Ep. 25: Case Study: Injury and Fines When Gas Cylinder Transport Goes Wrong

A devastating explosion. A life forever changed. And a powerful reminder of the risks that come with unsafe gas cylinder transport.

In this episode of Chemical Safety at Work, Mel and Pat examine the tragic 2017 incident in Bayswater, Victoria, where an acetylene cylinder exploded in the back of a customer’s ute—leaving him with catastrophic injuries and leading to a major WorkSafe prosecution.

Tune in as we break down:

• The system failures that led to the explosion.
• What AS 4332:2004 says about gas cylinder storage and transport.
• Why ventilation, cylinder orientation, and vehicle suitability matter.
• The court’s findings and what suppliers must do to fulfil their duty of care.
• How everyday practices can have devastating consequences if safety is overlooked.

This case isn’t just about workplace risk—it’s about the responsibility we all share to protect workers, customers, and the public.

🔗 Show notes include links to:

• The official WorkSafe case summary
• AS 4332:2004
• The ADG Code
• BOC - Guidelines for Cylinder Safety

Listen now and learn how to prevent the next disaster.

Chapters

• 0:00 Episode Introduction
• 1:38 The Bayswater Gas Cylinder Explosion
• 3:20 WorkSafe Prosecution Findings
• 3:50 Best Practices for Cylinder Transport
• 5:20 Key Takeaways and Closing

Transcript

Melissa Hampton: 0:06

You're listening to Chemical Safety at Work. I'm Mel.

Patrick Gee: 0:09

And I'm Pat. In today's episode, we're revisiting a devastating incident that occurred in Bayswater, Victoria, involving gas cylinders, unsafe transport and serious injuries. It led to a significant work, safe prosecution and a powerful reminder about the risks of flammable gases when transported incorrectly.

Melissa Hampton: 0:29

This case centres on a gas cylinder supplier which was sentenced in the Melbourne County Court in 2023 after being found guilty of two charges under the Occupational Health and Safety Act 2004, Vic.

Patrick Gee: 0:43

The incident dates back to 2017, when a worker was transporting two gas cylinders, one containing acetylene and the other oxygen that he had just picked up from a supplier's nearby store.

Melissa Hampton: 0:56

The explosion happened as he was driving along Mountain Highway in Bayswater. The cylinders were stored lying down in the fully enclosed rear compartment of a ute. Tragically, the combination of poor cylinder orientation and lack of ventilation led to an ignition of acetylene vapour.

Patrick Gee: 1:14

The resulting explosion was huge. Debris was thrown up to 200 metres, damaging nearby cars, homes and even overhead power lines. The worker now requires a wheelchair and suffers from memory loss due to extensive physical and psychological injuries.

Melissa Hampton: 1:31

Following a three-week jury trial, the company was fined a total of $550,000. $275,000 was for failing to provide a safe system of work and $275,000 was for failing to ensure that persons other than employees were not exposed to health and safety risks.

Patrick Gee: 1:51

They were also found not guilty on a third charge of failing to provide adequate training or instruction to workers. However, the court made it clear that the company's systems were insufficient to prevent this type of incident.

Melissa Hampton: 2:04

WorkSafe's investigation found that the likely cause was the ignition of an acetylene air mixture inside the sealed ute tray. The cylinders were unsecured and laid on their sides, against all best practice for compressed gas transport.

Patrick Gee: 2:18

It was determined that it would have been reasonably practicable for the company to ensure that cylinders were only transported when secured upright in a well-ventilated vehicle.

Melissa Hampton: 2:28

This incident shows how essential it is for suppliers to go beyond just handing over cylinders.

Patrick Gee: 2:33

In fact, WorkSafe recommends that suppliers consider offering delivery if a customer's vehicle doesn't meet the requirements, and that would have made all the difference here.

Melissa Hampton: 2:43

So what are best practices for transporting cylinders? Well, first, cylinders should be always secured upright, never lying flat. Second, the cargo area should be open to the air or, if using a closed vehicle, it must be fitted with a vented gas storage cabinet.

Patrick Gee: 3:01

And don't forget loose tools. Unrestrained objects in the same space can cause impact damage to valves or cylinders, increasing risk.

Melissa Hampton: 3:09

These controls are clearly outlined in AS4332-2004,. The storage and handling of gases in cylinders that stand is the go-to reference for safe storage, handling and transport of compressed gas cylinders in Australia.

Patrick Gee: 3:23

Suppliers should also ensure their staff are trained to check for vehicle suitability and provide clear information to customers on safe transport requirements.

Melissa Hampton: 3:32

In this case, the court noted that the explosion not only harmed the worker but also put at risk seven named individuals and others nearby, including people in nearby vehicles, homes and at the store itself.

Patrick Gee: 3:45

It's a stark reminder that workplace incidents don't just affect workers. They can affect the public and emergency services and the whole community. The key takeaway Whether you're supplying or transporting gas cylinders, the systems must be airtight.

Melissa Hampton: 4:06

Ventilation, cylinder orientation, restraint systems and vehicle suitability checks aren't optional extras. They're life-saving essentials and they're covered in AS4332.

Patrick Gee: 4:12

And if you're a supplier, you have a duty to step in when you see unsafe practices. Refusing to load can prevent catastrophe.

Melissa Hampton: 4:20

We'll link the full WorkSafe Victoria case summary AS4332, and guidance on transporting compressed gases in the show notes.

Patrick Gee: 4:29

Thanks for tuning in to Chemical Safety at Work. Stay safe and we'll catch you next time.

Melissa Hampton: 4:33

Take care.