Gas Station Safety Manual

What Should a Gas Station Safety Manual Include?

The contents of a Gas Station Safety Manual should reflect the facility’s actual operations.

A small gasoline station may need a different combination of programs than a large convenience store with fuel dispensers, a truck stop, a travel center with food service, or a service station performing minor vehicle maintenance.

Depending on operations, the manual may address:

• Gas station safety responsibilities.
• Hazard assessments.
• Safety inspections.
• Fuel dispensing.
• Gasoline and motor-fuel safety.
• Flammable liquids.
• Fuel spills and releases.
• Emergency fuel shutoff.
• Ignition-source control.
• Fire prevention.
• Fuel deliveries.
• Vehicle traffic.
• Electrical safety.
• Hazard Communication.
• Personal Protective Equipment.
• Propane cylinder exchange.
• Workplace violence.
• Robbery prevention.
• Cash handling.
• Late-night operations.
• Working alone.
• Convenience-store operations.
• Food service.
• Emergency procedures.

Programs and procedures should be selected according to the fuels, equipment, services, and workplace hazards actually present.

Gas Station Safety Program

An effective Gas Station Safety Program establishes responsibilities and procedures for safely storing and dispensing motor fuels, controlling ignition sources, preventing and responding to spills, maintaining dispensing equipment, protecting employees from vehicle traffic, and preparing employees for fire, robbery, violence, and other emergencies.

Management should provide employees with the equipment, safeguards, training, PPE, and resources necessary to perform assigned work safely.

Managers, supervisors, and other designated personnel should:

• Identify workplace hazards.
• Maintain applicable written safety programs.
• Maintain fuel-dispensing safeguards.
• Maintain emergency shutoff equipment.
• Control ignition sources.
• Establish spill-response procedures.
• Coordinate fuel deliveries.
• Maintain fire-protection equipment.
• Evaluate vehicle-traffic hazards.
• Maintain security procedures.
• Provide appropriate PPE.
• Conduct workplace inspections.
• Provide employee training.
• Correct unsafe conditions.
• Investigate incidents and injuries.
• Maintain applicable records.

Employees should follow established procedures, report damaged fuel equipment, promptly report spills and leaks, use required PPE, and follow emergency procedures.

Gas Station Hazard Assessments

Gas station operations should be evaluated to identify fire, chemical, physical, security, ergonomic, and other workplace hazards.

Hazard assessments may consider:

• Gasoline.
• Diesel fuel.
• Flammable vapors.
• Fuel dispensers.
• Fuel hoses and nozzles.
• Underground or aboveground tanks.
• Tank-truck deliveries.
• Fuel spills.
• Ignition sources.
• Electrical equipment.
• Vehicle traffic.
• Propane cylinders.
• Cleaning chemicals.
• Food-service equipment.
• Material handling.
• Workplace violence.
• Working alone.
• Severe weather.

Assessments should be reviewed when fuels, equipment, services, procedures, or workplace conditions change significantly.

Gas Station Safety Inspections

Periodic inspections can help identify unsafe conditions before they contribute to an injury, fire, spill, equipment failure, or other incident.

Inspections may include:

• Fuel dispensers.
• Hoses.
• Nozzles.
• Fuel islands.
• Emergency fuel shutoff.
• Vehicle-impact protection.
• Spill-control supplies.
• Fire extinguishers.
• No-smoking signs.
• Tank fill areas.
• Propane-storage areas.
• Electrical equipment.
• Parking lots.
• Walkways.
• Store areas.
• Chemical storage.
• PPE.
• Emergency exits.

Defective equipment and unsafe conditions should be promptly reported and corrected.

Job Safety Analysis (JSA/JHA)

A Job Safety Analysis (JSA/JHA) may be useful for selected gas-station tasks where a step-by-step hazard analysis can improve employee protection.

Potential JSAs/JHAs may address:

• Fuel spill response.
• Fuel delivery coordination.
• Dispenser inspection.
• Propane cylinder exchange.
• Trash removal.
• Exterior cleaning.
• Chemical handling.
• Minor vehicle-service activities.
• Working around vehicle traffic.

Routine customer fuel dispensing may be more appropriately addressed through established fuel-safety procedures, equipment safeguards, signs, and employee monitoring.

Fuel Dispensing Safety

Fuel dispensing is one of the defining operations of a gas station.

Gasoline and other motor fuels can create fire, vapor, spill, and exposure hazards.

