SafetyPaperwork
Air conditioning and refrigeration · Australia

SWMS for split system installation

By Safety PaperworkBuilt from Safe Work Australia and state regulator guidance · How we write and check theseUpdated

Yes. Split system installation usually includes high risk construction work (work on or near chemical, fuel or refrigerant lines; work on or near energised electrical installations or services), so a SWMS is required by law before work starts.

It must list the hazards, the controls and how they will be put in place, monitored and reviewed, and the workers must be consulted and sign before starting. The main hazards are falling from height, silica dust from concrete, brick, stone and tiles, electric shock from live wiring and fire from hot works.

Make this SWMS nowWord templatePDF

SWMS example: split system installation

This is a complete SWMS for split system installation, with 10 job steps. Open it in the builder to add your site, crew and signatures, change anything, and download a PDF. Or download the free Word template below and fill it in by hand.

Safe Work Method Statement (SWMS)
Split system air conditioner installation · Air conditioning and refrigeration · Example
Document SWMS-001 · Rev 1

High risk construction work covered

Work on or near chemical, fuel or refrigerant linesWork on or near energised electrical installations or services

Job steps, hazards and controls

#Job stepHazardsRisk beforeControlsRisk after
1Plan unit positions, checking walls for cables and pipes
  • Electric shock from live wiring
  • Gas and fuel lines
Extreme
  • Isolate the power before any work. Do not do live work except in the limited cases the WHS Regulations allow (r.157; in Qld, the Electrical Safety Regulation 2013). Eliminate
  • Lock out and tag the isolation point with your own personal lock and danger tag. Isolate
  • Electric shock from live wiring: see step 8 for the full controls Administrative
  • Isolate and purge the line before work, with the owner's approval. Eliminate
  • Lock off and tag the isolation valve. Isolate
  • Check for leaks with a gas detector before and during work, and ventilate the area. Engineering
  • Only licensed gasfitters work on gas lines. Administrative
  • Remove ignition sources: no smoking, no hot work and no sparking tools near the line. Administrative
  • Know where the shut-off valve is and what to do if a leak happens. Administrative
  • Wear safety glasses and gloves, and keep a fire extinguisher close by. PPE
Medium
2Set up a platform ladder or scaffold for high walls and the outdoor unit
  • Falling from a ladder
  • Falling from height
Extreme
  • Use a platform ladder, mobile scaffold or EWP for longer jobs instead of a straight ladder. Substitute
  • Use industrial-rated ladders (AS/NZS 1892, 120 kg or more) in good condition. Remove any damaged ladder from site. Engineering
  • Set extension ladders at a 4 to 1 angle on firm, level ground, tied or footed, and reaching 1 metre above the landing. Engineering
  • Use ladders only for short, light work. Do not carry heavy or awkward loads up a ladder. Administrative
  • Keep three points of contact and your belt buckle between the stiles. Do not overreach. Administrative
  • Do not stand on the top three rungs of an extension ladder or the top step of a stepladder. Administrative
  • Check the ladder before each use: feet, rungs, stiles and locks. Administrative
  • Wear non-slip safety boots with clean soles. PPE
  • Do the work from the ground where you can, for example pre-assemble on the ground or use extension poles. Eliminate
  • Install guardrails or edge protection on all open edges before work starts. Isolate
  • Use a scaffold, mobile work platform or EWP instead of working off a ladder. Engineering
  • Where edge protection is not practical, use a fall restraint or fall arrest system on a rated anchor point. Engineering
  • Everyone working at height holds a White Card and has been briefed on this SWMS before going up. Administrative
  • Have a written emergency and rescue plan, tested before work starts, so a worker hanging in a harness can be brought down within minutes (WHS Regulations r.80). Administrative
  • Wear a full body harness with a shock-absorbing lanyard, clipped on at all times when using fall arrest. PPE
Medium
3Core drill the wall with dust extraction
  • Silica dust from concrete, brick, stone and tiles
  • Loud noise
  • Injury from power tools
Extreme
  • If the job involves engineered stone: do not supply, fabricate or install engineered stone benchtops, panels or slabs (banned since 1 July 2024). Removing, repairing or making minor changes to existing engineered stone is only allowed with water suppression or on-tool extraction, a fitted respirator, and written notice to the regulator before the work starts. Eliminate
  • Order materials cut to size, or use low-dust methods such as score and snap or a block splitter. Substitute
  • Cut outdoors or in a separate area, with other people well away and upwind. Isolate
  • Use water on the blade or on-tool dust extraction connected to an H-class vacuum. Engineering
  • Clean up with a vacuum or wet methods. Never dry sweep or use compressed air. Administrative
  • If the cutting, grinding or drilling is high risk, prepare a silica risk control plan (or include the r.529CA assessment in this SWMS), train workers in silica risks and give them the plan before work starts. Administrative
  • Wear a fit-tested P2 (or better) respirator. PPE
  • Use quieter tools and methods, such as cut-to-size materials, low-noise machines and battery tools. Substitute
  • Keep noisy plant away from work areas, and use screens or distance between the noise and people. Isolate
  • Keep tools maintained and use mufflers on compressors and generators. Engineering
  • Limit time on noisy tools and rotate workers. Administrative
  • If you have to shout to be heard 1 metre away, wear hearing protection. Administrative
  • Keep exposure below 85 dB(A) over 8 hours. Give hearing tests to workers who often need hearing protection. Administrative
