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Air conditioning and refrigeration · Australia

SWMS for gas ducted heater replacement

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

Yes. Gas ducted heater replacement usually includes high risk construction work (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 electric shock from live wiring, disturbing asbestos, fire from hot works and lifting and carrying heavy loads.

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SWMS example: gas ducted heater replacement

This is a complete SWMS for gas ducted heater replacement, with 6 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 gas ducted heater · Air conditioning and refrigeration · Example
Document SWMS-001 · Rev 1

High risk construction work covered

Work on or near energised electrical installations or services

Job steps, hazards and controls

#Job stepHazardsRisk beforeControlsRisk after
1A licensed gasfitter isolates gas and power, then the supplies are locked off
  • Gas and fuel lines
  • 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
  • Gas and fuel lines: see step 5 for the full controls 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
  • 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
2Check flues and surrounds for asbestos
  • Disturbing asbestos
Extreme
  • Before work, check the asbestos register (workplaces built before 2004). For homes, or if there is no register, have a competent person identify asbestos or assume it is present. Eliminate
  • Seal off the work area and keep everyone else out. Isolate
  • If asbestos must be disturbed, keep it wet, use hand tools not power tools, and clean up with an H-class vacuum. Engineering
  • Friable asbestos (Class A) and more than 10 square metres of non-friable asbestos (Class B) must be removed by a licensed removalist. Administrative
  • Stop work straight away if you find suspect asbestos. Do not touch it and tell your supervisor. Administrative
  • Wear a fitted P2 (or better) respirator and disposable coveralls. PPE
Medium
3Remove the old unit with two people
  • Lifting and carrying heavy loads
  • Cuts from sharp edges
  • Tight spaces: roof spaces and under floors
High
  • 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
  • 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
  • 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
Medium
4Install the new unit, flue and connections
  • Gas and fuel lines
  • Fire from hot works
  • Falling from a ladder
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 5 for the full controls Administrative
  • 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
  • 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
Medium
5Leak test, commission and check for carbon monoxide
  • Pressure testing
  • Gas and fuel lines
  • Fire and emergencies
High
  • 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 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
  • Provide fire extinguishers suited to the site, checked and easy to reach. Engineering
  • Keep exits and escape routes clear and signed. Engineering
  • Have a site emergency plan: alarm, exits, assembly point and emergency contacts. Administrative
  • Keep a stocked first aid kit and at least one trained first aider on site. Administrative
  • Know the site address and how emergency services get in. Call 000. Administrative
Medium
6Remove old unit and clean up
  • 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 bootsWork glovesSafety glassesP2 dust maskInsulated electrical glovesArc-rated clothing and face shieldHalf-face respirator (P2 or P3 filters)OverallsCut-resistant glovesKnee padsHard hatWelding glovesFace shield

Plant and equipment

Hand toolsPipe press toolElectrical test equipmentTrailer

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.

Free SWMS template for gas ducted heater 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 gas ducted heater replacement

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

The safe sequence of work

  1. A licensed gasfitter isolates gas and power, then the supplies are locked off
  2. Check flues and surrounds for asbestos
  3. Remove the old unit with two people
  4. Install the new unit, flue and connections
  5. Leak test, commission and check for carbon monoxide
  6. Remove old unit and clean up

Hazards to watch on gas ducted heater replacement

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

Step 3Tight 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 5Pressure testingA pipe, fitting or cap fails under test pressure and blows apart, hitting people nearby.
Step 5Fire and emergenciesA fire, injury or other emergency happens and workers cannot get out, raise the alarm or get first aid in time.
Step 4Fire from hot worksSparks and heat from welding, grinding or flame torches set fire to timber, insulation, rubbish or fuel nearby.
Step 1, 4, 5Gas and fuel linesDamaging or opening a gas or fuel line causes a leak, fire or explosion.
Step 2Disturbing asbestosBuildings built before 1990 are likely to contain asbestos, and any built before 2004 may. Drilling, cutting or breaking it releases fibres that cause cancer years later.
Almost certainLikelyPossibleUnlikelyRareHow bad it could be: Insignificant to CatastrophicBA
Highest risk on gas ducted heater 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 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 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 Regulations, Chapter 8 (Asbestos); WHS Regulation 2011, Part 4.2 Hazardous manual tasks; AS 1674.1 Safety in welding and allied processes (fire precautions); WHS Regulation 2011, Part 4.4 Falls; WHS Regulation 2011, regulation 43 (emergency plans).

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 gas ducted heater replacement?

Yes. Gas ducted heater replacement usually includes high risk construction work (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 gas ducted heater replacement?

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

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Toolbox talks for this job

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

Sources