When this template fits
This RAMS is for UK contractors and hvac teams carrying out refrigerant pipework & brazing — 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
Run and braze refrigerant pipework with naked flame near combustibles, plus flux fume.
Sequence of works
- 1Obtain and brief all operatives on the hot-works permit. Confirm COSHH assessment for flux and filler rods is available, review SDS, and verify all operatives hold valid F-Gas certification if working on live refrigerant circuits.
- 2Survey the work area: identify and remove or shield combustibles within 3 m, check for asbestos-containing materials in older buildings (competent person survey required before disturbing), establish an exclusion zone and erect welding screens where other workers are present.
- 3If modifying an existing refrigerant circuit, fully recover refrigerant using compliant recovery equipment before cutting or heating any pipe. Record recovered quantities in the F-Gas log.
- 4Inspect and assemble oxy-fuel or air-propane brazing equipment: check cylinders are secured on trolleys, hoses are undamaged, flashback arrestors are fitted on both torch connections, and perform a leak test with detection fluid before igniting.
- 5Cut, deburr and dry-fit all pipe sections. Connect nitrogen purge supply to the pipe run to be brazed, set flow rate to purge the bore continuously throughout the brazing process.
- 6Don full PPE (heat-resistant gloves, face shield, flame-retardant overalls, safety footwear, and RPE if LEV is unavailable or inadequate). Position portable LEV or ensure forced ventilation is active before lighting torch.
- 7Braze joints following manufacturer's procedure: apply minimum flux consistent with joint quality, heat evenly, introduce filler rod at correct temperature, and extinguish torch immediately after each joint. Mark hot pipework and allow to cool before handling.
- 8On completion of brazing, conduct post-work fire watch for a minimum of 60 minutes. Pressure-test the completed pipework assembly with dry nitrogen to the design test pressure before any refrigerant charging.
- 9Charge refrigerant only using F-Gas certified personnel and compliant charging equipment. Record all refrigerant quantities in the site F-Gas register.
- 10Clear work area: remove all off-cuts, flux residues and gas cylinders. Return hot-works permit, record any incidents or near-misses, and update the COSHH assessment if materials or conditions changed during the task.
Hazards, risk rating & controls
Risk = likelihood × severity (1–25). Initial is before controls; residual is with controls applied.
Fire from naked flame near combustibles
Who’s at risk: Operatives, Other trades on site
- › Issue a hot-works permit before any brazing commences. Permit to identify combustibles, clearance distances, fire watch duration and responsible persons.
- › Remove combustible materials within minimum 3 m radius of the brazing point. Where removal is not practicable, shield with proprietary fire-resistant blankets or boards.
- › Maintain a trained fire watcher with appropriate extinguisher during brazing and for at least 60 minutes after work ceases. Final inspection before leaving the area.
- › Provide a suitable dry-powder or CO2 extinguisher (minimum 2 kg) immediately adjacent to the work area before brazing begins.
Burns from brazing torch and hot pipework
Who’s at risk: Operatives, Other trades on site
- › Extinguish torch immediately after each joint; never lay a lit torch down. Use regulators with flashback arrestors on both oxygen and fuel supplies.
- › Mark or verbally warn that pipework is hot immediately after brazing; allow adequate cooling time before handling. Use pipe-support clamps to avoid direct contact.
- › Wear BS EN 407 rated heat-resistant gloves and a face shield (minimum EN 175) when brazing or handling recently brazed pipe.
Inhalation of flux fumes and brazing smoke
Who’s at risk: Operatives, Other trades on site
- › Use self-fluxing phosphor-copper filler rods on copper-to-copper joints to eliminate separate flux application where possible.
- › Use portable on-tool or close-capture LEV to capture fumes at source. Ensure LEV is inspected and maintained. Where LEV is impracticable, provide general forced ventilation with a minimum of 10 air changes per hour.
- › Complete a written COSHH assessment referencing the SDS for each flux and filler rod used. Review workplace exposure limits against HSE EH40 for fluorides and copper fume.
