When this template fits
This RAMS is for UK contractors and hvac teams carrying out f-gas charging, recovery & leak testing — typically because a principal contractor or client has asked for a risk assessment and method statement before work can start. It covers the recognised building services & m&e hazards for this task, with the controls a reviewer expects to see.
What this RAMS includes
- ✓ 9 task-specific hazards scored on a 5×5 matrix (initial → residual)
- ✓ Specific control measures for each hazard, in hierarchy-of-control order
- ✓ A 10-step method statement (sequence of works)
- ✓ PPE, plant/equipment, permits and competence requirements
- ✓ Emergency arrangements and operative briefing / sign-off section
Scope of works
Charge, recover and leak-test refrigerant — asphyxiation in enclosed plant, flammable refrigerants, F-gas duties.
Sequence of works
- 1Pre-task: Review COSHH assessment and Safety Data Sheet for the specific refrigerant. Confirm all operatives hold valid F-Gas Category 1 certification. Carry out toolbox talk covering refrigerant hazards, flammability classification, confined-space controls and emergency procedures.
- 2Site survey and access: Inspect the plant room for ventilation, ignition sources, oxygen levels (initial reading) and confined-space classification. Establish exclusion zone with barriers and warning signs. Notify building manager and agree an emergency contact and evacuation route.
- 3Isolation and make-safe: Electrically isolate the refrigeration/AC unit at its local isolator, apply lock-off, and verify dead using a GS38-compliant voltage tester. Remove ignition sources if flammable refrigerant is involved and activate forced mechanical ventilation.
- 4Refrigerant recovery: Connect the recovery machine, manifold and rated hoses to the system. Recover all refrigerant into an approved, labelled recovery cylinder. Record type, quantity recovered and cylinder identification in the F-gas logbook. Do not vent any refrigerant to atmosphere.
- 5System opening and repair/component work: Only open the refrigerant circuit once full recovery is confirmed (system at 0 bar gauge). Carry out the required repair, component replacement or installation. Ensure all new joints, fittings and components are correctly rated.
- 6Nitrogen pressure testing and leak detection: Pressurise the circuit with dry nitrogen to the manufacturer's stated test pressure using a regulator fitted with a relief valve. Exclude personnel from the immediate zone during pressurisation. Apply electronic leak detector or bubble solution to all joints. Record test pressure, duration and result.
- 7Evacuation (vacuum): Once pressure test is passed and nitrogen vented to a safe external point, connect a vacuum pump and evacuate the circuit to ≤500 micron (0.67 mbar). Perform a standing vacuum test to confirm system integrity before charging.
- 8Refrigerant charging: Charge the correct refrigerant by weight using calibrated charging scales. Wear refrigerant-rated PPE throughout. Do not mix refrigerants or charge into a system that has not passed vacuum test. Record quantity charged in the F-gas logbook.
- 9Post-charge leak check and commissioning: Carry out a thorough electronic leak check of all connections after charging. Confirm system operating pressures and temperatures are within manufacturer's specification. Reinstate electrical isolation, restore power, and document all commissioning data.
- 10Close-out: Remove all tools, hoses, cylinders and equipment. Restore ventilation to normal. Update F-gas logbook with all required entries. Brief building manager on system status and any ongoing monitoring requirements. Dispose of or return refrigerant cylinders in accordance with F-Gas Regulation requirements.
Hazards, risk rating & controls
Risk = likelihood × severity (1–25). Initial is before controls; residual is with controls applied.
Asphyxiation from refrigerant release
Who’s at risk: Operatives, Other trades on site, Members of the public
- › Do not commence charging or recovery in any space that cannot be adequately ventilated. Assess whether work can be repositioned outside the confined space entirely.
- › Install temporary forced-air ventilation providing a minimum of 10 air changes per hour before and throughout work in plant rooms and enclosed spaces.
- › Deploy a calibrated fixed or portable gas detector suitable for the refrigerant in use. Set alarm thresholds below IDLH levels and ensure audible/visual alarm is active throughout the task.
