Safety warning issued after two workers in the Territory burned in different refuelling incidents

NT WorkSafe has issued a safety alert after two Territory workers suffered serious burn injuries in separate refuelling incidents involving petrol-powered pressure cleaners. Employers across the Northern Territory are being urged to review how fuel is stored, decanted and handled before another operator is hurt.

Safety alert at a glance

• Regulator: NT WorkSafe, which delivers inspection and advisory services throughout the Territory.
• Incidents: Two events roughly a month apart — one in Coomalie Shire, one in Darwin.
• Plant involved: Petrol-driven pressure washers, standard kit for cleaning services and grounds crews.
• Primary risk: Fuel vapour igniting on engine components that stay scorching after use.
• Priority control: Switch off, allow cooling, then refuel outdoors using approved containers.
• Response readiness: Extinguishers, cool running water and fast access to emergency services.

What happened in the Territory

Two workers have suffered serious burn injuries within the past month while refuelling petrol pressure cleaners at different jobs. The initial incident took place at a worksite located in the Coomalie Shire, while the subsequent event transpired at a Darwin site. Identical machines turn up daily on facility services contracts nationwide.

Burn trauma of this severity often means hospital admission, grafting and lengthy rehabilitation supported by specialist health services. Losing one experienced operator can also leave a small contractor scrambling to cover committed field services.

Why refuelling fires start

NT WorkSafe outlined the possible contributing factors along with actions needed to prevent similar events occurring in future. Petrol gives off vapour at ambient temperatures, and vapour — never the liquid itself — ignites, sometimes travelling metres to reach an ignition source.

Factors that typically combine before a flash fire include:

• Topping up a motor still running, or one that has not cooled sufficiently
• Fuel splashing onto exhausts, mufflers or cylinder heads that remain scorching after operation
• Vapour collecting inside sheds, trailers, utes and other confined spaces
• Static discharge while decanting from unearthed drums or plastic vessels
• Ignition points nearby: naked flames, cigarettes, grinders, welding leads, damaged extension cords
• Drink bottles or unapproved jugs used instead of certified jerry cans
• No extinguisher, clean water or first-aid services within reach of the fuelling point

How to prevent burn injuries during refuelling

Direct answer: stop the engine, let metalwork cool, refuel in open air clear of every ignition source, and pour only from approved containers. Businesses relying on plant hire services should confirm each unit arrives with a serviceable cap, tank and fuel line.

• Cool it down — never refuel a running engine, and wait until surfaces are safe to touch.
• Choose the right spot — outside, well ventilated, away from pits, drains and sparks.
• Bond and steady containers — earth metal cans, and decant at ground level rather than on a tray liner.
• Manage spills — funnels, drip trays and absorbents; wipe down thoroughly, then change any soaked clothing.
• Keep suppression close — a dry-powder extinguisher, plus operators drilled by accredited training services.
• Dress properly — flame-resistant or natural-fibre workwear, gloves and eye protection, since synthetics melt onto skin.
• Inspect the machine — check caps, seals, hoses and tanks during scheduled maintenance services.
• Brief every operator — a laminated refuelling guide at the fuel store reinforces each toolbox talk.

Petrol is a hazardous chemical, not a harmless consumable

Under work health and safety duties, petrol is classified as a flammable hazardous chemical. Sites need a current safety data sheet, a chemical register, correct labelling and a documented risk assessment covering decanting, stored volumes and spill response. Fuel suppliers offering refuelling services can advise on tank standards, bunding and signage.

Hold only what the shift requires, shield containers from direct sunlight, and never leave cans sealed inside a cabin. Independent consultants providing compliance services can audit fuel handling, while Safe Work Australia publishes a national code of practice that doubles as a storage guide for flammable liquids.

Document the task before the next refuel

A Job Safety Analysis converts an alert like this into controls crews can actually follow. Our digital JSA template functions as a step-by-step guide for pinpointing ignition sources, assigning duties and capturing sign-off onsite.

Operations juggling multiple contracts increasingly prefer cloud-based services, so one procedure update syncs to every crew instantly. Explore our safety software range, pairing digital inspection services with editable documentation, plus subscription services that keep templates aligned with current codes.

New supervisors benefit from a concise induction guide covering fuel handling, isolation and emergency procedures. Attach a quick-reference guide to each machine logbook so seasonal staff are never guessing.

Related safety alerts worth reading

• Safety warning after four Queensland workers injured in an explosion
• Warning to SA construction workers following a rise in electric shock incidents
• Safety warning issued after an Adelaide school playground incident

Where to learn more

Read the full alert on the NT WorkSafe website, then treat findings as a guide when reviewing every fuel-powered machine on your plant register. For more information about matching documents to your operations, our customer support services team is ready to help.