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Heating and ventilation · United Kingdom

Method statement for boiler replacement

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

You must assess the risks of boiler 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, disturbing asbestos, fire from hot works and lifting and carrying heavy loads.

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RAMS example: boiler replacement

This is a complete RAMS for boiler replacement, with 6 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 boiler · Heating and ventilation · Example
Document RAMS-001 · Rev 1

Risk assessment

#ActivityHazardsWho might be harmedRisk beforeControlsRisk after
1A Gas Safe registered engineer isolates gas and power, then the supplies are locked off
  • Gas and fuel lines
  • 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)
  • Know where the shut-off valve is and what to do if a leak happens. Control (procedures)
  • Wear safety glasses and gloves, and keep a fire extinguisher close by. PPE
  • 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)
  • 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
Medium (5)
2Check flues and surrounds for asbestos
  • Disturbing asbestos
Workers, Occupants, PublicVery high (15)
  • Before work on any building built before 2000, check the refurbishment and demolition asbestos survey for the work area (HSE HSG264). If there is none, presume asbestos is present or have it sampled before you start. Eliminate
  • Seal off the work area and keep everyone else out. Isolate
  • If asbestos must be disturbed, keep it wet, use hand tools not power tools, and clean up with an H-class vacuum. Control (engineering)
  • Most asbestos insulation, coatings and insulating board need a licensed contractor. Notifiable non-licensed work is notified to HSE before it starts. Other work needs trained workers and controls. Control (procedures)
  • Stop work straight away if you find suspect asbestos. Do not touch it and tell your supervisor. Control (procedures)
  • Wear a fit-tested FFP3 mask (or better) and disposable type 5 coveralls. PPE
Medium (5)
3Remove the old unit with two people
  • Lifting and carrying heavy loads
  • Cuts from sharp edges
  • Tight spaces: roof spaces and under floors
WorkersHigh (12)
  • 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)
  • 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)
  • 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)
Medium (6)
4Install the new unit, flue and connections
  • Gas and fuel lines
  • Fire from hot works
  • Falling from a ladder
Workers, Occupants, PublicVery high (15)
  • Gas and fuel lines: see step 1 for the full controls Control (procedures)
  • 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)
  • Use a podium step, mobile tower or MEWP for longer jobs instead of a straight ladder. Reduce / substitute
  • Use EN 131 professional ladders in good condition. Remove any damaged ladder from site. Control (engineering)
  • Set extension ladders at a 4 to 1 angle on firm, level ground, tied or footed, and reaching 1 metre above the landing. Control (engineering)
  • Use ladders only for short, light work (about 30 minutes in one spot). Do not carry heavy or awkward loads up a ladder. Control (procedures)
  • Keep three points of contact and your belt buckle between the stiles. Do not overreach. Control (procedures)
Medium (8)
5Leak test, commission and check for carbon monoxide
  • Pressure testing
  • Gas and fuel lines
  • Fire and emergencies
Workers, Occupants, Public, VisitorsHigh (10)
  • 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)
  • Gas and fuel lines: see step 1 for the full controls Control (procedures)
  • Provide fire extinguishers suited to the site, checked and easy to reach. Control (engineering)
  • Keep exits and escape routes clear and signed. Control (engineering)
  • Have a site emergency plan: alarm, exits, assembly point and emergency contacts. Control (procedures)
  • Keep a stocked first aid kit and at least one trained first aider on site. Control (procedures)
  • Know the site address and how emergency services get in. Call 999. Control (procedures)
Medium (5)
6Remove old unit and clean up
  • Poor housekeeping and waste
Workers, VisitorsMedium (8)
  • 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
Low (4)

Method statement: sequence of work

  1. A Gas Safe registered engineer isolates gas and power, then the supplies are locked off
  2. Check flues and surrounds for asbestos
  3. Remove the old unit with two people
  4. Install the new unit, flue and connections
  5. Leak test, commission and check for carbon monoxide
  6. Remove old unit and clean up

PPE

Safety bootsRigger glovesSafety glassesFFP3 dust maskInsulated electrical glovesArc-rated clothing and face shieldHalf-mask respirator (P3 filters)CoverallsCut-resistant glovesKnee padsSafety helmetWelding gauntletsFace shield

Plant and equipment

Hand toolsPress fitting toolElectrical test equipment (multifunction tester)Trailer

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 boiler 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 boiler replacement

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

The safe sequence of work

  1. A Gas Safe registered engineer isolates gas and power, then the supplies are locked off
  2. Check flues and surrounds for asbestos
  3. Remove the old unit with two people
  4. Install the new unit, flue and connections
  5. Leak test, commission and check for carbon monoxide
  6. Remove old unit and clean up

Hazards to watch on boiler replacement

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

Step 3Tight 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 5Pressure testingA pipe, fitting or cap fails under test pressure and blows apart, hitting people nearby.
Step 5Fire and emergenciesA fire, injury or other emergency happens and workers cannot get out, raise the alarm or get first aid in time.
Step 4Fire from hot worksSparks and heat from welding, grinding or flame torches set fire to timber, insulation, rubbish or fuel nearby.
Step 1, 4, 5Gas and fuel linesDamaging or opening a gas or fuel line causes a leak, fire or explosion.
Step 2Disturbing asbestosBuildings built before 2000 may contain asbestos. Drilling, cutting or breaking it releases fibres that cause cancer years later.
Very likelyLikelyPossibleUnlikelyVery unlikelyHow bad it could be: Negligible to FatalBA
Highest risk on boiler 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 major 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 work on a roof?
  • Is there a fragile roof, skylight or clear roof sheet?
  • Will you use a scaffold or mobile tower?
  • Will you use a MEWP (scissor lift or cherry picker)?

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 boiler replacement?

You must assess the risks of boiler 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 boiler replacement?

Usually Safety boots, Rigger gloves, Safety glasses, FFP3 dust mask, Insulated electrical gloves, Arc-rated clothing and face shield, Half-mask respirator (P3 filters), Coveralls, Cut-resistant gloves, Knee pads, Safety helmet, Welding gauntlets, Face shield. The site rules may add more, so check with the principal contractor.

More heating and ventilation RAMS

RAMSAir Conditioning Installation10 stepsRAMSDucted Air Conditioning6 stepsRAMSAir Conditioning Maintenance5 stepsRAMSRooftop AHU Replacement6 stepsRAMSDuctwork Installation5 stepsRAMSF-Gas Leak Repair6 steps

Related jobs in other trades

DemolitionSoft StripAlso involves disturbing asbestosElectricalConsumer Unit ReplacementAlso involves disturbing asbestosRoofingRe-RoofingAlso involves disturbing asbestosScaffoldingScaffold ErectionAlso involves falling from a ladderBricklayingBrickworkAlso involves falling from a ladder

Toolbox talks for this job

Toolbox talkLadder SafetyToolbox talkOverhead Power LinesToolbox talkAsbestos AwarenessToolbox talkHot Works Safety

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

Sources