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  • Basic Auto Repair Safety

  • Automotive Lift Safety

  • Brake and Clutch Repair Safety

  • Chemicals and Fluids Safety

  • Fire Safety

  • Frame Straightener Safety

  • Fuel Handling Safety

  • Grinder Safety

  • Hand Tool Safety

  • Inspection Pit Safety

  • Ladder Safety

  • Physical Lifting Safety

  • Power Tool Safety

  • Spray Painting Safety

  • Steering and Suspension Repair Safety

  • Tire Removal and Replacement Safety

  • Vehicle Handling Safety

  • Vehicle Jack Safety

  • Welding, Cutting, and Burning Safety

  • OSHA Requirements for Auto Repair Shops

Fuel Handling Safety

No smoking sign as a safety precaution in areas where fuel is handled

Fuel is a volatile material that presents both fire and inhalation risks, requiring precautions to be taken during transfer and storage.

Plan for the safe handling of fuel

All plans for the removal and retrieval of fuel must be in compliance with OSHA standard 1910.106, Flammable and Combustible Gases. Another helpful guide is The National Fire Protection Association standard 30A, Code For Motor Fuel Dispensing Facilities and Garages.

Employees assigned to fuel retrieval and removal must be properly trained. Warning signs should be posted in the appropriate areas, and access to the area should be limited while fuel is being drained from tanks.

Implement ignition source controls

A key part of handling fuel safety is prevent sources of ignition that could start the combustion process:

  • No smoking signs must be posted and no smoking rules enforced.
  • Replace incandescent lights with fluorescent lights.
  • There should be no welding, grinding, or use of power tools within 20 feet of where gas tanks are being emptied.
  • Observe all relevant fire safety precautions.

Safe fuel handling tools and equipment

Make sure you have the tools and equipment needed for draining fuel before you start the job. Always use a Factory Mutual (FM) rated portable pump and storage tank designed for the task.

Keep properly rated fire extinguishers on hand (Class B extinguishers for gasoline fires) and ensure that employees are training in their use.

When working on a fuel tank, use clamps to seals all lines coming off the tank. This will help to control gasoline drips and vapors. If fuel tank removal is required when replacing the fuel pump, use a non-sparking hammer and chisel.

Precautions before and after draining fuel

Always disconnect the vehicle's battery before draining fuel.

Disconnecting a vehicle battery before draining fuel.
Disconnect the battery to prevent it from acting as an ignition source.

If fuel removal and retrieval will be done indoors, make sure the area is properly ventilated before, during, and after fuel removal procedures. Also make sure the work area is free of trip and slip hazards.

Immediately clean up any spilled fuel using absorbent granules or other appropriate materials. After cleaning up, place the materials in an airtight, designated container.

Draining and refilling the fuel

For the protection of everyone in the shop, follow these precautions when draining and refilling:

  • Use metal containers with secure locks for drained fuel. Never use plastic containers.
  • Make sure the available containers are large enough to hold the drained fuel.
  • Use grounding strips between the vehicle chassis and the metal container to prevent static electricity buildup.
  • Mark fuel containers with hazard labels and store the containers properly in a well-ventilated, secure location.
  • The transfer of fuel from a container back to the fuel tank should generally be done outdoors. Make sure the shop area is well-ventilated if transferring fuel indoors.
Safety precautions for draining and refilling fuel in a repair shop.