How to Refill a Portable Gravity-Fed Eyewash Station (Expert Guide & Tips)

Contents

• Key Takeaways
• Importance of Proper Portable Eyewash Station Maintenance
  • Essential Tools and Materials for Portable Eye Wash Station Refill
  • What Is the Right Eyewash Solution Refill to Use?
• Step-by-Step Guide to Eye Wash Station Solution Refill
  • 1. Conduct Pre-Refill Inspection
  • 2. Drain Existing Water
  • 3. Clean and Sanitize the Tank
  • 4. Drain Wash Water and Rinse the Tank
  • 5. Fill the Tank with the Flushing Solution
  • 6. Test and Calibrate
  • 7. Documentation and Record Keeping
• Common Issues With Eye Wash Station Refills
• Third-Party Eye Wash Station Service
• Portable Eyewash Station Refill FAQs
  • What do you fill a portable eye wash station with?
  • How does a portable eye wash station work?
  • How often do portable eye wash stations need to be changed?
  • What is the checklist for portable eyewash inspection?
  • How often should eyewash bottles be replaced?

Key Takeaways

• A gravity-fed eyewash station must be refilled regularly with the proper eyewash solution to remain compliant and effective.

• Failing to maintain your portable eyewash station can result in serious safety violations and employee injuries.

• Always use manufacturer-approved cleaning agents, solutions and follow specified mixing ratios.

• A thorough pre-refill inspection helps prevent downstream issues like contamination and low flow rate.

• In remote or low-traffic areas, third-party eye wash station service may be the most reliable maintenance option.

Importance of Proper Portable Eyewash Station Maintenance

Portable eyewash station units are often placed in remote locations or low-traffic areas, where fixed plumbing isn’t available. But here’s the problem: the more out-of-the-way it is, the more likely it’s been forgotten. In fact, some of the most critical safety failures occur not because a station doesn’t exist, but because it hasn't been checked.

Whether it’s on a construction trailer or in a fast-moving warehouse, portable eyewash stations tend to quietly drift out of service until it’s too late. And during an emergency, the last thing you want to discover is that gravity-fed eyewash isn’t doing its job because someone missed a refill.

That’s why regular inspection and maintenance, especially proper eyewash solution refills, matter. And it starts with knowing how to do it the right way.

Essential Tools and Materials for Portable Eye Wash Station Refill

Here’s what you’ll need before starting a portable eyewash station refill:

What Is the Right Eyewash Solution Refill to Use?

Before you refill a portable eye wash station, it is important to choose the right eyewash solution to use. Selecting the correct eyewash solution is crucial for safety and extending the shelf life of your portable eyewash station:

Sterile Eyewash Solutions

Sterile eyewash solutions are pre-packaged and ready to use, sealed under aseptic conditions, and require no mixing. A common example is saline solution, which mimics the eye's natural fluid, making it ideal for flushing. While unopened sterile solutions typically have a long shelf life (24 to 36 months), they generally must be replaced within 7 to 30 days once the station is opened or the container is installed, depending on the manufacturer’s guidelines. Proper storage within the recommended temperature range is essential to maintain their effectiveness and safety.

Preserved Eyewash Solutions

Preserved eyewash solutions are designed for longer-term use, especially in remote locations or places where regular maintenance is less practical. These solutions contain additives that maintain the water's pH balance, preventing bacterial growth and ensuring safety and effectiveness in neutralizing harmful substances. Preserved eyewash solutions can be purchased as premixed formulas or as concentrates that need to be diluted with potable water. 

If using a concentrate, always adhere to the precise mixing ratio, typically 10 parts clean water to 1 part concentrate. When properly mixed and stored, preserved solutions usually remain effective for 3 to 6 months.

Eyewash additives vary to cater to different safety and maintenance requirements in workplaces. Below are the most commonly used types:

• • Buffered Saline (Sodium Chloride or Sodium Phosphate): Helps maintain an isotonic solution that matches the natural salt concentration of human tears. Reduces eye irritation and helps flush chemicals more gently.

  • Benzalkonium Chloride (BAC): A widely used preservative that controls bacteria, fungi, and algae. Only used in low concentrations to avoid eye irritation.

  • Sodium Benzoate or Potassium Sorbate: Food-grade preservatives used to inhibit microbial growth. Often found in preserved solutions with extended shelf life.

  • EDTA (Ethylenediaminetetraacetic Acid): Used in small amounts to bind metal ions and reduce microbial growth. Also helps maintain the clarity and stability of the solution.

  • pH Stabilizers: Ingredients like boric acid or sodium borate may be used to keep the solution close to neutral pH (around 7). This prevents burning or discomfort during use.

  • Deionized or Distilled Water: While not an additive itself, it’s the base for most concentrates and ensures no impurities interfere with the active ingredients.

Step-by-Step Guide to Eye Wash Station Solution Refill

Follow these steps to keep your portable gravity-fed station safe and ready for emergency use:

1. Conduct Pre-Refill Inspection

Start by conducting a thorough inspection of the unit. Check the container and hoses for any signs of leaks or damage that could affect the function of the station or lead to further contamination. Should you find any faulty components, repair or replace them immediately. Additionally, verify the expiration dates on all eyewash solutions and additives to be used. If they’re missing or unreadable, replace them.

