Air conditioning and refrigeration · Australia

SWMS for rooftop package unit replacement

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

Yes. Rooftop package unit replacement usually includes high risk construction work (risk of a person falling more than 2 metres; work on or near chemical, fuel or refrigerant lines), 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 a roof edge, falling through a fragile roof or skylight, electric shock from live wiring and public entering the work area.

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SWMS example: rooftop package unit replacement

This is a complete SWMS for rooftop package unit 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)

Rooftop unit replacement · Air conditioning and refrigeration · Example

Document SWMS-001 · Rev 1

High risk construction work covered

Risk of a person falling more than 2 metresWork on or near chemical, fuel or refrigerant linesWork on or near energised electrical installations or servicesWork in an area with movement of powered mobile plant

Job steps, hazards and controls

#	Job step	Hazards	Risk before	Controls	Risk after
1	Plan the crane lift and close the area below	Crane and lifting failure Public entering the work area Contact with overhead power lines	High	Barricade the lift zone and keep everyone out from under the load. Isolate Use a crane rated for the load at the radius, set up on firm ground with outrigger pads. Engineering Check slings, chains, shackles and hooks before use. Remove anything damaged or not tagged. Engineering Plan the lift: weight, radius, ground, path and landing area. Use a written lift plan for complex lifts. Administrative Crane operators and doggers or riggers hold the right High Risk Work Licence. Administrative Fence off the site with secure temporary fencing and lock the gates when you leave. Isolate Give pedestrians a safe, marked path around the work, with ramps for prams and wheelchairs. Isolate Use hoarding, covered walkways or catch fans where work is above public areas. Engineering Put signs at each entry: site name, contact number and "No unauthorised entry". Administrative Make the site safe at the end of each day: cover holes, lower plant, remove ladders and lock tools away. Administrative Ask the network operator to turn off, move or insulate the lines before work starts. Eliminate Use non-conductive (fibreglass) ladders near any power lines. Substitute Mark the safe distance with flags, tape or goal posts and keep all plant and people outside it. Isolate Keep out of the No Go Zone set by your state and the network operator, or get written approval and a safety observer. In NSW and Qld, untrained people and plant stay at least 3 m from lines on poles up to 132 kV, 6 m up to 330 kV and 8 m above 330 kV. In Victoria the limits differ, and work within 8 m of tower lines needs a spotter and the network operator's permission. Administrative Use a dedicated spotter whenever plant moves or raises anything near lines. Administrative Treat all lines as live. If plant touches a line, stay in the cab and keep everyone well away. Administrative	Medium
2	Set up roof edge protection or harness anchors	Falling from a roof edge Falling through a fragile roof or skylight	Extreme	Do what you can from the ground or from a scaffold at the gutter line, for example pre-assemble parts on the ground. Eliminate Install edge protection or guardrails on all open roof edges before work starts. Isolate Use a perimeter scaffold with handrails and toe boards along the eaves where practical. Engineering Where guardrails cannot be fitted, use fall restraint on certified roof anchors so workers cannot reach the edge. Engineering Only workers briefed on this SWMS go on the roof. Stop and review the SWMS if the roof, weather or method changes. Administrative Use one safe, controlled access point and keep others off the roof. Administrative Stop roof work in strong wind or rain, and when the roof is wet, icy or covered in dust or frost. Administrative Have a written emergency and rescue plan, tested before work starts, for any worker using a harness (WHS Regulations r.80). Administrative Wear a harness clipped to a rated anchor when using restraint or fall arrest, and soft-soled non-slip boots. PPE Work from underneath or from an EWP so nobody stands on the fragile roof. Eliminate Cover or guard every skylight and fragile sheet with a fixed, marked cover or mesh before work starts. Isolate Install safety mesh under new roof sheeting, and use crawl boards or staging to spread the load on fragile surfaces. Engineering Use fall arrest on rated anchors when working near fragile areas. Engineering Treat all roof sheets as fragile until a competent person confirms they are not. Old fibre cement and plastic sheets are fragile. Administrative Put "Fragile roof" signs at every roof access point. Administrative Never walk on sheets between purlins or along skylights. Stay on boards or staging. Administrative Wear a full body harness clipped to a rated anchor. PPE	Medium
3	Isolate power and gas, lock out and danger tag	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 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 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
4	Recover refrigerant before disconnecting	Refrigerant leaks	Medium	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	Low
5	Lift out the old unit and set the new one, keeping clear of the load	Crane and lifting failure Falling tools and materials Strong wind and storms	High	Use tag lines to control loads and agree on clear radio or hand signals. Administrative Stop lifting in high wind or when the operator cannot see the signaller. Administrative Never ride on a load or hook. Administrative Crane and lifting failure: see step 1 for the full controls Administrative Barricade and sign the drop zone under overhead work so nobody walks beneath. Isolate Fit toe boards, kick plates and mesh screens on scaffolds and edges. Engineering Use catch fans, debris netting or covered walkways where people pass below. Engineering Tether hand tools when working at height. Engineering Keep platforms tidy. Do not stack materials near edges or above toe board height. Administrative Check the forecast each morning and plan work at height and lifting around the weather. Eliminate Tie down or weigh down loose sheets, panels, boards and rubbish at the end of each shift. Engineering Set wind limits for roof work, platforms and cranes, using the manufacturer's limits, and stop when they are reached. Administrative Stop work and get down in lightning. Wait 30 minutes after the last thunder before going back up. Administrative Check scaffold, fencing and edge protection after strong wind before anyone uses them. Administrative	Medium
6	Connect, commission and clean the roof	Electric shock from live wiring Poor housekeeping and waste	Extreme	Electric shock from live wiring: see step 3 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 bootsHard hatSafety harness and lanyardHi-vis shirt or vestWork glovesSafety glassesSun protection (brim hat, long sleeves, SPF 50+)Insulated electrical glovesArc-rated clothing and face shieldFace shield

