Plumbing · Australia

SWMS for hot water system replacement

By Safety PaperworkBuilt from Safe Work Australia and state regulator guidance · How we write and check theseUpdated 9 November 2026

A SWMS is required by law if hot water system replacement includes any high risk construction work, such as working where someone could fall more than 2 metres. Many principal contractors ask for one either way.

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 electric shock from live wiring, fire from hot works, lifting and carrying heavy loads and gas and fuel lines.

Make this SWMS now Word template PDF

SWMS example: hot water system replacement

This is a complete SWMS for hot water system replacement, 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)

Replace a hot water system · Plumbing · Example

Document SWMS-001 · Rev 1

High risk construction work covered

None for this task on its own. Tick any that apply on your site.

Job steps, hazards and controls

#	Job step	Hazards	Risk before	Controls	Risk after
1	Check access to the unit and plan the removal route through stairs, roof spaces or tight cupboards	Tight spaces: roof spaces and under floors Lifting and carrying heavy loads	High	Do as much of the work as you can from outside the tight space. Eliminate Turn the power off at the switchboard before entering where you can, as damaged cables may be live. Isolate Lay crawl boards across the joists so you cannot step through the ceiling. Engineering Set up ventilation and lighting in the space. Engineering Limit time in hot roof spaces and take breaks somewhere cool. Administrative Tell someone when you go in and when you are out. Administrative Wear a dust mask, knee pads, gloves and a bump cap. PPE 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	Medium
2	Isolate power at the switchboard and gas or water at the meter, lock out and danger tag	Electric shock from live wiring Gas and fuel lines Stored energy	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 Gas and fuel lines: see step 8 for the full controls Administrative Release or block all stored energy before work: release the pressure in pipes, tanks and hoses, bleed hydraulics, release springs, lower loads. Eliminate Lock out and tag all energy sources with personal locks. Isolate Put mechanical blocks or props under raised parts like buckets, tipper bodies and doors. Engineering Test that the system is dead and nothing can move before you start. Administrative Follow the maker's procedure, for example for garage door and roller door springs. Administrative	Medium
3	Drain the old unit, watching for scalding water and steam	Hot water and steam Burns from hot surfaces Slips and trips	Medium	Turn the system off and let it cool before work. Eliminate Isolate and lock off the heat source and valves, and release the pressure. Isolate Hot water and steam: see step 9 for the full controls 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 Plan walkways and keep them clear of materials, hoses and leads. Eliminate Run leads and hoses overhead on hooks or stands, or along walls, not across walkways. Engineering Fill or cover holes, and lay boards or mats on muddy access paths. Engineering Clean up offcuts, packaging and spills as you go, not at the end of the day. Administrative Keep work areas, stairs and access paths well lit. Administrative	Low
4	Disconnect pipes, flue and wiring, and cap the gas line. Treat old fibre cement flues and base sheets as asbestos until checked, and do not cut or break them	Gas and fuel lines Electric shock from live wiring Cuts from sharp edges	Extreme	Check for leaks with a gas detector before and during work, and ventilate the area. Engineering Only licensed gasfitters work on gas lines. Administrative Gas and fuel lines: see step 8 for the full controls Administrative 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 Electric shock from live wiring: see step 8 for the full controls Administrative Deburr or cover sharp edges, and fit edge protectors on exposed sheet metal. Engineering Use knives with retractable or self-retracting blades. Engineering Cut away from your body and keep your other hand clear. Administrative Put used blades in a blade bin or sharps container. Administrative Use two people to handle large sheets of metal or glass. Administrative	Medium
5	Remove the old unit using a trolley and two people	Lifting and carrying heavy loads Cuts from sharp edges	High	Lifting and carrying heavy loads: see step 1 for the full controls Administrative Wear cut-resistant gloves and long sleeves. PPE Cuts from sharp edges: see step 4 for the full controls Administrative	Medium
6	Position and secure the new unit on a level base	Lifting and carrying heavy loads Tight spaces: roof spaces and under floors	High	Lifting and carrying heavy loads: see step 1 for the full controls Administrative Tight spaces: roof spaces and under floors: see step 1 for the full controls Administrative	Medium
7	Make pipe joins, with a hot work permit and an extinguisher at hand if soldering or brazing	Fire from hot works Burns from hot surfaces	Extreme	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 Keep a fire watch during the work and for at least 60 minutes after you finish. Administrative Check for smouldering behind walls, in ceilings and under floors before you leave. Administrative Wear flame-resistant clothing, welding gloves and eye or face protection. PPE Burns from hot surfaces: see step 3 for the full controls Administrative	Medium
8	Reconnect gas (by a licensed gasfitter) and power (by a licensed electrician, or a plumber with a restricted electrical licence where your state allows), then leak test the gas with a manometer or leak detection fluid, never a flame	Gas and fuel lines Pressure testing Electric shock from live wiring	Extreme	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 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 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	Medium
9	Fill and purge air, check the temperature and pressure relief valve and its drain, then commission. Store at 60°C or more, and fit or check a tempering valve so bathroom outlets get no more than 50°C (45°C in aged care, child care and health care), as AS/NZS 3500.4 requires	Hot water and steam Pressure testing	Medium	Turn the system off and let it cool before work. Eliminate Isolate and lock off the heat source and valves, and release the pressure. Isolate Check the temperature, and open fittings slowly while facing away. Administrative Keep a first aid kit and cool water ready for burns. Administrative Wear heat-resistant gloves, long sleeves and a face shield. PPE Wear safety glasses or a face shield. PPE Pressure testing: see step 8 for the full controls Administrative	Low
10	Take the old unit off site and clean up	Lifting and carrying heavy loads Poor housekeeping and waste	High	Lifting and carrying heavy loads: see step 1 for the full controls Administrative 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	Medium

