Product Overview

Summary: This Vehicle Refuelling Safe Operating Procedure sets out clear, practical steps for safely refuelling light vehicles, trucks, plant and mobile equipment in Australian workplaces. It helps control fire, explosion and environmental risks while ensuring workers follow consistent, compliant refuelling practices on-site, on-road and at depots.

Refuelling is one of the most frequent high-risk activities carried out across transport, construction, mining, agriculture and service industries. A single lapse in procedure can result in fuel spills, fires, explosions, environmental contamination or serious personal injury. This Vehicle Refuelling Safe Operating Procedure provides a clear, step-by-step framework for safely refuelling vehicles and mobile plant, whether at fixed fuel bowsers, on-site fuel tanks, or using portable fuel containers in the field. It gives your workers precise instructions on pre-start checks, isolating ignition sources, managing static electricity, controlling spills and responding to emergencies.

Developed for the Australian regulatory environment, this SOP helps businesses demonstrate due diligence under WHS legislation and environmental laws. It standardises refuelling practices across different sites and shifts, reducing reliance on informal habits or verbal instructions. By implementing this procedure, organisations can minimise fuel-related incidents, protect workers and contractors, reduce wastage and environmental clean-up costs, and provide clear evidence of risk management to regulators, clients and insurers.

Key Benefits

• Reduce the risk of fires, explosions and burns during vehicle and plant refuelling.
• Ensure consistent, compliant refuelling practices across all sites, shifts and operators.
• Minimise fuel spills, soil and water contamination, and associated clean-up costs.
• Support compliance with Australian WHS and environmental obligations related to fuel handling and storage.
• Strengthen worker training, inductions and toolbox talks with a clear, step-by-step reference document.

Who is this for?

• Fleet Managers
• Workshop Managers
• Site Supervisors
• Plant Operators
• Truck Drivers
• Light Vehicle Drivers
• Fuel Bowser Attendants
• Depot Managers
• WHS Managers
• Construction and Mining Supervisors
• Agricultural Operations Managers
• Facilities and Maintenance Coordinators

Hazards Addressed

• Fire and explosion from flammable vapours and ignition sources
• Static electricity build-up and discharge during refuelling
• Fuel spills leading to slips, trips and falls
• Inhalation of petrol or diesel vapours
• Skin and eye contact with fuel and fuel additives
• Environmental contamination of soil, stormwater and waterways
• Manual handling strains from moving fuel containers and hoses
• Vehicle movement and collision risks in refuelling areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Applicable Fuel Types
• 3.0 Roles and Responsibilities
• 4.0 Required Training and Competency
• 5.0 Required PPE and Safety Equipment
• 6.0 Pre-Refuelling Checks and Site Preparation
• 7.0 Safe Refuelling Procedure – Fixed Bowsers and Depots
• 8.0 Safe Refuelling Procedure – Mobile and On-Site Fuel Tanks
• 9.0 Safe Use of Portable Fuel Containers
• 10.0 Hazard Identification and Control Measures
• 11.0 Static Electricity and Ignition Source Controls
• 12.0 Spill Prevention, Response and Reporting
• 13.0 Emergency Procedures (Fire, Exposure, Major Spill)
• 14.0 Environmental Protection and Waste Management
• 15.0 Vehicle and Plant Isolation and Traffic Management in Refuelling Areas
• 16.0 Inspection, Maintenance and Housekeeping Requirements
• 17.0 Training, Induction and Communication
• 18.0 Document Control and Review

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory equivalents)
• Work Health and Safety Regulations 2011 (Cth and relevant state/territory equivalents)
• Safe Work Australia – Model Code of Practice: Managing risks of hazardous chemicals in the workplace
• Safe Work Australia – Model Code of Practice: Managing the work environment and facilities
• 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 legislation and guidelines applicable in each state or territory (for spill and contamination control)