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Plumbing · United Kingdom

Method statement for hot water cylinder replacement

By Safety PaperworkBuilt from HSE guidance and CDM 2015 · How we write and check theseUpdated

You must assess the risks of hot water cylinder replacement and record the significant findings if you employ 5 or more people. On CDM sites the principal contractor will ask for RAMS before you start.

RAMS cover the hazards, who could be harmed and how, the controls and the safe sequence of work, and the crew is briefed and signs. The main hazards are electric shock from live wiring, fire from hot works, lifting and carrying heavy loads and gas and fuel lines.

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RAMS example: hot water cylinder replacement

This is a complete RAMS for hot water cylinder replacement, with 10 job steps. Open it in the builder to add your site, crew and signatures, change anything, and download a PDF. Or download the free Word template below and fill it in by hand.

Risk Assessment and Method Statement (RAMS)
Replace a hot water cylinder · Plumbing · Example
Document RAMS-001 · Rev 1

Risk assessment

#ActivityHazardsWho might be harmedRisk beforeControlsRisk after
1Check access to the unit and plan the removal route through stairs, roof spaces or tight cupboards
  • Tight spaces: roof spaces and under floors
  • Lifting and carrying heavy loads
WorkersHigh (12)
  • Do as much of the work as you can from outside the tight space. Eliminate
  • Turn the power off at the consumer unit or distribution board before entering where you can, as damaged cables may be live. Isolate
  • Lay crawl boards across the joists so you cannot step through the ceiling. Control (engineering)
  • Set up ventilation and lighting in the space. Control (engineering)
  • Limit time in hot roof spaces and take breaks somewhere cool. Control (procedures)
  • Tell someone when you go in and when you are out. Control (procedures)
  • Wear a dust mask, knee pads, gloves and a bump cap. PPE
  • Plan to avoid carrying: have materials delivered, and old items picked up, as close as possible to where they are used. Eliminate
  • Use lighter or smaller loads: order smaller bags and shorter lengths, and drain or break down old items before moving them. Reduce / substitute
  • Use trolleys, pallet jacks, hoists, vacuum lifters or plant instead of carrying by hand. Control (engineering)
  • Use a two-person lift for anything heavy, long or awkward. Plan the route first and clear it. Control (procedures)
  • Keep the load close, back straight and no twisting. Turn with your feet. Control (procedures)
  • Rotate tasks and take breaks on long lifting jobs. Control (procedures)
  • Wear gloves for grip and safety boots to protect your feet. PPE
Medium (6)
2Isolate power at the consumer unit and gas or water at the meter, lock off and label
  • Electric shock from live wiring
  • Gas and fuel lines
  • Stored energy
Workers, Occupants, PublicVery high (15)
  • Isolate the power before any work. Do not work live. Eliminate
  • Lock out and tag the isolation point with your own personal lock and danger tag. Isolate
  • Prove dead at the point of work with an approved voltage indicator (GS38), and prove the tester before and after. Control (engineering)
  • Only competent, qualified electricians do electrical work, following a safe isolation procedure. Control (procedures)
  • Check for back feeds from solar, batteries and generators that can keep a circuit live after the main switch is off. Control (procedures)
  • Isolate and purge the line before work, with the owner's approval. Eliminate
  • Lock off and tag the isolation valve. Isolate
  • Gas and fuel lines: see step 8 for the full controls Control (procedures)
  • Release or block all stored energy before work: release the pressure in pipes, tanks and hoses, bleed hydraulics, release springs, lower loads. Eliminate
  • Lock out and tag all energy sources with personal locks. Isolate
  • Put mechanical blocks or props under raised parts like buckets, tipper bodies and doors. Control (engineering)
  • Test that the system is dead and nothing can move before you start. Control (procedures)
  • Follow the maker's procedure, for example for garage door and roller door springs. Control (procedures)
Medium (5)
3Drain the old unit, watching for scalding water and steam
  • Hot water and steam
  • Burns from hot surfaces
  • Slips and trips
Workers, Occupants, Visitors, PublicMedium (8)
  • Turn the system off and let it cool before work. Eliminate
  • Isolate and lock off the heat source and valves, and release the pressure. Isolate
  • Hot water and steam: see step 9 for the full controls Control (procedures)
  • Isolate heating systems and let parts cool before you touch them. Eliminate
  • Fit guards or insulation on hot pipes and equipment. Control (engineering)
  • Mark hot items with chalk or a "HOT" sign so others know. Control (procedures)
  • Keep a first aid kit and cool running water nearby for burns. Control (procedures)
  • Wear heat-resistant gloves and long sleeves. PPE
  • Plan walkways and keep them clear of materials, hoses and leads. Eliminate
  • Run leads and hoses overhead on hooks or stands, or along walls, not across walkways. Control (engineering)
  • Fill or cover holes, and lay boards or mats on muddy access paths. Control (engineering)
  • Clean up offcuts, packaging and spills as you go, not at the end of the day. Control (procedures)
  • Keep work areas, stairs and access paths well lit. Control (procedures)
Low (4)
4Disconnect pipes, flue and wiring, and cap the gas line
  • Gas and fuel lines
  • Electric shock from live wiring
  • Cuts from sharp edges
Workers, Occupants, PublicVery high (15)
  • Check for leaks with a gas detector before and during work, and ventilate the area. Control (engineering)
