Gas explosion hospitalises forklift driver

WorkSafe is calling on all industries to follow through on controlling risks once they are identified after a gas explosion burned a forklift driver. 

In March 2024, the forklift caught fire, igniting LPG that was being released from condemned cylinders. Several nine-kilogram gas bottles exploded, fuelling the fire. The driver was hospitalised with burns and was off work for nine weeks.

The gas cylinders supplier was imposed a fine of $300,000 and reparations of $5,000 at the Manukau District Court.

WorkSafe principal inspector, David Worsfold says this case isn’t just about flammable gases, but a pattern that transcends any single industry. 

“Whether you’re working with flammable gases, operating machinery, managing heights, or dealing with any workplace hazard, the principle is the same: identify the risk, implement controls that actually work, and make sure people follow them.”

WorkSafe says the case highlights a critical gap between knowing what should be done and actually doing it. Worsfold says businesses should ask themselves if their safety procedures are keeping their workers safe. The answer should be a sure, honest yes.

“This worker ended up in hospital because his employer didn’t take simple steps to eliminate an obvious risk. Every business leader should ask themselves: where are we making the same mistake?”

While LPG cylinders are convenient and widely used, they remain potentially dangerous if not handled correctly. 

The explosion highlights common risks, including poor hose connections, damaged or corroded cylinders, placing cylinders near heat, and incorrect storage.

Businesses must eliminate hazards where possible and control them where elimination isn’t feasible. 

Practical steps include having gas installations checked annually by a licensed fitter, keeping areas well ventilated and inspecting cylinders for damage.

Cylinders should be stored upright in compliant enclosures, checked connections regularly, kept cylinders away from heat or flames, and never tampering with valves or refilling cylinders yourself.

WorkSafe emphasizes that simply having procedures isn’t enough. Safety requires planning, monitoring, and enforcing practices every day. 

As this case shows, even a clear and obvious risk can cause serious injury if it isn’t managed.