  • Keep all guards fitted and working. Never tie back or remove a guard. Engineering
  • Clamp or secure the work piece. Do not hold it by hand. Engineering
  • Only trained, competent people use power tools, following the maker's instructions. Administrative
  • Check tools before use. Unplug or remove the battery before changing blades or bits. Administrative
  • No loose clothing, jewellery or long hair near spinning parts. Administrative
Medium
4Fix the wall bracket and mount the indoor unit
  • Falling from a ladder
  • Lifting and carrying heavy loads
High
  • Falling from a ladder: see step 2 for the full controls Administrative
  • Plan to avoid carrying: have materials delivered, and old items picked up, as close as possible to where they are used. Eliminate
  • Use lighter or smaller loads: order smaller bags and shorter lengths, and drain or break down old items before moving them. Substitute
  • Lifting and carrying heavy loads: see step 5 for the full controls Administrative
Medium
5Lift the outdoor unit with two people onto its bracket or pad
  • Lifting and carrying heavy loads
  • Falling from height
Extreme
  • Plan to avoid carrying: have materials delivered, and old items picked up, as close as possible to where they are used. Eliminate
  • Use lighter or smaller loads: order smaller bags and shorter lengths, and drain or break down old items before moving them. Substitute
  • Use trolleys, pallet jacks, hoists, vacuum lifters or plant instead of carrying by hand. Engineering
  • Use a two-person lift for anything heavy, long or awkward. Plan the route first and clear it. Administrative
  • Keep the load close, back straight and no twisting. Turn with your feet. Administrative
  • Rotate tasks and take breaks on long lifting jobs. Administrative
  • Wear gloves for grip and safety boots to protect your feet. PPE
  • Falling from height: see step 2 for the full controls Administrative
Medium
6Run and flare the pipework, brazing only under a hot work permit
  • Refrigerant leaks
  • Fire from hot works
  • Burns from hot surfaces
Extreme
  • Recover refrigerant into an approved cylinder before opening the system. Never vent it. Isolate
  • Ventilate closed spaces and use a leak detector during the work. Engineering
  • Only holders of a refrigerant handling licence (ARCtick) work on refrigerant systems. Administrative
  • Check the licence covers the job: the restricted split licence only covers single-head splits under 18 kW, and adding refrigerant needs an ARC Refrigerant Trading Authorisation (RTA) for the business. Administrative
  • With flammable refrigerants (such as R32 or R290), remove ignition sources and use spark-free tools. Administrative
  • Wear cold-rated gloves and safety glasses or a face shield. PPE
  • Use cold work methods where you can, such as bolting, press fittings or cutting with a saw instead of a torch. Eliminate
  • Move anything that can burn at least 15 metres away (AS 1674.1), or protect it with fire blankets or screens. Isolate
  • Use fire-resistant screens to stop sparks reaching people or gaps in walls and floors. Engineering
  • Get a hot work permit before starting. Administrative
  • Keep a charged fire extinguisher and fire blanket at the work spot. Administrative
  • Isolate heating systems and let parts cool before you touch them. Eliminate
  • Fit guards or insulation on hot pipes and equipment. Engineering
  • Mark hot items with chalk or a "HOT" sign so others know. Administrative
  • Keep a first aid kit and cool running water nearby for burns. Administrative
  • Wear heat-resistant gloves and long sleeves. PPE
Medium
7Pressure test with dry nitrogen through a regulator, keeping clear of fittings under pressure
  • Pressure testing
Medium
  • Test with water instead of air or gas where the system allows it. Never put water in refrigerant pipework, which is tested with dry nitrogen. Substitute
  • Keep people out of the test area with signs and barriers. Isolate
  • Use a calibrated gauge and a relief valve set to protect the system. Engineering
  • Test to the pressure the system calls for and hold it for the set time. Never go over. Administrative
  • Release the pressure fully before tightening anything or fixing leaks. Administrative
  • Wear safety glasses or a face shield. PPE
Low
8Electrical connection by a licensed electrician, with the circuit isolated
  • Electric shock from live wiring
Extreme
  • Isolate the power before any work. Do not do live work except in the limited cases the WHS Regulations allow (r.157; in Qld, the Electrical Safety Regulation 2013). Eliminate
  • Lock out and tag the isolation point with your own personal lock and danger tag. Isolate
  • Test before you touch: prove dead at the point of work with a voltage tester, proving the tester on a known live source before and after (AS/NZS 4836). Engineering
  • Only licensed electricians do electrical work. Administrative
  • Check for back feeds from solar, batteries and generators that can keep a circuit live after the main switch is off. Administrative
  • If live work cannot be avoided, use a permit, a safety observer and insulated tools. Administrative
  • Wear insulated gloves, arc-rated clothing and a face shield when testing or working near live parts. PPE
Medium
9Vacuum the system, open the service valves to let the outdoor unit's factory charge into the pipework, then commission
  • Refrigerant leaks
Medium
  • Refrigerant leaks: see step 6 for the full controls Administrative
Low
10Clean up and show the client how to use the system
  • Poor housekeeping and waste
Medium
  • Order materials to size and send packaging back where you can. Eliminate
  • Put skip bins and waste chutes close to the work. Engineering
  • Clean as you go, and do a full clean up at the end of each day. Administrative
  • Keep exits, stairs and walkways clear at all times. Administrative
  • Stack materials neatly on level ground, away from edges. Administrative
  • Wear gloves when handling waste. PPE
Low

