Product Overview

Summary: This SOP sets out a clear, step-by-step system for safely storing, handling, dispensing and tracking fuel for construction vehicles on Australian worksites. It helps businesses control fire and explosion risks, protect workers and the environment, and maintain reliable plant operations while demonstrating compliance with WHS and environmental obligations.

Fuel is the lifeblood of construction plant, but it also presents significant fire, explosion, environmental and health risks if it is not managed properly. This Fuel Management for Construction Vehicles SOP provides a practical, WHS-focused framework for how fuel is received, stored, decanted, transported, dispensed and recorded on site. It covers fixed and mobile fuel storage, refuelling in the field, hot work considerations, separation distances, spill response, and communication between plant operators and refuelling personnel. The procedure is written in plain, worksite-friendly language so that supervisors and operators can apply it consistently across projects.

By implementing this SOP, construction businesses can significantly reduce the likelihood of fuel-related incidents such as fires during refuelling, slips from spilled diesel, soil and water contamination, or vehicles being operated with unsafe fuel levels or leaks. It also helps standardise how fuel usage is monitored and controlled, supporting preventative maintenance and reducing wastage and theft. The document aligns with Australian WHS legislation and relevant standards, giving your organisation a defensible, documented system of work that supports inductions, toolbox talks, contractor management and incident investigations.

Key Benefits

• Reduce the risk of fuel-related fires, explosions and environmental spills on construction sites.
• Ensure consistent, compliant practices for fuel storage, handling, refuelling and record-keeping across all projects.
• Improve communication and coordination between plant operators, refuelling personnel and supervisors.
• Support WHS and environmental compliance, reducing the likelihood of regulatory action, fines or project shutdowns.
• Optimise fuel usage through better monitoring, reducing wastage, theft and unplanned equipment downtime.

Who is this for?

• Construction Site Managers
• Project Managers
• Plant and Fleet Managers
• Site Supervisors
• WHS Managers and Advisors
• Diesel Fitters and Plant Mechanics
• Leading Hands and Forepersons
• Fuel Truck Drivers and Mobile Refuelling Operators
• Civil Construction Contractors
• Mining and Quarry Operations Supervisors

Hazards Addressed

• Fire and explosion from ignition of flammable or combustible fuel vapours
• Static electricity discharge during fuel transfer
• Spills and leaks leading to soil and water contamination
• Slip and fall incidents from spilled fuel on walking and driving surfaces
• Inhalation of fuel vapours in poorly ventilated areas
• Burns from contact with hot engine components during refuelling
• Vehicle roll-away or movement during refuelling operations
• Manual handling injuries from moving fuel containers and hoses
• Environmental harm from improper disposal of contaminated materials

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Fuel Types
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Risk Management and Hazard Identification
• 6.0 Fuel Storage Requirements (Fixed and Mobile Tanks)
• 7.0 Transport and Handling of Fuel on Site
• 8.0 Pre-Refuelling Checks and Site Preparation
• 9.0 Safe Refuelling Procedures for Construction Vehicles
• 10.0 Hot Work and Engine Shutdown Requirements
• 11.0 Personal Protective Equipment (PPE) Requirements
• 12.0 Spill Prevention, Containment and Response
• 13.0 Fire Protection and Emergency Procedures
• 14.0 Environmental Protection and Waste Management
• 15.0 Fuel Inventory Control and Record-Keeping
• 16.0 Inspection, Maintenance and Housekeeping
• 17.0 Training, Competency and Induction Requirements
• 18.0 Incident Reporting and Investigation
• 19.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant State/Territory variants)
• Work Health and Safety Regulation 2011 (Cth and relevant State/Territory variants)
• Safe Work Australia – Managing risks of hazardous chemicals in the workplace Code of Practice
• Safe Work Australia – Managing the work environment and facilities Code of Practice
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 60079 series: Explosive atmospheres (for hazardous area considerations)
• AS/NZS 4761: Competencies for working with flammable and combustible liquids (where applicable)
• Environment Protection Acts and Regulations (State/Territory specific) relating to spills and contamination