HVAC Installation — Safe Work Method Statement
Safe Work Method Statement for the installation of heating, ventilation, and air conditioning systems including ductwork fabrication and installation, condenser unit placement, indoor unit mounting, and refrigerant pipework, in compliance with Australian WHS legislation.
Download this template
HVAC installation on construction sites involves a combination of trades and hazard types. The work constitutes High Risk Construction Work under the model WHS Regulations where it involves falls from height exceeding two metres — a common scenario when installing rooftop plant, ceiling-mounted air handlers, or high-level ductwork. A SWMS is required for these height elements, and fall prevention must be addressed through the hierarchy of controls: guardrails or handrails on rooftops, scaffolding or elevated work platforms for suspended ceiling work, and safety nets or catch platforms where elimination of the fall risk is not practicable.
Refrigerant handling is separately regulated under the Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 (Cth). Any person who handles refrigerants — including hydrochlorofluorocarbons (HCFCs), hydrofluorocarbons (HFCs), and the newer HFO refrigerants — must hold a current Refrigerant Handling Licence (RHL) issued under the Australian Government's Refrigerant Reclaim Australia scheme. Unauthorised venting of refrigerant to atmosphere is both an environmental offence under Commonwealth legislation and a WHS issue if high-pressure refrigerant is released near workers. HFO refrigerants such as R-1234yf are mildly flammable (A2L classification) and require specific storage and handling precautions. Natural refrigerants including ammonia (R-717) and CO₂ (R-744) in commercial systems require additional controls beyond the scope of standard HVAC installation.
Falls from rooftops during condenser unit placement and maintenance access are a leading cause of HVAC-related fatalities. Roof edge protection — guardrails or safety mesh — must be in place before any worker accesses a flat roof for HVAC installation, and maintenance walkways with handrails should be part of the design where ongoing maintenance will be required.
Customise this template with the specific HVAC system type, the refrigerant type and quantity, the installer's refrigerant handling licence number, the height work method and fall prevention controls, and the lifting plan for rooftop plant placement including crane or EWP details.
Personal Protective Equipment
High Risk Construction Work Types
- •Work at height involving the risk of falling more than 2 metres
- •Work on or near energised electrical installations or services
- •Work involving the handling of pressurised systems
Risk Assessment
1.Ductwork fabrication and installation
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Laceration from sharp sheet metal duct edges and corners | High | Wear cut-resistant Level 3 gloves at all times when fabricating, handling, and installing sheet metal ductwork. Use a purpose-built duct seaming tool for longitudinal seams — never use bare hands to fold sheet metal. Apply duct edge sealer or use a rubber mallet to flatten sharp flanges before carrying. Use mechanical duct lifts or scaffolding to lift and position ductwork above head height — avoid prolonged overhead manual handling of heavy duct sections. Brief all workers on correct handling techniques for sheet metal before commencing. | Low | HVAC Installer |
| Fall from ladder or scaffold during overhead duct installation | High | Use a Class 1 industrial ladder or adjustable scaffold platform for overhead duct installation work. Ladders must be secured at the top or footed by a second person, and placed on stable, level ground at the correct 1:4 angle (75°). Do not overreach from a ladder — reposition when the work is out of comfortable reach. For extended overhead installation work, use a work platform with guardrails in preference to a ladder. Wear a full harness connected to an anchor if working above 2 metres without edge protection. A second person should be present for all overhead duct installation. | Moderate | HVAC Installer / Site Supervisor |
2.Condenser unit placement and mechanical fixing
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Manual handling injury from lifting heavy condensing units | High | Commercial condensing units can weigh 50–200 kg. Use a mechanical lifting aid (engine crane, pallet jack, or crane lift) for any unit exceeding 25 kg per person. For roof-mounted condensers, use a crane with a certified dogger and rigging. Never manually carry condensing units up stairs or ladders. Set the condenser on a purpose-built slab, raised frame, or manufacturer-approved support. Two-person minimum for all condenser handling tasks within manual capacity. Complete a specific lift plan for crane lifts. | Low | HVAC Installer / Dogger |
3.Indoor unit mounting (split systems and cassettes)
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Fall or struck-by hazard during mounting of ceiling cassette units | High | Use an adjustable work platform or purpose-built HVAC lift table to elevate and hold cassette units while fixing is completed. Do not use a stepladder while holding a unit overhead — this requires both hands and creates significant instability. A minimum of two workers is required for all ceiling cassette installation — one mounting and one supporting. Inspect the ceiling structure before drilling or mounting to confirm the anchoring substrate is adequate for the unit's weight. Check for services in the ceiling void using a service locator before drilling. | Low | HVAC Installer |
4.Refrigerant pipework installation and pressure testing
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Refrigerant release causing asphyxiation or frostbite in enclosed areas | High | Only ARC-licensed (Australian Refrigeration Council) technicians may handle, recover, or charge refrigerants. All refrigerant work must be performed in compliance with the Ozone Protection and Synthetic Greenhouse Gas Management Act 1989. Do not work with refrigerants in enclosed or poorly ventilated spaces without a gas monitor capable of detecting the specific refrigerant. Wear cryogenic gloves when handling refrigerant lines under pressure. In the event of a significant refrigerant release in an enclosed space, evacuate immediately and ventilate before re-entering. | Low | ARC-Licensed Refrigeration Technician |
| High-pressure injury during nitrogen pressure testing of refrigerant pipework | High | Nitrogen pressure testing of refrigerant pipework must be performed using a calibrated regulator with a relief valve set to a pressure not exceeding the system test pressure (typically 4.0 MPa for R410A systems). Never use oxygen or air for pressure testing refrigerant lines. Ensure all personnel are clear of the test area during pressurisation. Monitor pressure for a minimum of 24 hours using a calibrated pressure gauge. In the event of a pressure drop, investigate and repair before re-testing. Only ARC-licensed technicians may perform pressure tests on refrigerant circuits. | Low | ARC-Licensed Refrigeration Technician |
5.Electrical connection and commissioning
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Electric shock during electrical connection of HVAC systems | High | All electrical connection and commissioning work must be performed by a licensed electrician. Before any electrical connection or disconnection, confirm the supply circuit is de-energised using a lockout/tagout procedure. Test with a calibrated non-contact voltage tester before touching any terminals. Verify that the circuit is rated correctly for the unit's full load current. Never work on live circuits. After connection, the electrician must verify polarity, earth continuity, and insulation resistance before commissioning. A Certificate of Compliance must be issued for all electrical work. | Low | Licensed Electrician |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.