PPE

Steel cap bootsSafety glassesWork glovesP2 dust maskHearing protection (earmuffs or plugs)Insulated electrical glovesArc-rated clothing and face shieldHard hatHalf-face respirator (P2 or P3 filters)Face shieldWelding glovesOveralls

Plant and equipment

Power drillCore drillExtension ladderElectrical test equipmentHand tools

Permits and plans

Electrical isolation permitHot work permit

Emergency

Call 000. Add the nearest hospital, the assembly point and the first aider for your site.

Sign-off

Supervisor and every worker sign to confirm they have read and understood this SWMS.

Page 1 of the free split system installation SWMS template: business details, high risk construction work and job steps with hazards, risk ratings and controls

Free SWMS template for split system installation

Word (.docx) and PDF, A4 landscape, no email needed. Fill in your site details, then print or send it.

Word template (.docx)PDF template

Make yours in 2 minutes

Same document, filled in for your job. Answer a few yes or no questions, the crew signs on the phone, and you send the PDF.

Start this SWMS

Pre-start checklist for split system installation

Tick these off before work starts. They come from the hazards, permits and equipment in this job.

The safe sequence of work

  1. Plan unit positions, checking walls for cables and pipes
  2. Set up a platform ladder or scaffold for high walls and the outdoor unit
  3. Core drill the wall with dust extraction
  4. Fix the wall bracket and mount the indoor unit
  5. Lift the outdoor unit with two people onto its bracket or pad
  6. Run and flare the pipework, brazing only under a hot work permit
  7. Pressure test with dry nitrogen through a regulator, keeping clear of fittings under pressure
  8. Electrical connection by a licensed electrician, with the circuit isolated
  9. Vacuum the system, open the service valves to let the outdoor unit's factory charge into the pipework, then commission
  10. Clean up and show the client how to use the system

Hazards to watch on split system installation

The hazards most specific to this job, and the step where each one comes up.

Step 6, 9Refrigerant leaksRefrigerant gas causes frostbite, pushes oxygen out of small rooms, and some types catch fire.
Step 6Burns from hot surfacesTouching hot pipes, tools, bitumen, solder or freshly welded metal burns the skin.
Step 7Pressure testingA pipe, fitting or cap fails under test pressure and blows apart, hitting people nearby.
Step 6Fire from hot worksSparks and heat from welding, grinding or flame torches set fire to timber, insulation, rubbish or fuel nearby.
Step 1Gas and fuel linesDamaging or opening a gas or fuel line causes a leak, fire or explosion.
Step 3Injury from power toolsDrills, saws, routers and sanders kick back, catch clothing or throw debris, causing cuts, broken bones and eye injuries.
Almost certainLikelyPossibleUnlikelyRareHow bad it could be: Insignificant to CatastrophicBA
Highest risk on split system installation: Extreme before controls (B), down to Medium after controls (A), on the Australia 5 by 5 risk matrix (likely and catastrophic becomes unlikely and major).