- › Where LEV cannot adequately control exposure, wear a half-mask respirator fitted with a combined P3/A2B2E2 filter cartridge. RPE to be face-fit tested.
Oxygen-enriched atmosphere and gas cylinder hazard
Who’s at risk: Operatives, Other trades on site
- › Check all connections with leak-detection fluid (not naked flame) before each use. Inspect hoses and regulators for damage. Use flashback arrestors on all torch connections.
- › Store and transport cylinders upright and secured. Keep oxygen and fuel gas cylinders segregated by at least 3 m or a fire-resistant partition. Never store in confined spaces or near heat sources.
- › Use a portable gas detector before and during brazing in enclosed or semi-enclosed spaces to check for oxygen enrichment or flammable gas accumulation.
Refrigerant exposure and release
Who’s at risk: Operatives, Other trades on site
- › Fully recover all refrigerant from the affected circuit using F-Gas compliant recovery equipment before cutting or heating any refrigerant-carrying pipework. Only F-Gas certified operatives to carry out recovery.
- › Purge the internal bore of refrigerant pipework with dry nitrogen during brazing to prevent oxidation and to confirm the line is clear of refrigerant.
- › Ensure adequate ventilation when working on refrigerant systems to prevent oxygen-deficient atmosphere in the event of an uncontrolled release.
Eye injury from brazing spatter and UV radiation
Who’s at risk: Operatives, Other trades on site
- › Wear a brazing/welding face shield or goggles with appropriate filter shade (minimum EN 169 shade 4–5 for brazing) and full face protection against spatter.
- › Erect welding screens to protect nearby workers from spatter and heat radiation.
Manual handling of heavy pipe and cylinders
Who’s at risk: Operatives, Other trades on site
- › Use cylinder trolleys for all gas cylinder movements. Use pipe rollers, supports or a second person for long or heavy pipe runs.
- › Operatives to be trained in safe manual handling techniques. Task-specific manual handling risk assessment to be completed where loads exceed HSE guideline weights.
Slips and trips from pipe, hoses and equipment
Who’s at risk: Operatives, Other trades on site
- › Route hoses along walls or overhead wherever possible and keep work area clear of loose pipe off-cuts, fittings and packaging throughout the shift.
- › Provide sufficient portable or fixed lighting in work areas so hazards on the floor and underfoot are clearly visible.
Working at height during pipe runs
Who’s at risk: Operatives, Other trades on site
- › Use a podium step unit or low-level tower scaffold to provide a stable working platform with edge protection for sustained overhead pipe installation work.
- › Ladders only to be used for access or short-duration tasks. Inspect before use, secure at top or foot, and never carry the brazing torch while ascending or descending.
- › Establish a ground-level exclusion zone beneath overhead brazing to protect persons from falling pipe, fittings or brazing spatter.
PPE
- ✓ Safety footwear (EN ISO 20345)
- ✓ Hi-vis clothing
- ✓ Safety gloves (task-appropriate)
- ✓ Hard hat (EN 397) where overhead risk or site rules require
- ✓ Eye/face protection
- ✓ Flame-resistant gloves
- ✓ RPE per the COSHH assessment
- ✓ Chemical-resistant gloves
- ✓ Safety harness and lanyard where fall arrest is the selected control
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 refrigerant pipework & brazing 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 refrigerant pipework & brazing, 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 refrigerant pipework & brazing?
Regulatory Reform (Fire Safety) Order 2005, Management of Health and Safety at Work Regulations 1999, reg 3 — risk assessment, Control of Substances Hazardous to Health Regulations 2002 (COSHH) are the main ones, alongside COSHH 2002, reg 7 — prevention or control of exposure, Manual Handling Operations Regulations 1992, Work at Height Regulations 2005. The Health and Safety at Work etc. Act 1974 and CDM 2015 apply to all construction work.
Does a method statement 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.