  • Only Gas Safe registered engineers work on gas fittings. Control (procedures)
  • Gas and fuel lines: see step 8 for the full controls Control (procedures)
  • If live work cannot be avoided, use a permit, a safety observer and insulated tools. Control (procedures)
  • Wear insulated gloves, arc-rated clothing and a face shield when testing or working near live parts. PPE
  • Electric shock from live wiring: see step 2 for the full controls Control (procedures)
  • Deburr or cover sharp edges, and fit edge protectors on exposed sheet metal. Control (engineering)
  • Use knives with retractable or self-retracting blades. Control (engineering)
  • Cuts from sharp edges: see step 5 for the full controls Control (procedures)
Medium (5)
5Remove the old unit using a trolley and two people
  • Lifting and carrying heavy loads
  • Cuts from sharp edges
WorkersHigh (12)
  • Lifting and carrying heavy loads: see step 1 for the full controls Control (procedures)
  • Deburr or cover sharp edges, and fit edge protectors on exposed sheet metal. Control (engineering)
  • Use knives with retractable or self-retracting blades. Control (engineering)
  • Cut away from your body and keep your other hand clear. Control (procedures)
  • Put used blades in a blade bin or sharps container. Control (procedures)
  • Use two people to handle large sheets of metal or glass. Control (procedures)
  • Wear cut-resistant gloves and long sleeves. PPE
Medium (6)
6Position and secure the new unit on a level base
  • Lifting and carrying heavy loads
  • Tight spaces: roof spaces and under floors
WorkersHigh (12)
  • Lifting and carrying heavy loads: see step 1 for the full controls Control (procedures)
  • Tight spaces: roof spaces and under floors: see step 1 for the full controls Control (procedures)
Medium (6)
7Make pipe joins, with a hot work permit and an extinguisher at hand if soldering or brazing
  • Fire from hot works
  • Burns from hot surfaces
Workers, Occupants, PublicVery high (15)
  • Use cold work methods where you can, such as bolting, press fittings or cutting with a saw instead of a torch. Eliminate
  • Move anything that can burn at least 10 metres away, or cover it with fire blankets. Isolate
  • Use fire-resistant screens to stop sparks reaching people or gaps in walls and floors. Control (engineering)
  • Get a hot work permit before starting. Control (procedures)
  • Keep a charged fire extinguisher and fire blanket at the work spot. Control (procedures)
  • Keep a fire watch during the work and for at least 60 minutes after you finish. Control (procedures)
  • Check for smouldering behind walls, in ceilings and under floors before you leave. Control (procedures)
  • Wear flame-resistant clothing, welding gloves and eye or face protection. PPE
  • Burns from hot surfaces: see step 3 for the full controls Control (procedures)
Medium (5)
8Reconnect gas (by a Gas Safe registered engineer) and power (by a qualified electrician), then leak test
  • Gas and fuel lines
  • Pressure testing
  • Electric shock from live wiring
Workers, Occupants, PublicVery high (15)
  • Isolate and purge the line before work, with the owner's approval. Eliminate
  • Lock off and tag the isolation valve. Isolate
  • Check for leaks with a gas detector before and during work, and ventilate the area. Control (engineering)
  • Only Gas Safe registered engineers work on gas fittings. Control (procedures)
  • Remove ignition sources: no smoking, no hot work and no sparking tools near the line. Control (procedures)
  • Test with water instead of air or gas where the system allows it. Never put water in refrigerant pipework, which is tested with dry nitrogen. Reduce / substitute
  • Keep people out of the test area with signs and barriers. Isolate
  • Pressure testing: see step 9 for the full controls Control (procedures)
  • Electric shock from live wiring: see step 2 for the full controls Control (procedures)
Medium (5)
9Fill and purge air, check the relief valve, commission and set the temperature
  • Hot water and steam
  • Pressure testing
Workers, OccupantsMedium (8)
  • Turn the system off and let it cool before work. Eliminate
  • Isolate and lock off the heat source and valves, and release the pressure. Isolate
  • Check the temperature, and open fittings slowly while facing away. Control (procedures)
  • Keep a first aid kit and cool water ready for burns. Control (procedures)
  • Wear heat-resistant gloves, long sleeves and a face shield. PPE
  • Test with water instead of air or gas where the system allows it. Never put water in refrigerant pipework, which is tested with dry nitrogen. Reduce / substitute
  • Keep people out of the test area with signs and barriers. Isolate
  • Use a calibrated gauge and a relief valve set to protect the system. Control (engineering)
  • Test to the pressure the system calls for and hold it for the set time. Never go over. Control (procedures)
  • Release the pressure fully before tightening anything or fixing leaks. Control (procedures)
  • Wear safety glasses or a face shield. PPE
Low (4)
10Take the old unit off site and clean up
  • Lifting and carrying heavy loads
  • Poor housekeeping and waste
Workers, VisitorsHigh (12)
  • Lifting and carrying heavy loads: see step 1 for the full controls Control (procedures)
  • Order materials to size and send packaging back where you can. Eliminate
  • Put skips and waste chutes close to the work. Control (engineering)
  • Clean as you go, and do a full clean up at the end of each day. Control (procedures)
  • Keep exits, stairs and walkways clear at all times. Control (procedures)
  • Stack materials neatly on level ground, away from edges. Control (procedures)
  • Use a registered waste carrier and keep waste transfer notes for at least 2 years. Keep hazardous waste such as asbestos separate, with consignment notes (special waste in Scotland). Control (procedures)
  • Wear gloves when handling waste. PPE
Medium (6)

