A forklift driver was hospitalised with severe burns in March 2024 after nine-kilogram LPG gas cylinders exploded while being emptied on a worksite. The worker required nine weeks off work to recover from the injuries. In the prosecution that followed, the Manukau District Court imposed a $300,000 fine on the gas supplier and ordered $5,000 in reparations to the injured worker.
The cylinders involved had been condemned — assessed as unfit for service — but were still being emptied rather than being safely decommissioned. The explosion that resulted was foreseeable and preventable, and WorkSafe NZ has used the case to reiterate the controls that every workplace using LPG is required to have in place.
The Controls WorkSafe Requires
LPG management on construction sites and industrial premises carries specific obligations under health and safety law. WorkSafe has outlined the core requirements clearly following this case:
Cylinders must undergo annual inspection by a licensed inspector. Storage must be in upright, compliant enclosures with adequate ventilation to prevent gas accumulation. Cylinders must be kept well away from heat sources and open flame. Connections must be checked regularly for leaks. Any cylinder that has been condemned must not be used or emptied through standard operational processes — decommissioning must follow the required procedure.
The Broader LPG Risk on Construction Sites
LPG is widely used on construction sites for heating, cutting, and equipment operation. The familiarity of LPG cylinders and the routine nature of their use can create a false sense of security about the risks involved. Gas is invisible, and a leak can accumulate in an enclosed space to explosive concentrations without obvious warning.
For site managers, the WorkSafe requirements are not bureaucratic formalities — they reflect the real consequences of gas-related incidents. A $300,000 penalty and a worker with severe burns is a severe outcome that proper controls would have prevented.
What to Check on Your Site
Any site using LPG should confirm: cylinders are stored upright in a well-ventilated, compliant enclosure away from ignition sources; inspection records are current; connections are checked regularly; condemned or damaged cylinders are removed from service immediately and disposed of through the correct channel; and all staff who handle cylinders have been trained in the relevant procedures.
Explore more health and safety guidance for New Zealand construction and industrial sites, or connect with WorkSafe-recognised safety advisers and training providers.