What changes on your site

This example covers the job itself. Your site may add more. Add controls for any of these that apply (the builder asks you these as yes or no questions):

  • Will anyone work more than 2 metres off the ground?
  • Will anyone work on a roof?
  • Is there a skylight, clear sheet, fibro or other fragile roofing?
  • Will you use a scaffold or mobile tower?
  • Will you use an EWP (scissor lift or boom lift)?

Licences and legal requirements in Australia

This task can involve these high risk construction work categories under the WHS Regulations:

  • Work on or near chemical, fuel or refrigerant lines
  • Work on or near energised electrical installations or services

A SWMS must be prepared before any high risk construction work starts. It must list the high risk work, the hazards and risks, the control measures, and how those controls will be put in place, monitored and reviewed. It must be easy for the workers to read and understand.

Rules that apply: WHS Regulation 2011, Part 4.7 General electrical safety; WHS Regulation 2011, Part 4.4 Falls; WHS Regulations, Chapter 8A (Crystalline silica substances and engineered stone); WHS Regulation 2011, Part 4.1 Noise; WHS Regulation 2011, Part 4.2 Hazardous manual tasks; Ozone Protection and Synthetic Greenhouse Gas Management Act 1989; AS 1674.1 Safety in welding and allied processes (fire precautions).

Each state has its own regulator and some extra rules: New South Wales, Victoria, Queensland, Western Australia, South Australia and Australian Capital Territory.

Why SWMS get rejected

Principal contractors send documents back for these reasons. This example avoids them, but check yours too.

  • It is generic: another site address, tasks that are not on this job, or no sign it was reviewed for this site. WorkSafe WA says a generic SWMS may not meet the regulations unless it is reviewed and amended for the workplace.
  • The HRCW boxes are not ticked, or the ticks do not match the tasks (for example a roof job with no falls box ticked).
  • Falls are controlled only by "be careful", training or a harness, with no edge protection or scaffold and no reason why higher controls are not reasonably practicable.
  • Workers will clip on to a harness but there is no rescue plan for someone left hanging.
  • The "how controls are implemented, monitored and reviewed" part is missing, or it says the same thing on every row.
  • No worker sign-on, no person responsible for compliance, or a date given to the principal contractor that is before they actually received it.
  • Licence or White Card details are missing for workers operating plant or doing licensed high risk work.

Questions

Do I need a SWMS for split system installation?

Yes. Split system installation usually includes high risk construction work (work on or near chemical, fuel or refrigerant lines; work on or near energised electrical installations or services), so a SWMS is required by law before work starts.

Who signs the SWMS?

The person conducting the business (PCBU) or their supervisor prepares it with the workers, and every worker doing the high risk work signs to show they were consulted and understand it. Give a copy to the principal contractor before work starts.

How long do I keep it?

Keep this SWMS, and every revised version, until the high risk construction work is finished, where workers and inspectors can see it on site. If a notifiable incident happens during the work, keep it for at least 2 years after the incident.

What PPE is needed for split system installation?

Usually Steel cap boots, Safety glasses, Work gloves, P2 dust mask, Hearing protection (earmuffs or plugs), Insulated electrical gloves, Arc-rated clothing and face shield, Hard hat, Half-face respirator (P2 or P3 filters), Face shield, Welding gloves, Overalls. The site rules may add more, so check with the principal contractor.

More air conditioning and refrigeration SWMS

SWMSDucted Air Conditioning Installation6 stepsSWMSGas Ducted Heater Replacement6 stepsSWMSAir Conditioning Servicing5 stepsSWMSRooftop Package Unit Replacement6 stepsSWMSDuctwork Installation5 stepsSWMSRefrigerant Recovery and Regas6 steps

Related jobs in other trades

PlumbingHot Water System ReplacementAlso involves electric shock from live wiringDemolitionInternal Strip OutAlso involves electric shock from live wiringRoofingRoof Tile ReplacementAlso involves falling from a ladderConcretingConcrete Cutting and Core DrillingAlso involves electric shock from live wiringRoofingGutter ReplacementAlso involves falling from heightElectricalSwitchboard UpgradeAlso involves electric shock from live wiring

Toolbox talks for this job

Toolbox talkLadder SafetyToolbox talkOverhead Power LinesToolbox talkExtension Leads and Power ToolsToolbox talkSilica Dust

Blank SWMS template: free SWMS templates. Also for other countries: United Kingdom (RAMS) · United States (JHA) · Canada (FLHA)

Sources