Product Overview

Summary: This Fuel Handling and Storage Safe Operating Procedure sets out clear, practical steps for safely receiving, transferring, dispensing and storing fuels in Australian workplaces. It helps you manage fire, explosion and environmental risks while demonstrating robust compliance with WHS and dangerous goods requirements.

Fuel is essential to many Australian workplaces, from construction sites and transport depots to farms, workshops and civil projects. It also presents significant hazards if poorly managed, including fire, explosion, environmental contamination and regulatory non-compliance. This Fuel Handling and Storage Safe Operating Procedure provides a clear, step-by-step framework for how fuel is to be received, transferred, stored, dispensed and monitored on site. It translates complex WHS and dangerous goods obligations into practical instructions that workers can follow every day.

The SOP supports PCBUs to meet their primary duty of care by defining safe systems of work for handling petrol, diesel and other common fuels. It addresses common problem areas such as decanting from bulk tanks, mobile fuel trailers, refuelling plant and vehicles, managing ignition sources, spill response and housekeeping around storage areas. By standardising how fuel is managed across your business, this document reduces the likelihood of serious incidents, improves worker competence and provides evidence of due diligence in the event of an audit, inspection or incident investigation.

Key Benefits

• Reduce the risk of fires, explosions and fuel-related incidents through clearly defined handling and storage controls.
• Ensure compliance with WHS legislation, dangerous goods requirements and relevant Australian Standards for fuel storage and transfer.
• Standardise fuel handling practices across multiple sites, shifts and contractors to improve consistency and control.
• Minimise environmental harm and clean-up costs by setting out robust spill prevention and response procedures.
• Strengthen worker training and competency by providing a clear reference document for inductions, toolbox talks and refresher training.

Who is this for?

• Operations Managers
• Workshop Supervisors
• Fleet Managers
• Site Supervisors
• WHS Managers and Advisors
• Fuel Store Attendants
• Maintenance Technicians
• Construction Project Managers
• Farm and Station Managers
• Transport and Logistics Coordinators

Hazards Addressed

• Fire and explosion from flammable vapours and ignition sources
• Static electricity discharge during fuel transfer
• Spills and leaks leading to environmental contamination of soil and waterways
• Inhalation of fuel vapours in poorly ventilated areas
• Skin and eye contact with fuels and fuel additives
• Manual handling injuries when moving fuel containers and hoses
• Vehicle and plant movement risks in refuelling areas
• Confined space risks where fuel vapours may accumulate
• Burns from contact with hot engine components during refuelling

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Fuel Types Covered
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Controls for Fuel Handling
• 6.0 Fuel Storage Requirements (Fixed Tanks, Portable Containers and Mobile Bowsers)
• 7.0 Safe Fuel Receiving and Transfer Procedures
• 8.0 Safe Refuelling of Vehicles, Plant and Equipment
• 9.0 Control of Ignition Sources and Static Electricity
• 10.0 Personal Protective Equipment (PPE) Requirements
• 11.0 Housekeeping, Inspection and Maintenance of Storage Areas
• 12.0 Spill Prevention, Containment and Emergency Response
• 13.0 Fire Protection and Emergency Procedures
• 14.0 Environmental Protection and Waste Management
• 15.0 Training, Induction and Communication
• 16.0 Recordkeeping, Monitoring and Review of the Procedure

Legislation & References

• Work Health and Safety Act 2011 (Cth and state/territory variants)
• Work Health and Safety Regulation 2011 (Cth and state/territory variants) – Hazardous chemicals and dangerous goods provisions
• Safe Work Australia – Managing risks of hazardous chemicals in the workplace: Code of Practice
• Safe Work Australia – Managing risks of plant in the workplace: Code of Practice
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 60079 series: Explosive atmospheres (for hazardous area classification where applicable)
• AS/NZS 4766: Polyethylene storage tanks for water and chemicals (where relevant to fuel tanks)
• Environment Protection legislation and guidelines applicable in each state or territory (for spill management and contamination prevention)