Plant and equipment

Crane (Franna or mobile): HRWL for the crane class (e.g. C2, CN, C6), plus Dogging licence (DG) where slinging needs judgement or the load is out of the operator's viewHand toolsElectrical test equipmentExtension ladder

Permits and plans

Lift planRoof access permitWorking at heights permitElectrical isolation 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 rooftop package unit 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 rooftop package unit 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
Edge protection installed and checked before anyone works above 2 m
Fragile roof areas and skylights covered or barricaded
Isolation, lockout and test for dead done before work starts
Overhead lines identified and safe distances marked
Exclusion zone below the work and public kept out
Wind and weather checked; stop work limits agreed
First aider, first aid kit and emergency number (000) confirmed
PPE checked and worn: steel cap boots, hard hat, safety harness and lanyard, hi-vis shirt or vest

The safe sequence of work

Plan the crane lift and close the area below
Set up roof edge protection or harness anchors
Isolate power and gas, lock out and danger tag
Recover refrigerant before disconnecting
Lift out the old unit and set the new one, keeping clear of the load
Connect, commission and clean the roof

Hazards to watch on rooftop package unit replacement

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

Step 4Refrigerant leaksRefrigerant gas causes frostbite, pushes oxygen out of small rooms, and some types catch fire.

Step 2Falling through a fragile roof or skylightA worker steps on a skylight, clear sheet or old fibre cement roof and falls through to the floor below.

Step 1, 5Crane and lifting failureA load falls or swings, or the crane tips, crushing workers under or near the lift.

Step 1Contact with overhead power linesA ladder, EWP, crane, tipper or long length of material touches or gets close to an overhead line and electrocutes people.

Step 3Gas and fuel linesDamaging or opening a gas or fuel line causes a leak, fire or explosion.

Step 5Strong wind and stormsWind blows sheets, panels and people off roofs and scaffolds, and storms and lightning make work at height and lifting unsafe.

Highest risk on rooftop package unit replacement: 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 use a ladder or stepladder?
Will anyone work on a roof?
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:

Risk of a person falling more than 2 metres
Work on or near chemical, fuel or refrigerant lines
Work on or near energised electrical installations or services
Work in an area with movement of powered mobile plant

Equipment on this job that needs a licence, ticket or training:

Crane (Franna or mobile): HRWL for the crane class (e.g. C2, CN, C6), plus Dogging licence (DG) where slinging needs judgement or the load is out of the operator's view

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 4.5 High risk work and Part 5.1 Plant; WHS Regulation 2011, Part 4.4 Falls; WHS Regulation 2011, Part 4.7 General electrical safety; Ozone Protection and Synthetic Greenhouse Gas Management Act 1989; WHS Regulation 2011, Part 3.2 (falling objects).

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 rooftop package unit 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 rooftop package unit replacement?

Usually Steel cap boots, Hard hat, Safety harness and lanyard, Hi-vis shirt or vest, Work gloves, Safety glasses, Sun protection (brim hat, long sleeves, SPF 50+), Insulated electrical gloves, Arc-rated clothing and face shield, Face shield. The site rules may add more, so check with the principal contractor.

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