- › Where the space meets the definition of a confined space, implement a permit-to-enter system with a trained standby person stationed outside and emergency rescue provisions in place.
Fire and explosion from flammable refrigerants
Who’s at risk: Operatives, Other trades on site, Members of the public
- › Before handling flammable refrigerants, remove or isolate all ignition sources including naked flames, non-intrinsically-safe electrical equipment, hot-work activities and smoking within the work zone.
- › Classify the work area as a DSEAR hazardous zone during handling operations. Use only intrinsically-safe or Ex-rated tools, gas detectors and lighting appropriate to the zone classification.
- › Conduct a specific DSEAR risk assessment. Ensure all operatives hold F-Gas Category 1 certification and are trained in the specific properties and safe handling of the flammable refrigerant in use.
- › Position an appropriate fire extinguisher (CO2 or dry powder) at the egress point of the work area. Do not use water-based extinguishers near refrigerant systems.
F-gas regulatory non-compliance
Who’s at risk: Operatives, Other trades on site, Members of the public
- › All charging, recovery and leak-testing operations must be carried out by operatives holding a valid UK F-Gas Category 1 (or appropriate category) certificate. Refrigerant recovery cylinders must be rated and colour-coded correctly.
- › Always recover refrigerant into an approved, labelled recovery cylinder using a dedicated recovery machine before opening any part of the refrigerant circuit. Record refrigerant type, weight recovered and cylinder identification.
- › Maintain an up-to-date equipment logbook recording all refrigerant additions, removals, leak checks and servicing as required. Retain records for a minimum of 5 years.
Refrigerant contact — cold burns and skin/eye injury
Who’s at risk: Operatives, Other trades on site, Members of the public
- › Pressure-test the circuit with dry nitrogen to the appropriate test pressure before introducing refrigerant, to identify and rectify leaks before refrigerant is present.
- › Produce a COSHH assessment for each refrigerant used referencing the Safety Data Sheet. Communicate health effects, emergency measures and first aid to all operatives.
- › Wear cryogenic/refrigerant-rated gloves, chemical splash goggles and a face shield when making or breaking refrigerant connections or handling recovery cylinders.
High-pressure system failure
Who’s at risk: Operatives, Other trades on site, Members of the public
- › Always fit a two-stage pressure regulator with an integral pressure-relief valve to the nitrogen cylinder. Never pressurise above the system design test pressure stated on the equipment nameplate or manufacturer's data.
- › Use only hoses, manifold gauge sets and fittings rated for the maximum system working pressure. Inspect all equipment for damage before use and remove from service any item that is cracked, perished or shows signs of corrosion.
- › Establish a minimum 1-metre exclusion zone around the system under pressure test. Stand clear of potential hose-whip arcs when applying pressure. Never exceed the test pressure.
Oxygen-enriched atmosphere from nitrogen purging
Who’s at risk: Operatives, Other trades on site, Members of the public
- › Vent nitrogen purge gas via a dedicated line to outside the building or to a well-ventilated area. Never vent nitrogen into the occupied plant room or enclosed workspace.
- › Maintain active O2 monitoring (alarm at <19.5% v/v) throughout any nitrogen operations in the plant room. Evacuate immediately if alarm activates.
- › Keep nitrogen cylinder valve closed when not actively pressurising. Use only the minimum quantity of nitrogen required. Store cylinders outside the confined space where practicable.
Electric shock from refrigerant system electrical components
Who’s at risk: Operatives, Other trades on site, Members of the public
- › Isolate the unit at its local isolator and apply a lock-off device and personal lock before opening any electrical enclosures or commencing work on refrigerant connections that require panel removal.
- › Use a calibrated voltage tester (GS38-compliant) to prove isolation before touching any conductors. Re-verify after any interruption to work.
- › Use insulated screwdrivers and probes rated to the system voltage. Wear anti-static, rubber-soled footwear where VFD/inverter equipment is present.
