5 Tips for Setting Up Mobile Refueling at Construction Sites

In construction sites, where time is a critical resource, even minor fuelling delays can have a significant impact on the project. Whether it’s a bulldozer running dry mid-task or a fleet of trucks waiting for fuel off-site, these interruptions can derail schedules and inflate operational costs. That’s why mobile refuelling stations have become a practical solution for construction projects across Australia.

With immediate access to fuel, a construction site can run smoothly without interruptions. It enhances productivity and minimises the need to transport equipment off-site for fuelling, which saves time and reduces wear and tear on machinery. However, setting up a mobile refuelling station isn’t as simple as parking a fuel tank on-site. To establish a safe and efficient setup, site managers and contractors must carefully plan and think things through.

With that in mind, here are some key tips and considerations to help you set up a mobile refuelling station that works safely and efficiently on your construction site

1. Select the Right Fuel Storage Solutions

The type of fuel storage you choose will set the foundation for the safety and efficiency of your mobile refuelling station. In Australia, the most commonly used options are self-bunded tanks, which feature an inner tank surrounded by an outer tank to contain potential leaks or spills. These tanks are ideal for construction sites as they meet environmental regulations and simplify spill management. When exploring different self bunded diesel tanks for sale, it’s essential to consider the fuel needs of your equipment and how frequently refuelling is required. For larger sites with numerous machines, high-capacity tanks might be more beneficial, while smaller or temporary sites may opt for smaller, trailer-mounted units for flexibility.

Material durability is also important; steel tanks in particular are often preferred for their strength and longevity. Additionally, tanks should be compatible with the type of fuel being stored, such as diesel or petrol, and equipped with reliable dispensing systems. Finally, consider tanks with built-in flow meters, filters, and lockable access points to enhance operational control and security.

2. Find the Ideal Location for Your Refuelling Station

The location of your refuelling station within your construction site is crucial to both safety and efficiency. A mobile refuelling station should be positioned on a flat, stable surface to ensure the tank remains secure and level, reducing the risk of tipping or leakage. Make sure to also avoid areas with loose soil, uneven ground, or where water tends to pool during rain, as this can compromise the stability of the storage unit and lead to environmental hazards.

Furthermore, the site should be easily accessible to both on-site machinery and external fuel delivery vehicles, but not so central that it interferes with normal operations or high-traffic zones. Keeping the station slightly offset from central areas helps minimise the risk of accidents and allows for a designated, controlled space for fuelling.

3. Maintain a Safe Distance from Ignition Sources

One of the most important safety rules in setting up a refuelling station is maintaining a safe distance from ignition sources. Remember that fuel vapours are extremely flammable, and even a minor spark—from tools, machinery, or electrical systems—can trigger a serious fire or explosion. Additionally,

Australian standards, including the Australian Dangerous Goods Code and various state regulations, specify minimum clearance distances between fuel storage and potential ignition points. To stay compliant and reduce risk, position the refuelling station well away from common ignition sources, which include welding and cutting equipment, generators, open flames, and areas prone to static discharge.

4. Implement Site Safety Measures

Comprehensive safety protocols are vital to prevent accidents during refuelling operations. At a minimum, every mobile refuelling station should be equipped with appropriate fire extinguishers that are regularly inspected and easily accessible. Spill containment kits should also be on hand to manage any leaks or overflows quickly. These kits usually include absorbent materials, drip trays, disposal bags, and personal protective equipment.

The staff assigned to refuelling tasks should be trained in safe handling procedures, such as shutting off engines before fuelling, wearing protective gear correctly, and recognising signs of equipment malfunction. Regular toolbox talks and refresher training help reinforce these practices. In addition to physical safety measures, clear signage must be displayed around the refuelling area, indicating potential hazards and emergency procedures. Lastly, barriers or bollards should be installed to physically separate the fuelling zone from other operational areas, reducing the likelihood of vehicle collisions or unauthorised entry.

5. Set Up Emergency Protocols

Despite thorough safety planning, emergencies can still happen, making it essential to have a well-documented and practised emergency response plan. It should outline clear actions for handling fuel spills, fires, and accidental exposure to fuel or vapours. Site personnel must be familiar with evacuation routes and assembly points, and emergency contact numbers—including the local fire services, medical teams, and environmental authorities—should be visible near the refuelling station as well. Additionally, all incidents, no matter how minor, should be reported and documented to help refine safety procedures and enhance future response efforts.

Setting up a mobile refuelling station at your construction site is more than a logistical task; it’s a strategic decision that impacts your project’s efficiency and safety. For the best outcomes, consider engaging experienced professionals or fuel suppliers who understand the regulatory landscape and can support you in building a reliable and compliant fuelling setup. With a well-planned refuelling station, it can contribute to the overall success of your construction project.