Employees should understand:

• Normal dispenser operation.
• Emergency shutdown procedures.
• Spill-response procedures.
• Ignition-source restrictions.
• Customer fueling rules.
• How to recognize damaged equipment.
• When dispensing should be stopped.
• How to obtain emergency assistance.

Employees should not attempt unauthorized repairs to fuel-dispensing equipment.

Gasoline and Motor Fuels

Gasoline is a highly flammable motor fuel capable of producing ignitable vapors.

Employees should minimize unnecessary contact with gasoline and other fuels and follow established procedures for storage, dispensing, spills, and emergency response.

Employees should understand that fuel vapors can travel and may be ignited by a distant ignition source.

Flammable Liquids

Motor fuels and other flammable liquids should be stored, handled, and dispensed according to applicable requirements and established procedures.

Controls should address:

• Approved storage.
• Dispensing equipment.
• Ignition sources.
• Spill control.
• Electrical equipment.
• Fire protection.
• Waste disposal.
• Employee training.

Flammable liquids should not be stored where they obstruct exits or emergency access.

Fuel Dispensers

Fuel dispensers should be maintained in safe operating condition.

Employees should report:

• Fuel leaks.
• Damaged housings.
• Loose components.
• Damaged hoses.
• Damaged nozzles.
• Malfunctioning shutoffs.
• Evidence of vehicle impact.
• Electrical damage.
• Unusual odors or operating conditions.

Damaged equipment should be taken out of service or otherwise controlled as appropriate until evaluated by authorized personnel.

Fuel Hoses and Nozzles

Fuel hoses and nozzles should be periodically inspected for visible damage.

Potential problems include:

• Cracks.
• Cuts.
• Abrasion.
• Leaks.
• Damaged fittings.
• Damaged nozzles.
• Malfunctioning automatic shutoff features.

Employees should promptly report defects.

Dispenser Inspection

Routine inspections should verify that dispensing equipment and surrounding areas remain in safe condition.

Inspections may consider:

• Evidence of leaks.
• Hoses and nozzles.
• Dispenser condition.
• Vehicle-impact protection.
• Emergency shutoff access.
• Required signs.
• Fire extinguishers.
• Fuel-island housekeeping.
• Lighting.
• Spill-control supplies.

Inspection frequency should reflect the facility’s operations and conditions.

Vehicle-Impact Protection

Fuel dispensers and other vulnerable equipment should be appropriately protected from vehicle collision.

Employees should promptly report:

• Damaged bollards.
• Damaged islands.
• Evidence of vehicle impact.
• Shifted or damaged dispensers.
• Damaged piping or equipment.

A dispenser that has been struck by a vehicle should not simply be returned to service without appropriate evaluation.

Customer Fueling Safety

Employees should monitor fuel areas as appropriate and respond when unsafe conditions are observed.

Examples may include:

• Smoking near dispensers.
• Open flames.
• Fuel spills.
• Damaged equipment.
• Improper portable containers.
• Vehicles striking equipment.
• Customers driving away with nozzles attached.
• Other unsafe fueling behavior.

Employees should follow established procedures rather than placing themselves at unnecessary risk during customer confrontations.

Portable Fuel Containers

Fuel should be dispensed only into appropriate portable containers.

Containers should be designed and constructed for the fuel being dispensed and maintained in safe condition.

Employees should not knowingly permit dispensing into obviously unsuitable containers.

Portable containers should be handled in a manner that minimizes spills and ignition hazards.

Emergency Fuel Shutoff

Gas stations should have clearly identified and readily accessible emergency means for shutting off power to fuel-dispensing equipment as required.

Employees expected to respond to fuel emergencies should know:

• Where the emergency shutoff is located.
• What equipment it controls.
• How to activate it.
• Circumstances that may require shutdown.
• How to summon emergency assistance.

Access to the emergency shutoff should remain unobstructed.

Using the Emergency Shutoff

Circumstances that may require emergency fuel shutdown can include:

• Significant fuel release.
• Fire.
• Dispenser damage.
• Vehicle collision with fuel equipment.
• Uncontrolled fuel flow.
• Other conditions creating an immediate fire or fuel-release hazard.

Employees should follow facility emergency procedures after activating the shutdown.

Fuel dispensing should not simply resume until the condition has been appropriately evaluated and the equipment is safe to operate.

Ignition-Source Control

Gasoline vapors and other flammable vapors can ignite when they contact an ignition source.

