WorkSafe issues safety alert following gas cylinder explosion in work vehicle

WorkSafe Issues Safety Alert Following Gas Cylinder Explosion in Work Vehicle

WorkSafe Victoria has issued a safety alert reminding employers and employees of serious hazards linked to transport of dangerous goods in tool of trade (TOT) vehicles. The alert follows a workplace incident involving a gas cylinder explosion that left a worker with severe injuries.

Victoria’s workplace safety regulator confirmed a serious injury resulted from an explosion involving a TOT vehicle. Investigators believe the worker was handling flammable gas cylinders at the time, which may have contributed directly to the blast.

Why This Safety Alert Matters for Tradespeople

WorkSafe noted that tradespeople have lost lives or sustained severe injuries in past explosions of work vehicles transporting dangerous goods. Proper management of these risks remains critical for any business relying on TOT vehicles for daily operations.

Cylinders containing flammable gas can pose extreme danger when stored or transported incorrectly, particularly in confined vehicle spaces exposed to heat or electrical faults. Even a minor spark near an electrical fitting can trigger catastrophic failure when dangerous goods aren't secured properly.

Transport Limits Under the Dangerous Goods Regulations

The safety watchdog stresses that anyone transporting dangerous goods as a Transport Operator (TOT) must follow transport limits set for TOT vehicles under the Dangerous Goods (Transport by Road or Rail) Regulations 2018.

According to WorkSafe Victoria, "If transported dangerous goods do not meet the criteria or quantity requirements to be transported in a TOT vehicle, then you must comply with the commercial transportation requirements under these Regulations."

Businesses should review their internal management systems to confirm cylinder quantities, storage configurations and vehicle fittings align with these regulations. Where transport volumes exceed TOT thresholds, commercial transport rules apply instead, and compliance gaps here often expose both drivers and surrounding workers to unnecessary danger.

Key Management Actions for Businesses Using TOT Vehicles

Effective management of dangerous goods transport requires more than a compliance checklist — it demands ongoing risk assessment tailored to each vehicle and cargo type. Consider these management priorities:

• Confirm cylinder quantities against TOT transport limits before every job.
• Inspect vehicle electrical systems regularly, since faulty wiring near flammable gas cylinders significantly raises explosion danger.
• Secure cylinders using approved restraints to prevent movement during transport.
• Train workers on correct handling, storage and emergency response procedures for dangerous goods.
• Maintain clear separation between cylinders and electrical components, including battery terminals and wiring looms.

Sound management of these hazards protects not only the worker handling cylinders but also colleagues, clients and the public who may come into contact with a TOT vehicle on-site or on the road.

Electrical Hazards Compound Dangerous Goods Risk

Electrical faults within a vehicle can act as an ignition source for flammable gas leaking from a compromised cylinder. Businesses should include electrical safety checks as part of routine vehicle maintenance, given that electrical faults often go unnoticed until it's too late.

Any modification to a TOT vehicle involving electrical wiring, lighting or auxiliary power sources warrants inspection by a qualified electrical technician. This step reduces danger and supports safer transport of dangerous goods across all vehicle types used on-site.

Health and Safety Implications for Employers

Beyond regulatory compliance, this incident highlights broader health and safety obligations employers hold toward staff transporting dangerous goods. Workplace injuries from vehicle explosions carry long-term health consequences for affected workers and their families.

Employers should integrate dangerous goods management into their broader Work Health & Safety (WHS) Policy to ensure consistent oversight across all transport activities. A documented Work Health and Safety Manual (WHSM) can also help standardise procedures for cylinder handling, vehicle inspections and incident reporting.

This alert follows similar warnings from safety regulators across Australasia. Readers may also find value in WorkSafe New Zealand's safety alert after a hot work incident, which addresses comparable ignition-source hazards, or the recent WorkSafe reminder on safety as electric vehicle use increases, given growing overlap between electrical systems and transport safety concerns. WorkSafe WA's reminder on mobile plant safety following two fatal incidents further reinforces how equipment-related hazards demand consistent management attention.

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