Petrol storage and handling risks in workplaces

WorkSafe New Zealand is urging businesses to take a fresh look at how they store and handle petrol, warning that even small lapses can create serious and entirely foreseeable risks.

Petrol is one of the most common – and most underestimated – hazards in workplaces. Its vapours ignite easily, and everyday sources such as heat, sparks, static electricity, running engines, or electrical equipment can be enough to trigger a fire or explosion when controls are inadequate.

More than a fire hazard

While petrol’s flammability is well known, its toxic vapours pose an additional layer of danger. Inhaling petrol fumes can lead to respiratory irritation, dizziness, loss of coordination, and in high concentrations, unconsciousness or even death. When petrol is kept in enclosed or poorly ventilated areas, or stored in containers that don’t meet safety standards, vapours can accumulate and create an explosive atmosphere. Crucially, this risk isn’t limited to large volumes – just a few litres stored incorrectly can be enough to create dangerous conditions.

What the law requires

New Zealand’s regulatory framework sets clear expectations for safe petrol storage. Only approved containers may be used, and portable containers are generally restricted to 25 litres. They must never be filled beyond 95 percent capacity to allow for thermal expansion. Once a workplace stores more than 50 litres, a location compliance certificate becomes mandatory. This certification confirms that a qualified assessor has inspected the site and verified that it meets the required safety standards. It’s a risk based system: the more petrol you store, the more robust the controls must be.

Safe storage starts with the basics

Petrol must be kept well away from ignition sources and protected from heat and sunlight, both of which can increase vapour pressure and degrade containers. Storing fuel inside vehicles or enclosed spaces is particularly hazardous due to limited ventilation and the potential for vapour build up. WorkSafe stresses that petrol should never be kept in general purpose rooms, cupboards, or storage areas containing electrical equipment that could spark.

Handling petrol safely

Operational practices matter just as much as storage. Refuelling should only occur when engines are switched off and have cooled sufficiently to eliminate the risk of ignition from hot surfaces. Fuel transfer should be carried out outdoors using proper equipment – funnels, spouts, or purpose designed pumps – to minimise spills. During transport, containers must be secured to prevent tipping or leakage. And if clothing becomes contaminated with petrol, it should be removed immediately to reduce both health risks and the chance of ignition.

Further information can be found at worksafe.govt.nz

Published in WIRED issue 81/June 2026 by Fencing Contractors Association NZ

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