Potential ignition sources include:

• Smoking.
• Open flames.
• Hot work.
• Electrical sparks.
• Mechanical sparks.
• Hot surfaces.
• Static discharge.
• Other spark-producing equipment.

Ignition sources should be eliminated or controlled in areas where flammable vapors may be present.

No Smoking and Open Flames

Smoking and open flames should be prohibited in areas used for fueling, servicing fuel systems, and receiving or dispensing flammable liquids.

Required signs should remain visible and legible.

Employees should follow established procedures when customers violate smoking or open-flame restrictions while avoiding unnecessary confrontation.

Vehicle Engines During Fueling

Vehicle or equipment engines should be shut off during fueling as required.

Employees should follow facility procedures when unsafe fueling conditions are observed.

Hot Work Near Fuel Systems

Welding, cutting, grinding, and other spark- or heat-producing work can create a serious ignition hazard near fuel systems.

Hot work near fuel-storage or dispensing systems should be performed only under appropriately controlled conditions by authorized personnel.

Potential fuel and vapor hazards should be evaluated before work begins.

Employees who are not trained or authorized to perform such work should not attempt repairs involving heat or sparks.

Fuel Spill Prevention

Fuel spills should be prevented through appropriate equipment maintenance, inspections, work practices, customer monitoring, and fuel-delivery procedures.

Employees should promptly report:

• Leaking dispensers.
• Leaking hoses.
• Damaged nozzles.
• Damaged fill connections.
• Evidence of tank overfill.
• Repeated unexplained fuel odors.
• Other conditions indicating a potential release.

Fuel Spill Response

Employees should receive instruction appropriate to the types of fuel spills they are expected to handle.

Procedures should address:

• Stopping dispensing.
• Activating emergency shutdown when appropriate.
• Eliminating or controlling ignition sources.
• Restricting access.
• Protecting employees and customers.
• Using spill-control materials when appropriate.
• Reporting the release.
• Obtaining emergency assistance.

Employees should not attempt response activities beyond their training, equipment, or assigned responsibilities.

Small Incidental Fuel Spills

Employees may be assigned to handle small incidental spills when the release can be safely controlled using available procedures and equipment.

Employees should:

• Stop the source when it can be done safely.
• Prevent ignition.
• Keep customers and vehicles away.
• Use appropriate PPE.
• Use approved absorbent or spill-control materials.
• Dispose of contaminated materials appropriately.

A spill that cannot be safely controlled should be treated as an emergency rather than an ordinary cleanup task.

Large or Uncontrolled Fuel Releases

Large, continuing, or otherwise uncontrolled releases can create serious fire, explosion, exposure, and environmental hazards.

Employees should follow emergency procedures, which may include:

• Emergency fuel shutdown.
• Area isolation.
• Evacuation.
• Emergency-service notification.
• Preventing vehicle entry.
• Eliminating ignition sources when safe to do so.
• Specialized spill response.

Employees should not enter dangerous vapor or fire conditions to stop a release.

Spill Kits and Response Supplies

Appropriate spill-control materials should be readily available for the spills employees are expected and trained to handle.

Supplies should be periodically inspected and replenished after use.

Employees should understand the location and proper use of available materials.

Drainage and Waste Disposal

Fuel spills should be prevented from entering buildings, public sewers, drainage systems, or waterways as required.

Gasoline, crankcase drainings, and other flammable liquids should not be dumped into sewers.

Employees should follow established procedures for collecting and disposing of contaminated absorbents, fuel waste, used oil, and other materials.

Fuel Deliveries

Fuel deliveries can create significant hazards involving flammable liquids, tank trucks, transfer hoses, vehicle traffic, vapors, spills, and ignition sources.

The station should establish procedures for coordinating fuel deliveries.

Employees involved in deliveries should understand their responsibilities before transfer begins.

Tank-Truck Fuel Deliveries

During fuel delivery, employees should remain alert for:

• Tank-truck movement.
• Customer vehicles.
• Transfer hoses.
• Open fill connections.
• Fuel vapors.
• Ignition sources.
• Spills.
• Unauthorized persons entering the transfer area.

Station employees should not perform delivery-driver tasks unless trained, authorized, and expected to do so.

Delivery Area Control

The fuel-delivery area should be managed to reduce unnecessary vehicle and pedestrian interference.

Where appropriate, controls may include:

• Cones.
• Barriers.
• Signs.
• Temporary lane restrictions.
• Employee monitoring.

Customers should be kept away from open fill connections, transfer hoses, and other hazards.

Traffic During Fuel Deliveries

Tank trucks may obstruct normal traffic patterns and create additional blind spots.

