Worker sustains burns in drum explosion during cutting task (25 June 2026)

A worker at a vehicle dismantling and automotive repair workshop was using a plasma cutter to remove the top from a previously used 205L steel tight-head drum.

The drum exploded, igniting the worker’s trousers and throwing him several metres backwards.

The worker sustained serious burn injuries.

Three drums, a forklift and other materials in a factory setting
Image 1: Steel tight-head drum involved in incident.
Plasma cutter on ground near police tape
Image 2: Plasma cutter used in incident.
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                             

Safety information

Consider ‘reasonably practicable’ control measures to manage the risks associated with cutting, welding, grinding and other hot work activities on drums, containers or vessels.

Ensure:

  • Hot work is not permitted on drums, containers or vessels unless their contents and any residual hazards have been identified and appropriately controlled by a competent person.
  • Elimination of the risk is considered first, including using alternative methods or equipment that do not generate heat, sparks or flames.
  • All containers are inspected and assessed to determine previous contents and the potential presence of flammable, combustible or explosive atmospheres.
  • Drums that may have contained hazardous substances are appropriately cleaned, decontaminated, purged or otherwise made safe by a competent person before any cutting activity is undertaken.
  • A risk assessment is completed before commencing any work involving hot work processes such as plasma cutting, oxy-fuel cutting, welding or grinding.
  • Safe systems of work are developed, documented and implemented for hazardous tasks.
  • Workers are provided with adequate information, training, instruction and supervision regarding the safe performance of the task.
  • Appropriate personal protective equipment is provided and used.
  • Emergency procedures are established and workers are trained in responding to fires, explosions and burn injuries.
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