PPE

Steel cap bootsWork glovesSafety glassesP2 dust maskKnee padsHard hatFace shieldOverallsWelding glovesCut-resistant gloves

Plant and equipment

Hand toolsPipe press toolLPG gas torchTrailer

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 hot water system replacement SWMS template: business details, high risk construction work and job steps with hazards, risk ratings and controls

Free SWMS template for hot water system replacement

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 hot water system replacement

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

SWMS read, explained and signed by everyone on the job
Isolation, lockout and test for dead done before work starts
Hot work permit issued, extinguisher at hand, fire watch arranged
First aider, first aid kit and emergency number (000) confirmed
PPE checked and worn: steel cap boots, work gloves, safety glasses, P2 dust mask

The safe sequence of work

Check access to the unit and plan the removal route through stairs, roof spaces or tight cupboards
Isolate power at the switchboard and gas or water at the meter, lock out and danger tag
Drain the old unit, watching for scalding water and steam
Disconnect pipes, flue and wiring, and cap the gas line. Treat old fibre cement flues and base sheets as asbestos until checked, and do not cut or break them
Remove the old unit using a trolley and two people
Position and secure the new unit on a level base
Make pipe joins, with a hot work permit and an extinguisher at hand if soldering or brazing
Reconnect gas (by a licensed gasfitter) and power (by a licensed electrician, or a plumber with a restricted electrical licence where your state allows), then leak test the gas with a manometer or leak detection fluid, never a flame
Fill and purge air, check the temperature and pressure relief valve and its drain, then commission. Store at 60°C or more, and fit or check a tempering valve so bathroom outlets get no more than 50°C (45°C in aged care, child care and health care), as AS/NZS 3500.4 requires
Take the old unit off site and clean up

Hazards to watch on hot water system replacement

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

Step 3, 9Hot water and steamOpening hot water systems, boilers or steam lines scalds workers.

Step 1, 6Tight spaces: roof spaces and under floorsCrawling through roof spaces, under floors or in tight ceilings leads to falls through the ceiling, heat stress, shocks and cuts.

Step 3, 7Burns from hot surfacesTouching hot pipes, tools, bitumen, solder or freshly welded metal burns the skin.

Step 8, 9Pressure testingA pipe, fitting or cap fails under test pressure and blows apart, hitting people nearby.

Step 2Stored energyEnergy left in springs, hydraulics, compressed gas, raised loads or capacitors releases suddenly and crushes or injures workers.

Step 7Fire from hot worksSparks and heat from welding, grinding or flame torches set fire to timber, insulation, rubbish or fuel nearby.

Highest risk on hot water system replacement: Extreme before controls (B), down to Medium after controls (A), on the Australia 5 by 5 risk matrix (possible and catastrophic becomes unlikely and moderate).

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 use a ladder or stepladder?
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?

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 hot water system replacement?

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 hot water system replacement?

Usually Steel cap boots, Work gloves, Safety glasses, P2 dust mask, Knee pads, Hard hat, Face shield, Overalls, Welding gloves, Cut-resistant gloves. The site rules may add more, so check with the principal contractor.

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Toolbox talks for this job

Toolbox talkOverhead Power Lines Toolbox talkSlips, Trips and Falls Toolbox talkHot Works Safety Toolbox talkConfined Spaces

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