Employees should avoid standing between moving vehicles, tank trucks, dispensers, buildings, or other fixed objects.

Employees directing traffic should do so only when trained and when it can be performed safely.

Fill Connections

Tank fill connections should remain appropriately identified, secured, and maintained.

Employees should report damaged caps, covers, containment equipment, or other abnormalities.

Open fill connections should not be left unnecessarily unattended or exposed.

Spill Prevention During Delivery

Fuel-transfer activities should be monitored according to established procedures.

Employees should know how to report:

• Overfills.
• Hose failures.
• Connection leaks.
• Tank leaks.
• Fuel releases.
• Other abnormal conditions.

Emergency procedures should be initiated when conditions warrant.

Fire Prevention

Fire prevention is a critical component of gas station safety.

Controls should address:

• Flammable liquids.
• Ignition sources.
• Smoking.
• Electrical equipment.
• Fuel spills.
• Fuel deliveries.
• Hot work.
• Fire extinguishers.
• Emergency shutdown.
• Employee training.

Employees should understand that attempting to fight a fuel fire may be inappropriate when conditions exceed their training or available equipment.

Fire Extinguishers

Required fire extinguishers should be appropriately located and readily accessible.

Employees should not block access with merchandise, vehicles, waste, or equipment.

Extinguishers should be inspected and maintained as required.

Employees expected or permitted to use portable fire extinguishers should receive applicable instruction.

Fuel-Fire Emergency Procedures

During a fuel fire, employees should prioritize life safety.

Procedures may include:

• Activating emergency fuel shutoff when it can be done safely.
• Calling emergency services.
• Evacuating employees and customers.
• Restricting access.
• Moving to the designated assembly area.

Employees should not enter dangerous fire or vapor conditions to protect property.

Electrical Safety Around Fuel Systems

Electrical equipment near fuel-storage and dispensing systems may require special design and installation because flammable vapors may be present.

Employees should not modify, bypass, or perform unauthorized electrical work on:

• Fuel dispensers.
• Pumps.
• Emergency shutoff systems.
• Lighting.
• Wiring.
• Fuel-system controls.

Electrical repairs should be performed by appropriately qualified or authorized personnel.

Hazardous/Classified Locations

Certain areas around fuel dispensing and storage equipment may be classified because flammable vapor-air mixtures can occur.

Electrical equipment and wiring within these areas should be appropriate for the location.

General employees should not install or substitute ordinary electrical equipment in areas requiring specialized equipment.

Electrical Equipment

Employees should report:

• Damaged wiring.
• Broken receptacles.
• Exposed conductors.
• Damaged dispenser electrical components.
• Sparking.
• Overheating.
• Repeated breaker trips.
• Other abnormal electrical conditions.

Damaged equipment should be removed from use or appropriately controlled until repaired.

Fuel-System Maintenance and Repair

Fuel dispensers, tanks, piping, electrical components, and other specialized fuel-system equipment should be serviced only by appropriately trained and authorized personnel.

Station employees should not dismantle or repair fuel equipment unless the task is within their assigned responsibilities and they have the necessary training and authorization.

Work areas should be protected from customers and vehicle traffic during maintenance.

Vehicle Traffic Safety

Gas station employees may work around continuously moving customer vehicles, delivery trucks, service vehicles, and other traffic.

Employees working outside should:

• Remain alert.
• Avoid vehicle blind spots.
• Make themselves visible.
• Avoid standing behind moving vehicles.
• Use designated walkways where provided.
• Avoid unnecessary use of phones or other distractions.
• Watch for backing vehicles.

Employees should never assume a driver has seen them.

Fuel Island Traffic

Fuel islands may have vehicles approaching from multiple directions.

Employees should avoid walking between closely spaced moving vehicles whenever possible.

Work around dispensers should be scheduled or controlled to minimize employee exposure to traffic.

Pedestrian Safety

Employees walking through parking lots and fuel islands should remain alert for:

• Turning vehicles.
• Backing vehicles.
• Large trucks.
• Distracted drivers.
• Poor visibility.
• Weather conditions.

High-visibility apparel may be appropriate for certain exterior or traffic-exposed tasks.

Parking Lot and Exterior Safety

Exterior areas should be periodically inspected for:

• Potholes.
• Damaged pavement.
• Poor lighting.
• Debris.
• Ice or snow.
• Fuel or oil spills.
• Damaged curbs.
• Trip hazards.
• Security concerns.

