Ensure safe and controlled fuel handling with this Refuelling Plant & Equipment SWMS. This document outlines a structured approach to identifying and controlling hazards associated with refuelling activities. It provides essential risk controls, hazard management strategies, and best practices to support compliance with Australian workplace safety standards while ensuring a safe work environment.
 
Hazards & Control Measures Covered:
1️⃣ Pre-Operating Safety Checks
Poor Preparation & Lack of Competence – Safety Data Sheets (SDS) must be available on-site and reviewed before handling fuel. All staff must be trained and competent in refuelling procedures.
Exposure to Chemicals & Fumes – Workers must wear appropriate PPE, including gloves and respiratory protection. Refuelling must occur in a well-ventilated area.
Explosion & Fuel Spill Risks – Fuel containers and hoses must be inspected for leaks or damage before use. Emergency spill resources must be available on-site.
2️⃣ Labelling & Storage Requirements
Unknown Substance or Incorrect Decanting – Fuel must not be transferred into unlabelled containers or food/beverage containers. Proper labelling must be maintained at all times.
Container Integrity & Spill Containment – Fuel storage containers must be in good condition and stored in bunded areas to contain leaks. A spill kit must be accessible at all times.
Compatibility with Other Chemicals – SDS must be reviewed to ensure fuel is stored correctly and away from incompatible substances.
3️⃣ Decanting & Handling Procedures
Incorrect Decanting Practices – Fuel must only be transferred into properly labelled containers. SDS instructions must be followed precisely.
Hygiene & Contamination Risks – Workers must wash hands before eating and after handling fuel. PPE must be washed and stored appropriately after use.
Fire & Explosion Hazards – No smoking or open flames are permitted near the decanting area. Refuelling must be conducted in a well-ventilated outdoor space.
4️⃣ Fuel Spill & Fire Prevention
Spill Containment & Cleanup – Fuel spills must be cleaned immediately using SDS-approved methods. All spills must be reported.
Fire Prevention Measures – Fuel must only be handled in designated areas away from ignition sources. Engines must be switched off during refuelling.
Handling Handheld Equipment – Petrol-powered handheld equipment must be refuelled on the ground, away from static electricity risks. A fire extinguisher must be readily available.
5️⃣ Traffic & Vehicle Safety During Refuelling
Pedestrian & Vehicle Collisions – Where possible, vehicle movements should be minimised. Drivers must notify personnel before moving vehicles and adhere to site speed limits.
Unlicensed Operator Risks – Only licensed personnel are permitted to operate and refuel plant/vehicles. Vehicles must be moved at a controlled speed, especially in confined spaces.
Traffic Accidents at Refuel Station – Operators must move vehicles at a very slow speed when entering and exiting refuel bays to prevent collisions.
6️⃣ Mechanical & Equipment Safety
Unserviceable Plant & Vehicles – Vehicles must have a current risk assessment, logbooks, registration, and maintenance records. Operators must conduct pre-start inspections.
Refuelling Safety Procedures – All vehicles must be switched off before refuelling, and hoses must be inspected for damage before use.
Exiting Refuel Area Safely – Vehicles must exit at a slow and controlled speed, with the operator ensuring a clear path before moving.
7️⃣ Emergency Preparedness & Incident Response
First Aid & Fire Safety Measures – Workers must be aware of the location and use of first aid kits and fire-fighting equipment. Emergency contact details must be readily available.
Incident Reporting & Work Cessation – Any injuries, near misses, or unexpected hazards must be reported immediately. Work must stop until risks are reassessed and controlled.
Activation of Site Emergency Procedures – In case of a major incident, emergency protocols must be followed, including contacting emergency services and securing the site.
 
Key Features of the SWMS:
Supports Compliance – Helps businesses align with Australian workplace safety standards for fuel handling and refuelling procedures.
Structured Risk Management – Identifies hazards, implements control measures, and provides step-by-step safety guidelines for refuelling operations.
Emergency Readiness – Establishes clear procedures for spill containment, fire prevention, and emergency response.
Fully Customisable – Can be tailored to specific refuelling environments, plant and equipment requirements, and industry standards.
 
Who is This SWMS Suitable For?
This Refuelling Plant & Equipment SWMS is essential for:
Construction & Civil Engineering Teams
Mining & Heavy Machinery Operators
Transport & Logistics Companies
Industrial & Agricultural Equipment Operators
 
Additional Resources:
Included with your purchase is a free copy of our Legislation & Codes of Practice Reference List to support your WHS documentation.
 
Ensure safe and compliant refuelling operations. Download the Refuelling Plant & Equipment SWMS today and implement best-practice risk management for your site.