How your depot layout could be making theft easier
As a perennial issue for site managers and fleet managers, fuel security is a key focus of most security strategies, which often encompass specific measures like lighting, locks, alarms and CCTV. However, something that’s often overlooked is that sometimes the real issue lies with the layout of the depot itself. Certain layouts can make it easy for employees, contractors, or opportunistic thieves to steal fuel without detection. And while no layout is completely foolproof, smart design choices can significantly reduce the risk. With decades of experience to our name here at TankSafe, and a long history of helping our customers secure their fuel supplies, we’re no strangers to the issues that can be posed by poor layouts – so here’s what you need to know!
Common mistakes with depot layout
Key problems often include:
Poor lighting and inconsistent visibility
Gaps in CCTV coverage caused by stacked goods or blind zones
Fuel tanks and pumps located in isolated or unsupervised areas
Lack of zoning between access routes, pedestrian paths and high-risk areas
Yard expansion without security planning, creating oversight gaps
One of the biggest challenges is the sheer scale and complexity of modern depots. With multiple lorries, pumps, storage tanks and access points, it’s easy for layout to become an afterthought. Common problems include inconsistent lighting, which creates shadows and dark patches where illicit activity can take place unnoticed. Even with floodlights, poor placement can mean that the most sensitive areas being left exposed, such as refuelling zones or tank access points. The same goes for CCTV; blind spots can be created by stacked containers, large cabs, or awkward yard layouts.
A lack of zoning is another regular flaw. When pedestrian and traffic access routes are not separated, or when high-value fuel areas are left in general access zones, it becomes far easier for people to approach tanks or pumps without raising suspicion. Depots often evolve over time, and this can sometimes result in vulnerable areas that no longer align with the way security staff operate.
Skimming is the biggest threat
While it’s true that some fuel thefts are carried out by criminal gangs, the biggest threat in most depots is skimming. This where small amounts of fuel are repeatedly taken by employees, subcontractors or even trusted long-term staff.
It’s often subtle and systematic, and typically involves an employee filling a personal jerry can while pretending to top off a lorry. These small-scale thefts add up quickly and are notoriously hard to detect, especially if the layout enables lorries to loiter unmonitored or if fuel access points aren't controlled.
Part of the reason skimming is so effective is because it hides in plain sight. Depot design that enables drivers to fuel their lorries without oversight, or park for long periods in unsupervised areas, makes it easier for these thefts to continue undetected. Even basic actions like topping off a tank “after hours” or switching cabs during low-staffed periods can provide cover for regular skimming. Plus, if fuel records aren’t tightly matched to mileage or load data, even significant losses can remain invisible for weeks.
How layout changes can boost security
The good news is that simple layout changes can dramatically improve your depot’s security profile. For starters, it’s a good idea to think about visibility. Positioning fuel tanks and pumps within open, well-lit, and highly visible areas makes them harder to access unnoticed. You can also use bollards or barriers to funnel lorries through controlled fuelling points, ensuring they can only fill up in supervised zones.
Integrated CCTV and lighting design also makes a huge difference. It helps to ensure that cameras are placed to cover not just fuelling areas, but also the routes that lorries take before and after fuelling. Ideally, avoid stacking containers or placing cabs in a way that blocks camera sight lines. Every blind spot is a vulnerability.
Natural surveillance also plays a role – that means placing key areas within line of sight of offices, canteens or frequently used paths, which makes it more difficult for theft to occur without someone noticing. Layout can also be used to support auditing: marking fuelling zones clearly, controlling entry to those areas, and requiring cab ID or access cards helps. Signage helps too. Clear visual boundaries and instructions deter casual misuse and remind staff that the area is actively monitored.
Control the flow of vehicles
Tightening up unstructured traffic movement another useful way to ensure that fuel theft doesn’t go unnoticed. Designated routes through the depot help direct all traffic past monitoring points. You can increase natural and technological oversight by positioning fuel lanes so they are visible from main work areas, offices or CCTV hubs. It also enables timed access to fuelling – for example, restricting refuelling to shift start or end times when supervisors are present.
Crucially, controlling flow doesn’t necessarily mean complicating access – it means removing ambiguity. One-way systems reduce opportunities for doubling back. Holding zones keep lorries visible and separate before they are dispatched or refuelled. Even parking arrangements play a role: if cabs are parked in neat, well-monitored lines rather than scattered across a site, it’s far easier to spot unusual behaviour.
Traffic segregation matters too. You can limit exposure to sensitive areas by separating operational fleet from visitors, or dividing drivers from depot contractors. (After all, if everyone can reach the tanks, it becomes impossible to enforce responsibility.) Good layout makes it immediately obvious who should be where.
How we can help with TankSafe Optimum
Even with a well-planned layout and tight operational controls, physical tank protection is your last and most important line of defence. That’s where we can help, with TankSafe® Optimum.
TankSafe Optimum is the only 3-in-1 fuel security device on the market. It prevents fuel theft, eliminates the risk of overfilling, and stops spills – all in a single unit. Thanks to a patented locking float valve, the device seals off the tank once it’s near full capacity. It doesn’t rely on software or detection – it physically blocks theft from happening. There’s no alarm to be triggered, no log to check, no system to fail. It turns each tank into a secure unit that can’t be tampered with. So, if you’re a fleet manager looking to introduce a final, proven layer of fuel security, it’s an unquestionably helpful asset.
If you’ve got any questions, feel free to head over to our FAQs page, where we answer some of the most commonly asked questions regarding our products and services. However, if it doesn’t address your queries, you can give us a call on 01253 400 401, and we’ll be happy to help however we can!