Unsafe conditions should be corrected or appropriately protected.

Hazard Communication

Gas stations using hazardous chemicals should maintain an appropriate Hazard Communication Program.

The program should address applicable:

• Chemical inventories.
• Safety Data Sheets.
• Container labeling.
• Employee information and training.
• Non-routine tasks.
• Contractor communication.

Employees should understand how to obtain and use Safety Data Sheets.

Cleaning Chemicals

Employees using cleaners, degreasers, disinfectants, glass cleaners, restroom chemicals, or other hazardous products should follow label and Safety Data Sheet precautions.

Employees should:

• Use required PPE.
• Follow dilution instructions.
• Maintain labels.
• Avoid unauthorized chemical mixing.
• Store chemicals appropriately.
• Report spills and damaged containers.

Personal Protective Equipment

PPE should be selected according to the hazards employees are expected to encounter.

Depending on the task, PPE may include:

• Chemical-resistant gloves.
• Eye protection.
• Face protection.
• High-visibility apparel.
• Protective footwear.
• Other task-specific protection.

Employees should understand when PPE is required and its limitations.

Eye and Face Protection

Eye or face protection may be necessary during fuel-spill cleanup, chemical handling, maintenance, battery work, or other tasks involving splash or particle hazards.

Protection should be selected according to the anticipated exposure.

Hand Protection

Employees should use appropriate gloves when handling chemicals, contaminated spill materials, waste, sharp objects, or other hand hazards.

The glove material should be appropriate for the substance or task involved.

Propane Cylinder Exchange — When Applicable

Gas stations that sell or exchange propane cylinders should establish procedures for safe cylinder handling and storage.

Employees should receive appropriate instruction before handling exchange cylinders.

Procedures may address:

• Cylinder condition.
• Storage.
• Ignition sources.
• Customer exchanges.
• Damaged cylinders.
• Security.
• Emergency response.

Cylinder-exchange operations should be distinguished from facilities that actually fill propane cylinders.

Propane Cylinder Storage

Propane cylinders should be stored in appropriate designated areas.

Storage areas should be:

• Protected from vehicle impact where necessary.
• Kept away from inappropriate ignition sources.
• Maintained in orderly condition.
• Protected from unauthorized access as appropriate.

Employees should promptly report damaged storage cages or barriers.

Damaged Propane Cylinders

Employees should not knowingly provide visibly damaged or leaking cylinders to customers.

Suspected leaking or damaged cylinders should be handled according to established procedures.

Employees should avoid creating ignition sources near a suspected propane leak.

Workplace Violence Prevention

Gas stations can present elevated workplace-violence risks because employees may work with cash, interact with the public, work alone, and work during late-night or early-morning hours.

A workplace-violence prevention program should reflect the station’s location, hours, staffing, previous incidents, security systems, and other risk factors.

Controls may include:

• Cash-control procedures.
• Visibility.
• Lighting.
• Security cameras.
• Alarm or duress systems.
• Access control.
• Employee training.
• Incident reporting.
• Emergency communication.

Robbery Prevention

Robbery-prevention measures should reduce incentives and opportunities for violent crime where practical.

Measures may include:

• Limiting accessible cash.
• Using drop safes.
• Maintaining good visibility.
• Exterior lighting.
• Security cameras.
• Appropriate signs.
• Controlled access.
• Employee training.

Employees should understand the station’s robbery-response procedures.

Response During a Robbery

During a robbery, employee safety should take priority over protecting cash, merchandise, or property.

Employees should generally:

• Avoid unnecessary resistance.
• Avoid sudden or threatening movements.
• Follow established procedures.
• Observe details only when it can be done safely.
• Contact law enforcement when safe.
• Preserve the scene after the offender leaves.

Employees should not pursue a fleeing robber.

Cash Handling

Cash-handling procedures may include:

• Limiting register cash.
• Making periodic safe drops.
• Restricting access to safes.
• Avoiding unnecessary cash counting in public view.
• Maintaining robbery-prevention signs where appropriate.

Procedures should reflect the facility’s hours, staffing, and transaction volume.

Late-Night Operations

Late-night and early-morning operations may create increased security concerns.

Controls may include:

• Increased lighting.
• Restricted access.
• Transaction windows.
• Additional staffing.
• Security systems.
• Cash-control procedures.
• Check-in procedures.
• Emergency communication.

The appropriate measures should reflect the station’s actual risk factors.

