Flammable liquids are used every day in manufacturing, laboratories, maintenance workshops, automotive facilities and chemical processing plants. While purpose-designed safety equipment plays an important role in reducing risk, many workplace incidents occur because of preventable human error rather than equipment failure.

Simple mistakes—such as using the wrong container, overlooking chemical compatibility or failing to inspect equipment—can increase the likelihood of spills, vapour release, fires and injuries.

Understanding these common risks is the first step towards creating a safer workplace. This guide highlights seven mistakes frequently seen when handling flammable liquids and outlines practical ways to avoid them.

Many incidents involving flammable liquids can be prevented by avoiding these common mistakes:

• Using unsuitable containers.
• Ignoring chemical compatibility.
• Leaving containers open after use.
• Poor housekeeping and storage practices.
• Failing to control ignition sources.
• Skipping routine equipment inspections.
• Inadequate employee training.

Addressing these areas helps reduce fire risks while supporting safer handling of hazardous liquids.

Modern safety cans and hazardous liquid containers are engineered with features such as self-closing lids, flame arresters and pressure relief mechanisms. However, even the safest equipment cannot compensate for poor working practices.

Developing a strong safety culture means combining appropriate equipment with training, regular inspections and clearly documented procedures.

Not every container is suitable for storing or dispensing flammable liquids.

Improvised containers or those made from incompatible materials can increase the risk of leaks, chemical degradation and accidental ignition.

Best Practice

• Use purpose-designed safety cans for flammable liquids.
• Select the correct material for the chemical being stored.
• Choose the appropriate Type I or Type II safety can based on the application.
• Always consult the chemical's Safety Data Sheet (SDS).

Related Guide: Safety Can Buying Guide

Mistake 2: Overlooking Chemical Compatibility

One of the most common mistakes is assuming one container is suitable for every chemical.

Some substances can attack certain materials over time, leading to weakened containers, leaks or contamination.

Best Practice

• Check the SDS before selecting a container.
• Verify compatibility between the chemical and the container material.
• Use polyethylene or stainless steel where appropriate for corrosive substances.
• Never transfer chemicals into unapproved containers.

Related Guide: Chemical Compatibility Guide

Mistake 3: Leaving Containers Open

Open containers allow flammable vapours to escape into the workplace, increasing the risk of exposure and creating potentially flammable atmospheres.

They are also more likely to become contaminated by dust, debris or moisture.

Best Practice

• Close containers immediately after dispensing.
• Use safety cans with self-closing lids.
• Avoid leaving partially filled containers unattended.
• Minimise the time containers remain open during transfers.

Mistake 4: Poor Housekeeping

Small spills, leaking containers and cluttered storage areas can quickly become significant hazards.

Poor housekeeping also makes emergency response more difficult if an incident occurs.

Best Practice

• Clean up spills immediately using appropriate spill response procedures.
• Clearly label all containers.
• Store incompatible chemicals separately.
• Keep storage and dispensing areas tidy and well organised.
• Dispose of contaminated wipes and absorbents in suitable waste containers. 

Mistake 5: Ignoring Ignition Sources

Flammable liquid vapours can ignite when exposed to sparks, hot surfaces, open flames or static electricity.

Many workplace fires occur because ignition sources have not been identified or adequately controlled.

Best Practice

• Keep flammable liquids away from naked flames and heat sources.
• Switch off equipment where appropriate before refuelling or dispensing.
• Consider bonding and grounding conductive containers where required by your site's risk assessment.
• Ensure adequate ventilation in areas where vapours may accumulate.

Mistake 6: Failing to Inspect Equipment

Safety equipment should never be treated as "fit and forget".

Over time, seals can wear, lids may become damaged and flame arresters can become blocked by contamination.

Routine inspections help identify these issues before they become safety hazards.

Best Practice

Inspect safety cans regularly for:

• Damaged lids
• Worn seals and gaskets
• Corrosion
• Dents or cracks
• Damaged flame arresters
• Missing or illegible labels

Remove damaged containers from service immediately.

Mistake 7: Assuming Training is One-Time Activity

Even experienced employees benefit from refresher training, particularly when new chemicals, equipment or procedures are introduced.

Consistent training helps reinforce safe behaviours and reduces the likelihood of human error.

Best Practice

Provide regular training on:

• Safe handling of flammable liquids
• Reading Safety Data Sheets (SDS)
• Correct use of safety cans
• Emergency spill procedures
• Fire prevention measures
• Reporting damaged equipment

Encouraging employees to report hazards and near misses also helps strengthen your workplace safety culture.

A Simple Flammable Liquid Safety Checklist

Before handling flammable liquids, ask:

1. Have I reviewed the Safety Data Sheet (SDS)?
2. Am I using the correct safety can?
3. Is the container compatible with the chemical?
4. Has the safety can been inspected?
5. Are ignition sources controlled?
6. Is the work area clean and organised?
7. Are containers correctly labelled?
8. Do I know what to do in the event of a spill?

Taking a few moments to complete these checks can significantly reduce the likelihood of an incident.

What causes most workplace incidents involving flammable liquids?

Many incidents result from preventable factors such as poor housekeeping, unsuitable containers, inadequate training, damaged equipment or uncontrolled ignition sources.

Can safety cans prevent fires?

Safety cans are designed to reduce risks through features such as self-closing lids, flame arresters and pressure relief mechanisms. However, they should always be used alongside safe working procedures and risk assessments.

Why is chemical compatibility important?

Using an incompatible container can lead to corrosion, leaks or degradation, increasing the risk of spills and exposure.

How often should safety cans be inspected?

Safety cans should be inspected before use and as part of routine workplace maintenance programmes. Damaged containers should be removed from service.

Why is employee training so important?

Training helps ensure employees understand how to handle hazardous liquids safely, identify risks and respond appropriately in the event of an emergency.

Safe handling of flammable liquids depends on more than choosing the right equipment. It requires attention to detail, good housekeeping, regular inspections and ongoing employee awareness.

By avoiding common mistakes and following established best practices, organisations can reduce fire risks, improve workplace safety and protect employees, facilities and the environment.

Explore Justrite's range of safety cans, hazardous liquid storage solutions and workplace safety resources to help build a safer and more compliant workplace.