Method statement: sequence of work

  1. Check access to the unit and plan the removal route through stairs, roof spaces or tight cupboards
  2. Isolate power at the consumer unit and gas or water at the meter, lock off and label
  3. Drain the old unit, watching for scalding water and steam
  4. Disconnect pipes, flue and wiring, and cap the gas line
  5. Remove the old unit using a trolley and two people
  6. Position and secure the new unit on a level base
  7. Make pipe joins, with a hot work permit and an extinguisher at hand if soldering or brazing
  8. Reconnect gas (by a Gas Safe registered engineer) and power (by a qualified electrician), then leak test
  9. Fill and purge air, check the relief valve, commission and set the temperature
  10. Take the old unit off site and clean up

PPE

Safety bootsRigger glovesSafety glassesFFP3 dust maskKnee padsSafety helmetFace shieldCoverallsWelding gauntletsCut-resistant gloves

Plant and equipment

Hand toolsPress fitting toolPropane gas torchTrailer

Permits and plans

Permit to work (electrical isolation)Hot works permit (fire watch at least 60 minutes after)

Emergency

Call 999. Add the nearest A&E, the assembly point and the first aider for your site.

Sign-off

Supervisor and every worker sign to confirm they have read and understood this RAMS.

Free RAMS template for hot water cylinder replacement

Word (.docx) and PDF, A4 landscape, no email needed. Fill in your site details, then print or send it.

Word template (.docx)PDF template

Make yours in 2 minutes

Same document, filled in for your job. Answer a few yes or no questions, the crew signs on the phone, and you send the PDF.

Start this RAMS

Pre-start checklist for hot water cylinder replacement

Tick these off before work starts. They come from the hazards, permits and equipment in this job.