Working Alone

Employees working alone may face increased risk during robbery, workplace violence, medical emergencies, fuel spills, fires, and other incidents.

Procedures should address:

• Emergency communication.
• Check-in procedures where appropriate.
• Security systems.
• Access control.
• Tasks that should not be performed alone.

Higher-risk work should be evaluated to determine whether working alone is appropriate.

Store Security

Security procedures may address:

• Doors and locks.
• Exterior lighting.
• Windows and visibility.
• Security cameras.
• Alarm systems.
• Duress alarms.
• Restricted areas.
• Employee-only areas.
• Opening and closing procedures.

Security measures should not obstruct required emergency egress.

Customer Confrontations

Employees may encounter angry, intoxicated, threatening, or aggressive customers.

Employees should be trained to:

• Maintain appropriate distance.
• Avoid unnecessary escalation.
• Obtain assistance.
• Follow established security procedures.
• Contact law enforcement when appropriate.
• Move to a safer location when necessary.

Employees should not unnecessarily place themselves in danger to protect property.

Shoplifting Response

Employees should follow company procedures when shoplifting is suspected.

Employees should not physically pursue, restrain, or confront suspected shoplifters when doing so could expose themselves or others to violence.

Property recovery should not take priority over employee safety.

Emergency Communication

Employees should have reliable means to summon assistance during:

• Robbery.
• Workplace violence.
• Fire.
• Fuel spills.
• Medical emergencies.
• Other serious incidents.

Employees should know the facility address or location information necessary to direct emergency responders.

Convenience Store Operations — When Applicable

Gas stations containing convenience stores should address retail hazards in addition to fuel operations.

Potential hazards include:

• Stocking.
• Manual lifting.
• Box cutters.
• Slips and falls.
• Cleaning chemicals.
• Coolers.
• Food-service equipment.
• Trash handling.
• Workplace violence.

Store procedures should be integrated with the facility’s overall safety program.

Food-Service Safety — When Applicable

Facilities preparing or serving food should evaluate occupational hazards involving:

• Hot surfaces.
• Fryers.
• Ovens.
• Knives.
• Slicers.
• Hot liquids.
• Cleaning chemicals.
• Slippery floors.
• Electrical equipment.

Employee safety procedures should complement, but not be confused with, food-safety and sanitation requirements intended primarily to protect consumers.

Fryer Safety — When Applicable

Employees working with deep fryers may be exposed to hot oil, steam, splashes, and burns.

Employees should follow established procedures for:

• Cooking.
• Filtering.
• Cleaning.
• Adding or removing oil.
• Responding to grease fires.

Water should not be used on a cooking-oil fire.

Hot Beverage Safety

Coffee, hot water, and other heated beverages can cause burns.

Employees should use appropriate containers, equipment, and handling procedures.

Spills should be promptly corrected.

Knives and Cutting Tools

Employees should use knives and cutting tools appropriate for the task.

Knives should be stored safely when not in use.

Employees should cut away from the body and maintain appropriate control of the material being cut.

Box Cutter Safety

Employees using box cutters or utility knives should:

• Use appropriate cutting tools.
• Keep hands clear of the cutting path.
• Retract or cover blades when not in use.
• Replace damaged tools.
• Dispose of blades safely.

Stocking and Shelving

Merchandise should be stored securely and shelves should not be overloaded.

Heavy items should be placed where practical to reduce difficult lifting and falling-object hazards.

Employees should use appropriate ladders or step stools rather than standing on boxes, shelves, or other improvised surfaces.

Manual Lifting and Material Handling

Employees may handle cases of beverages, merchandise, ice, propane cylinders, trash, and other materials.

Employees should evaluate loads before lifting and obtain assistance when necessary.

Carts, hand trucks, and other material-handling equipment should be used when practical.

Ergonomics

Repetitive stocking, lifting, cashier work, cleaning, and prolonged standing can create ergonomic stress.

Work practices should reduce unnecessary:

• Heavy lifting.
• Repetitive reaching.
• Twisting.
• Awkward postures.
• Forceful exertion.

Employees should report persistent musculoskeletal symptoms.

Ladders and Step Stools

Appropriate ladders or step stools should be used when employees must reach elevated shelves or equipment.

Employees should not stand on:

• Chairs.
• Boxes.
• Shelving.
• Counters.
• Other improvised surfaces.

Damaged ladders or step stools should be removed from service.

Coolers and Freezers — When Applicable

Employees entering walk-in coolers or freezers should be protected from:

• Slippery floors.
• Cold exposure.
• Falling merchandise.
• Blocked exits.
• Material-handling hazards.