2. Drain Existing Water

Next, remove any remaining solution from the tank. If the station is equipped with a drain valve, open it and allow the fluid to flow into a bucket or drain pan. If not, use a siphon pump or carefully tip the unit to pour the old solution out. Never reuse leftover solution, as its integrity is compromised once exposed to air or used. Always dispose of the old fluid according to local environmental or hazardous waste guidelines.

3. Clean and Sanitize the Tank

With the tank empty, clean it thoroughly using a soft-bristled brush and a manufacturer-approved cleaner or disinfectant. Be sure to reach all interior surfaces, including seams and corners, where residue might build up. Avoid using abrasive pads or unapproved chemicals like bleach, which can damage the tank or leave behind harmful residue.

Disassemble the parts that come into contact with the eyewash solution, such as nozzles and hoses, and soak them in the same approved cleaning solution used for the tank for about 10 to 15 minutes. 

4. Drain Wash Water and Rinse the Tank

Once cleaning is complete, rinse all parts thoroughly with sterile water to remove any traces of cleaning agents. Partially fill the tank, swirl or agitate the water to lift out any remaining cleaner, then drain it completely. Repeat this process until no scent or visible residue remains. Proper rinsing is important to prevent chemical interaction between cleaning agents and the new eyewash solution.

5. Fill the Tank with the Flushing Solution

After rinsing, fill the tank with the correct eyewash solution refill. Using a clean funnel, carefully pour the prepared solution into the eyewash station’s reservoir until the pronounced max fill line. Avoid touching the inside of the container or the spout of the funnel with your hands.

If using a premixed solution, simply pour it into the wide fill opening until it reaches the fill line specified by the manufacturer. If using a concentrated additive, carefully measure and mix it with sterile or treated water as per the manufacturer's instructions. Ensure the mixture meets the exact dilution ratio, typically 10:1. Never reuse old or expired solutions. 

After refilling, make sure the eyewash station is properly sealed and covered to prevent airborne contaminants from entering the tank. 

6. Test and Calibrate

With the tank filled, activate the portable eyewash to test the system. Both nozzles must deliver a steady, even flow of fluid with a soft stream, reaching the correct flow rate. According to ANSI standards, the system should be able to deliver at least 1.5 liters per minute (or 0.4 gallons per minute) for a full 15 minutes. 

Additionally, check the temperature of the water; it should be tepid, ideally between 60°F and 100°F, to avoid causing thermal shock or increasing the victim’s discomfort. Look for any signs of leaks or weak pressure, and resolve any issues before returning the portable eyewash station to service. 

7. Documentation and Record Keeping

Finish by updating your maintenance documentation. Record the date of the refill, the brand and type of solution used, its expiration date, and the name or initials of the technician performing the work. Attach a new dated service tag to the station in a visible spot, so future checks can be tracked at a glance. If any parts were replaced or if irregularities were found, make a note of them in the maintenance log.

Common Issues With Eye Wash Station Refills

Even when refilled on schedule, eye wash stations can develop performance issues if something is overlooked during cleaning, mixing, or maintenance. This section highlights common problems along with straightforward fixes to keep the portable gravity-fed eyewash station reliable and compliant:

Third-Party Eye Wash Station Service

If your team lacks time or training to handle eye wash station service, working with a third-party provider can be a practical solution. These companies typically offer:

• • Scheduled inspections and refills

  • Cleaning and calibration services

  • Documentation support for compliance audits

This option is especially useful in remote locations or for businesses managing multiple gravity-fed units. Look for providers who follow ANSI/ISEA Z358.1 standards and can supply approved eyewash solutions for your specific station models.

Portable Eyewash Station Refill FAQs

What do you fill a portable eye wash station with?

A portable eyewash station should be filled with either a sterile saline solution, preserved water, or any appropriate FDA-approved eyewash solution that meets ANSI Z358.1-2014 standards.

How does a portable eye wash station work?

A portable eyewash station, like a gravity-fed unit, works by using gravity to deliver a controlled flow of eyewash solution through nozzles to flush the eyes, which can be activated by pulling down the activation tray.

How often do portable eye wash stations need to be changed?

Portable eye wash stations should be checked at least monthly and the solution changed according to the manufacturer's recommendations or if it becomes contaminated. Generally, preserved solutions require changing every three to six months.

What is the checklist for portable eyewash inspection?

The checklist for portable eyewash inspection should include checking for cleanliness, ensuring the solution is not contaminated, verifying the expiration date of the solution, testing the flow rate and operation, and ensuring no leaks or damage to the unit.

How often should eyewash bottles be replaced?

Eyewash bottles should be replaced by their expiration date or immediately after opening or use, whichever comes first. Most sealed bottles have a shelf life of 2 to 3 years, but once opened, they are no longer sterile and should be discarded, even if unused.