The safe sequence of work

  1. Check access to the unit and plan the removal route through stairs, roof spaces or tight cupboards
  2. Isolate power at the consumer unit and gas or water at the meter, lock off and label
  3. Drain the old unit, watching for scalding water and steam
  4. Disconnect pipes, flue and wiring, and cap the gas line
  5. Remove the old unit using a trolley and two people
  6. Position and secure the new unit on a level base
  7. Make pipe joins, with a hot work permit and an extinguisher at hand if soldering or brazing
  8. Reconnect gas (by a Gas Safe registered engineer) and power (by a qualified electrician), then leak test
  9. Fill and purge air, check the relief valve, commission and set the temperature
  10. Take the old unit off site and clean up

Hazards to watch on hot water cylinder replacement

The hazards most specific to this job, and the step where each one comes up.

Step 3, 9Hot water and steamOpening hot water systems, boilers or steam lines scalds workers.
Step 1, 6Tight spaces: roof spaces and under floorsCrawling through roof spaces, under floors or in tight ceilings leads to falls through the ceiling, heat stress, shocks and cuts.
Step 3, 7Burns from hot surfacesTouching hot pipes, tools, bitumen, solder or freshly welded metal burns the skin.
Step 8, 9Pressure testingA pipe, fitting or cap fails under test pressure and blows apart, hitting people nearby.
Step 2Stored energyEnergy left in springs, hydraulics, compressed gas, raised loads or capacitors releases suddenly and crushes or injures workers.
Step 7Fire from hot worksSparks and heat from welding, grinding or flame torches set fire to timber, insulation, rubbish or fuel nearby.
Very likelyLikelyPossibleUnlikelyVery unlikelyHow bad it could be: Negligible to FatalBA
Highest risk on hot water cylinder replacement: Very high before controls (B), down to Medium after controls (A), on the United Kingdom 5 by 5 risk matrix (possible and fatal becomes unlikely and lost time injury).

What changes on your site

This example covers the job itself. Your site may add more. Add controls for any of these that apply (the builder asks you these as yes or no questions):

  • Will anyone work at height, anywhere a fall could hurt them?
  • Will anyone use a ladder or stepladder?
  • Will anyone work on a roof?
  • Is there a fragile roof, skylight or clear roof sheet?
  • Will you use a scaffold or mobile tower?

Why RAMS get rejected

Principal contractors send documents back for these reasons. This example avoids them, but check yours too.

  • The method statement is only a list of headings that repeats the risk table and never says how the work is done.
  • The method sequence does not match the risk assessment, for example the method strips the roof before the scaffold is handed over.
  • Residual risk is still High after controls with no extra measures or explanation.
  • It reads as copied: another firm, another address, or wording that does not fit UK sites. HSE warns that copying an example and adding your name does not satisfy the law.
  • Work on an older building with no reference to an asbestos survey.
  • Plant and access equipment listed with no inspection, thorough examination or competence evidence.
  • No briefing record, no revision history, or no named supervisor.

Questions

Do I need RAMS for hot water cylinder replacement?

You must assess the risks of hot water cylinder replacement and record the significant findings if you employ 5 or more people. On CDM sites the principal contractor will ask for RAMS before you start.

Who signs the RAMS?

The person who wrote it and the person who approved it sign and date it. Every worker signs the briefing register after it is explained to them, and the principal contractor reviews and accepts it before you start.

How long do I keep it?

Keep this RAMS, every revision and the signed briefing register with the site file for the length of the job, and keep a copy in your records afterwards.

What PPE is needed for hot water cylinder replacement?

Usually Safety boots, Rigger gloves, Safety glasses, FFP3 dust mask, Knee pads, Safety helmet, Face shield, Coveralls, Welding gauntlets, Cut-resistant gloves. The site rules may add more, so check with the principal contractor.

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Related jobs in other trades

DemolitionSoft StripAlso involves electric shock from live wiringElectricalConsumer Unit ReplacementAlso involves electric shock from live wiringRoofingRe-RoofingAlso involves cuts from sharp edges

Toolbox talks for this job

Toolbox talkOverhead Power LinesToolbox talkSlips, Trips and FallsToolbox talkHot Works SafetyToolbox talkConfined Spaces

Blank RAMS template: free RAMS templates. Also for other countries: Australia (SWMS) · United States (JHA) · Canada (FLHA)

Sources