Doors and release mechanisms should remain functional.

Slips, Trips and Falls

Potential slip and trip hazards include:

• Fuel.
• Oil.
• Water.
• Ice.
• Food and beverage spills.
• Mats.
• Cords.
• Merchandise.
• Damaged pavement.

Hazards should be promptly corrected or appropriately protected.

Housekeeping

Store, fuel-island, storage, restroom, exterior, and service areas should be maintained in orderly condition.

Emergency equipment, electrical panels, exits, and walkways should remain accessible.

Trash, packaging, and combustible materials should not be allowed to accumulate in unsafe locations.

Trash and Waste Handling

Employees should use appropriate procedures when handling trash.

Employees should not:

• Reach blindly into waste containers.
• Manually compress trash bags.
• Handle broken glass without appropriate protection.

Fuel-contaminated materials and other hazardous wastes should be handled separately as required.

Used Oil — When Applicable

Service stations collecting or generating used oil should establish appropriate storage, handling, spill-control, and disposal procedures.

Used oil should be kept in suitable containers and protected from releases.

Employees should promptly report leaking containers.

Minor Vehicle Maintenance — When Applicable

Some service stations may perform minor vehicle-maintenance activities.

Applicable procedures may address:

• Vehicle movement.
• Jacks and lifts.
• Batteries.
• Tires.
• Hand and power tools.
• Chemicals.
• Used oil.
• Lockout/Tagout where applicable.

Facilities performing substantial automotive repair should maintain safety procedures appropriate to those operations rather than relying solely on gas-station procedures.

Battery Safety — When Applicable

Employees handling vehicle batteries may be exposed to corrosive electrolyte, electrical energy, and lifting hazards.

Appropriate PPE and handling procedures should be used.

Employees should avoid creating sparks or ignition sources near batteries where flammable gases may be present.

Tire Service — When Applicable

Employees performing tire work should use appropriate equipment and procedures.

Specialized tire servicing should be performed only by employees with the necessary training.

Damaged equipment should not be used.

Vehicle Lifts and Jacks — When Applicable

Employees should use vehicle lifts and jacks according to manufacturer instructions and established procedures.

Employees should not work beneath inadequately supported vehicles.

Only appropriately trained employees should operate specialized lifting equipment.

Young Worker Safety

Young employees may have limited workplace experience and may require additional instruction and supervision.

Training should address the hazards associated with their assigned duties, including:

• Vehicle traffic.
• Workplace violence.
• Fuel spills.
• Cleaning chemicals.
• Lifting.
• Hot equipment.
• Cutting tools.
• Slips and falls.

Young workers should not be assigned tasks prohibited by applicable child-labor requirements.

Equipment Restrictions for Young Workers

Managers should determine whether age restrictions apply before assigning young employees to potentially hazardous equipment or tasks.

Restrictions may affect certain:

• Compactors.
• Balers.
• Powered equipment.
• Driving.
• Food-processing equipment.
• Other hazardous occupations.

Supervisors should not assume that a task is permitted simply because an employee is willing to perform it.

Heat Stress — When Applicable

Employees performing extended outdoor work may be exposed to high temperatures.

Controls may include:

• Drinking water.
• Rest.
• Shade or cooling.
• Acclimatization.
• Employee training.
• Emergency response.

Cold Stress — When Applicable

Employees working outdoors during cold weather may be exposed to cold stress.

Appropriate clothing, work practices, warming opportunities, and training should reflect environmental conditions and work duration.

Severe Weather

Gas station employees may work during thunderstorms, high winds, extreme temperatures, snow, ice, or other severe weather.

The facility should establish procedures appropriate to foreseeable local conditions.

Employees should not be required to perform unnecessary exterior work when severe conditions create unacceptable risk.

Emergency Action Plan

Employees should understand procedures for foreseeable emergencies.

The Emergency Action Plan may address:

• Fuel fires.
• Fuel releases.
• Building fires.
• Gas leaks.
• Workplace violence.
• Robbery.
• Medical emergencies.
• Severe weather.
• Power failure.
• Evacuation.
• Shelter-in-place.

Employees should understand alarms, emergency communication, exit routes, assembly locations, and assigned responsibilities.

First Aid

The facility should maintain procedures for obtaining prompt medical assistance for employee injuries.

Employees should understand how to report:

• Fuel exposure.
• Chemical exposure.
• Burns.
• Cuts.
• Falls.
• Workplace-violence injuries.
• Other occupational injuries.

