Construction Fuel Spills: Your Multi-Layered Guide to Contamination Prevention

Fuel spills create messes that go far beyond diesel on the ground. The hidden costs and risks of leaks and spills, from regulatory fines and shutdowns to environmental and reputational harm,can quickly derail a project.

A substantial spill can cost around $20,000 to clean up, shuttering a jobsite until environmental and safety inspections are complete. Even a small spill in a containment pan can cost $150 to pump out.

All that makes achieving a zero-spill jobsite more than aspirational: Preventing leaks and spills is critical to safeguarding your bottom line and avoiding a visit from the EPA.

The goal? Prevent spills, drips and associated costs so you can own the project at hand.

What’s covered in this guide?

Click on the links below to skip to specific section:

• What is fuel contamination?
• Reducing fuel spills
• Fuel tank maintenance
• Spill pans vs double walled fuel tanks

What you need to know about fuel contamination

There are different types of contamination. Fuel is contaminated when there’s an undesirable substance present in fuel and, if left undetected and used, it can cause equipment failure. On the other hand, a fuel spill can contaminate the local environment – for which you’ll likely need to front the costs. 

Both types of contamination can lead to shutdowns and reputational damage. We’ve covered both fuel spills and diesel contamination in a number of blogs; we’ve compiled them here in this comprehensive guide. Here you’ll gain an overview the causes and costs of storage-related spills, outline steps for spill response and equip you with prevention strategies to allow for worry-free and secure fuel management. 

For tips and tricks for contaminants and protecting your equipment, read more about fuel contamination in our guide.

Fuel Spills: Causes and How to Avoid Them

Fuel spills and leaks can stem from multiple issues on a jobsite, typically involving the lack of structural integrity of a fuel storage tank.

Traditional round fuel storage tanks, while sometimes cost-effective up front, can prove less secure with robust use. Such tanks can collapse if improperly transported around a jobsite, or even drip if unsecured while transported by a vehicle over bumpy terrain. Even if properly moved, traditional round tanks can eventually leak due to dings and bumps resulting from normal use.

To prevent spills, start by confirming what’s in your tank. Clearly labeling a tank’s contents and capacity provides a visual reminder for distributors to monitor fuel consumption and avoid overfilling. Next, only refuel in a safe, remote area of your site: This should be in a space away from all potential fire hazards and contaminants, should a drip or spill accidentally occur.

In addition to safe refueling, there are two more key elements to preventing spills: regular tank maintenance and proper containment.

Want to learn more about containing fuel spills? Click to read our how-to guide.

Fuel Tank Maintenance: The Key to Avoiding Spills

A well-kept tank is a spill-free tank. That’s why weekly tank maintenance informed by proper inspections is key to your operations. Your goal is to spot and remove any debris or liquid buildup in the tank or pumps – always with proper PPE – and inspect the tank for any dings, dents or punctures that could cause leaks.

Reminder: Always situate your tank away from any hazards prior to inspection.

Here’s what to check each week:

1. Check for leaks, water and debris: Clear any vegetation and obstacles from around the tank so you can clearly inspect for leaks or spills. Check for water or any buildup. In a double-walled cube tank, check the interstitial containment area for any fuel or water that may have accumulated. Using proper training and PPE, remove any such accumulation, secure the cabinet, and treat it as hazardous waste.
   
2. Check fuel quality and levels: Poor-quality fuel can harm your tank and your equipment, so it’s important to regularly inspect what’s in the tank. Look for off colors or cloudiness, unusual odors and sludge or sediment. Such sediment is more likely to build up in a nearly empty tank. This buildup can affect the filter and pumps as well, prompting leaks, so always note fuel levels too.
   
3. Check your filters: Each feed line will likely have a mesh strainer (filter) that should be checked for sludge or debris, the buildup of which can cause a low flow rate and further complications. The filter is typically found near the butterfly valve or inside the tank at the end of the line. Replace water filters as needed.
   
4. Check pumps, vents and valves: Inspect all pumps, vents and valves to make sure they’re clear. Remove filler caps and check gaskets to ensure that they’re functional and intact. Then check the threads and clean with a wire brush. Apply lithium grease to threads to prevent rust.
   
5. Check hinges and locks: Check locks and door or cover hinges for wear, rust and any necessary replacements. Lubricate hinges to avoid rust, and consider spraying PTFE grease on moving parts or locking mechanisms to keep them in working condition.

For additional information, see your fuel distributor for a Manufacturer Safety Data Sheet. We also cover fuel tank maintenance in more detail in our guide.

Containment 101: Spill Pans vs. Double Walls

A fuel tank’s containment equipment goes a long way toward keeping operations running. The goal of your tank’s containment is to act as a secondary backup that catches on-site spills and helps prevent contamination, injuries and resulting fines. But not all containment is equal. 

Here’s a breakdown of two popular containments: traditional spill pans and double-walled systems.

Spill Pans: Tried and True – with Caveats

Also known as drip or containment trays, spill pans work by catching leaks and drips from a tank. They’re an effective go-to containment solution for traditional round tanks, but they do come with drawbacks to consider:

Excess Water and Debris: Because they’re outside the tank, spill pans may collect rainwater and debris, requiring additional maintenance — about $150 in cleanup costs every time it rains.

Excess Footprint: Spill pans require plenty of space to work effectively, which can cause access issues for refueling or maintenance on congested sites. They must be relocated when the tank moves too, adding an extra hurdle to mobility.

Excess Regulations: Depending on location, spill trays are subject to specific regulations dictating containment capacity and pan material — any of which may pose related fines for violations.

Double-Walled Tanks: Simple, Modern, Foolproof

At Western Global, our range of modern cube-shaped tanks come with built-in double-walled weatherproof containment. Double-walled tanks use an enclosed, weatherproof cabinet to secure the inner tank and supporting components, protecting your tank and fuel — no exterior containment needed.

Let’s dive into the benefits of this modern, streamlined option:

Continual Savings: Because of their securely contained outer cabinet, double-walled tanks are protected from excess rainfall and associated cleanups drip pans face, as well as the associated cleanup and maintenance costs. In addition, the lockable cabinet protects pumps and meters from the elements to extend the life of those components and reduce the risk of contamination.

Simplified Cleaning: Double-walled tanks  have removable inner tanks, simplifying cleaning. Inspection hatches let you peek at fuel and levels without even removing the tank, simplifying maintenance. And when it’s time to move the tank, the containment simply comes with it — adding efficiency to your operations.

Deterred Theft: The standard lockable cabinets not only prevent contamination and weather damage, but — in addition to site security and fuel monitoring systems — provide an effective barrier to fuel theft on your site when tanks are unattended.

Plan for Peace of Mind with Western Global Fuel Tanks

Whether you use old-school round tanks and trays or modern, simplified Western Global fuel tanks, a spill prevention plan can help keep your jobsites safe, productive and fine-free. Should the worst-case scenario occur, we’ve got tips for dealing with on-site spills and how to deal with DEF, too. 

Ready for total peace of mind? Explore 110% containment with our double-walled fuel tanks.