace for the first time.

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Adhesives, insecticides, automotive sprays, solvents, cleaners, paints, and varnishes are all hazardous substances and capable of causing injury if a workers inhales or absorbs the chemicals. It is so important for supervisors to check the Safety Data Sheets (SDSs) before allowing any new chemical into the workplace, sometimes this practice is forgotten when the substance arrives packaged in a neat little aerosol can.

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A worker was using a can of spray paint to mark pieces of steel ready for cutting with an acetylene/oxygen cutting torch. A piece of molten metal fell onto the spray can which ruptured and the paint inside ignited. The worker was showered in burning paint and suffered terrible burns, but he was lucky the acetylene and O2 cylinders did not explode as well. Even empty cans must never be punctured or pierced as chemical residues can still present an explosion hazard.

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According to the AS/NZS 3833:2007 - The storage and handling of mixed classes of dangerous goods, in packages and intermediate bulk containers, aerosol cans must be:

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Making sure your workplace operates legally and safely doesn’t happen by accident or chance — for more information about managing aerosols and other Dangerous Goods in the workplace why not download our free eBook Aerosol Safety and Storage. We explain your legal obligations when  handling and storing aerosol cans in clear, concise English and use plenty of real-world examples so you can relate the contents back to your own workplace. Download and read it today.

Aerosol cans are dangerous because of the unusual mix of substances stored under pressure inside THE metal canister. Even if the active ingredient is not a hazardous chemical (eg, food products) the can is still capable of exploding or turning into a dangerous projectile. The biggest problem with aerosol cans in the workplace is their potential to ignite or explode other Dangerous Goods and Hazardous Substances.

Aerosol storage that meets the requirements of the Australian Standard will help keep your people, property and environment safe.