Appropriate first-aid supplies should be readily available.

Gas Station Safety Training

Employee safety training should reflect assigned duties and workplace hazards.

Depending on operations, training may address:

• Fuel dispensing.
• Flammable liquids.
• Emergency fuel shutoff.
• Fuel spills.
• Ignition sources.
• Fire prevention.
• Fuel deliveries.
• Vehicle traffic.
• Hazard Communication.
• PPE.
• Propane cylinders.
• Workplace violence.
• Robbery response.
• Cash handling.
• Working alone.
• Food-service equipment.
• Emergency procedures.

Employees should receive task-specific instruction before independently performing higher-hazard work.

New Employee Safety Orientation

New employees should receive appropriate safety orientation before working independently.

Orientation may address:

• General gas station safety.
• Fuel hazards.
• Emergency fuel shutoff.
• Spill reporting.
• Fire procedures.
• Vehicle traffic.
• Workplace violence.
• Robbery response.
• Hazard Communication.
• PPE.
• Emergency communication.
• Injury reporting.

Employees should understand which tasks they are not authorized to perform.

Gas Station JSA/JHA

Gas stations can use JSAs/JHAs to document safe work practices for selected higher-hazard tasks.

Potential Gas Station JSAs/JHAs include:

• Fuel spill response.
• Fuel delivery coordination.
• Propane cylinder exchange.
• Exterior cleaning.
• Trash handling.
• Dispenser inspection.
• Working around vehicle traffic.
• Minor vehicle maintenance.

Gas Station Safety Meetings

Periodic safety meetings can reinforce safe work practices and address current concerns.

Potential topics include:

• Fuel spills.
• Emergency shutdown.
• Ignition sources.
• Fire prevention.
• Fuel deliveries.
• Vehicle traffic.
• Robbery prevention.
• Workplace violence.
• Cash handling.
• Slips and falls.
• Propane safety.
• Emergency procedures.

Recordkeeping

Gas stations should maintain occupational safety and health records required for their operations.

Records may include:

• Employee training.
• Safety inspections.
• Fuel-related incidents.
• Spill reports.
• Workplace-violence incidents.
• Equipment inspections.
• Fire-protection inspections.
• Injury reports.
• Other required program records.

Additional Safety Programs

Depending on gas-station operations, additional safety programs may be necessary for:

• Flammable Liquids.
• Spill Prevention and Response.
• Hazard Communication.
• Personal Protective Equipment.
• Workplace Violence Prevention.
• Workplace Security.
• Working Alone.
• Fire Prevention.
• Electrical Safety.
• Lockout/Tagout.
• Compressed Gas Cylinders.
• Manual Lifting and Material Handling.
• Heat Stress Prevention.
• Cold Stress.
• Vehicle Safety.
• Hazardous Waste Management.
• Food Service Safety.
• Short Service Employees.

These programs should be included when employee activities or workplace hazards make them applicable rather than automatically adding programs unrelated to the facility.

Building a Gas Station Safety Manual

A useful Gas Station Safety Manual should reflect the actual facility rather than simply adapting a generic retail or convenience-store safety manual.

A fuel-only station may require a different combination of programs than a convenience store with fuel pumps, a service station performing vehicle maintenance, or a large travel center with food service, propane sales, and significant truck traffic.

The manual should consider:

• Fuels stored and dispensed.
• Fuel-storage systems.
• Dispensers.
• Fuel deliveries.
• Spill hazards.
• Fire hazards.
• Vehicle traffic.
• Propane operations.
• Store operations.
• Food service.
• Vehicle-service activities.
• Operating hours.
• Staffing.
• Working-alone conditions.
• Workplace-violence risks.

Selecting the appropriate programs creates a manual that is comprehensive without filling it with procedures unrelated to the facility.

Customized Gas Station Safety Manuals

A Gas Station Safety Manual can be developed around the facility’s fuel systems, dispensers, storage tanks, fuel-delivery operations, store activities, food service, propane sales, vehicle-service operations, staffing, security risks, and other workplace hazards.

The finished manual may incorporate applicable programs for Flammable Liquids, Spill Prevention and Response, Fire Prevention, Hazard Communication, PPE, Workplace Violence Prevention, Working Alone, Electrical Safety, Compressed Gas Cylinders, vehicle traffic, emergency procedures, and other hazards present within the operation.

This provides gas station and service station employers with a practical safety manual organized around the work their employees actually perform.