Machinery Maintenance & Refuelling Risk Assessment Template

Typical hazards & measures

• Competence, supervision and briefings — Authorise maintainers/refuelers by role; verify competence on the specific model. Deliver a pre-task brief covering hazards, isolation points, torque specs and test procedures. Supervise new staff; use checklists, sign-off sheets and stop-work authority to catch errors before release.
• Fuel handling and storage — Store petrol/diesel in approved, labelled containers within a ventilated, bunded cabinet; segregate from oxidisers and ignition. Keep quantities to task need. Inspect cans and hoses for damage. Provide spill kits, extinguishers, no-smoking signage, and update the chemical inventory.
• Security and unauthorised access — Control keys and fuel cards; lock stores and isolators. Park machines disabled (e.g., battery disconnected) when unattended. Supervise visitors and contractors; sign in and brief. Remove fuel cans from vehicles overnight; CCTV or lighting where risk warrants; report losses promptly.
• Slips and trips from oils and tools — Keep a clean floor policy: lay absorbent mats under work, wipe spills immediately, and bin oily rags. Route leads and hoses overhead or with covers; maintain clear walkways. Use anti-slip footwear and good lighting. Store tools in trays, not on the floor; mark wet areas.
• Battery maintenance and charging — Charge in a ventilated area; keep sources of ignition away. Check terminals for corrosion; isolate before work. Use insulated tools, face/eye protection and acid-resistant gloves; neutralise acid with bicarbonate. Secure batteries upright; follow maker guidance on lithium packs.