Manual handling of refrigerant cylinders and equipment
Who’s at risk: Operatives, Other trades on site, Members of the public
- › Use a cylinder trolley or sack truck with securing strap to transport refrigerant and nitrogen cylinders. Plan equipment access routes to the plant room to minimise manual carrying distance.
- › Where mechanical aids cannot be used due to access constraints, use a two-person lift technique. Assess posture, grip and load weight before lifting. Avoid twisting movements.
Disturbance of building occupants and impact on occupied premises
Who’s at risk: Operatives, Other trades on site, Members of the public
- › Arrange charging, recovery and leak-testing for out-of-hours periods to minimise occupant exposure to refrigerant vapour, noise and disruption.
- › Provide advance written notice to the building manager and occupants of planned works, potential odours, system downtime and emergency procedures. Agree an evacuation route and point of contact.
- › Erect physical barriers and post refrigerant hazard warning signs at all access points to the work area. Prevent unauthorised entry throughout the task.
PPE
- ✓ Safety footwear (EN ISO 20345)
- ✓ Hi-vis clothing
- ✓ Safety gloves (task-appropriate)
- ✓ Hard hat (EN 397) where overhead risk or site rules require
- ✓ RPE per the COSHH assessment
- ✓ Chemical-resistant gloves
- ✓ Insulated gloves where live work is unavoidable
Competence
- ✓ F-Gas certification (company and personnel — e.g. REFCOM, F Gas Register or Bureau Veritas) for any refrigerant handling — a separate statutory requirement, not covered by this RAMS
- ✓ Site induction completed; CSCS or equivalent where the site requires it
Schemes (CSCS, PASMA, IPAF…) evidence competence; they are not statutory requirements in themselves.
Plant & equipment
- › Isolation valves / pipe-freezing kit
- › Gas tightness test gauge (gas work)
- › Press tool or soldering/brazing set
- › MEWP or tower for high-level plant
- › LEV / extraction for brazing fume
Permits & legislation
What principal contractors usually check
- ✓ Named competence where required (Gas Safe / F-Gas / Part P)
- ✓ Service isolation and test-before-touch (gas tightness, electrical lock-off)
- ✓ Hot-works permit and fire watch for brazing/soldering near combustibles
- ✓ The document is site-specific — real address, access arrangements and dates, not a generic template
- ✓ Hazards match the actual task and the controls are specific (not “take care” and “use PPE”)
- ✓ Named supervisor and competent person, with operative sign-off space
- ✓ Emergency and rescue arrangements that work for this site
The report builder runs these as pre-submission checks before you download — or run an existing document through the free RAMS pre-submission checker.
Frequently asked questions
Who should write a f-gas charging, recovery & leak testing RAMS?
Someone competent to plan the work — usually the contractor doing the job or their supervisor. A template like this gives you the recognised hazards and controls for f-gas charging, recovery & leak testing, but the person signing it off must review it as the competent person and confirm it matches the actual site and method.
How long is the RAMS valid for?
Until something changes — there's no fixed expiry in law. Review it if the method, site conditions, equipment or people change, after any incident or near miss, and at sensible intervals on longer jobs. Date the review and re-brief the team.
What regulations apply to f-gas charging, recovery & leak testing?
Confined Spaces Regulations 1997, Regulatory Reform (Fire Safety) Order 2005, F-Gas Regulation (GB) — refrigeration, air conditioning and refrigerant handling are the main ones, alongside PUWER 1998 — Provision and Use of Work Equipment Regulations, Electricity at Work Regulations 1989, Manual Handling Operations Regulations 1992, Health and Safety at Work etc. Act 1974, section 3. The Health and Safety at Work etc. Act 1974 and CDM 2015 apply to all construction work.
Does a RAMS need to be site-specific?
Yes — this is the most common reason documents get sent back. Principal contractors reject generic copy-paste RAMS. Your document should name the site, access arrangements, dates, supervisor and any site-specific hazards. The RamsDocs builder fills these in for you and flags what's missing before you download.
Is this template free?
Yes — everything on RamsDocs is free during early access, including building a site-specific version of this RAMS and downloading the PDF. No card required.