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JHA for furnace replacement

By SiteSortedBuilt from OSHA standards and guidance · How we write and check theseUpdated

OSHA expects employers to find and control hazards on every job, and many general contractors require a written JHA for furnace replacement before you start.

A JHA breaks the job into steps, lists the hazards in each step and the controls that protect the crew, and the crew signs it. 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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JHA example: furnace replacement

This is a complete JHA for furnace 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.

Job Hazard Analysis (JHA)
Replace a furnace · HVAC · Example
Document JHA-001 · Rev 1

Job steps, hazards and controls

#Job stepHazardsRisk beforeControlsRisk after
1A licensed gas fitter isolates gas and power, then the supplies are locked off
  • Gas and fuel lines
  • Electric shock from live wiring
Critical
  • Isolate and purge the line before work, with the owner's approval. Elimination
  • Lock off and tag the isolation valve. Engineering (guarding)
  • Gas and fuel lines: see step 5 for the full controls Administrative
  • Isolate the power before any work. Do not work live. Elimination
  • Lock out and tag the disconnecting means with your own personal lock and tag so the circuit cannot be energized (29 CFR 1926.417). Engineering (guarding)
  • Test before you touch: prove dead at the point of work with a tested voltage tester. Engineering
  • Only qualified persons work on or near exposed energized parts. Administrative
  • Check for back feeds from solar, batteries and generators that can keep a circuit live after the main switch is off. Administrative
  • If energized work cannot be avoided, use an energized work permit, a safety observer and insulated tools, following NFPA 70E. 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
Critical
  • Treat insulation, surfacing and resilient flooring in buildings built before 1981 as asbestos unless testing shows otherwise, and get the owner's asbestos survey before you start. Elimination
  • Seal off the work area and keep everyone else out. Engineering (guarding)
  • If asbestos must be disturbed, keep it wet, use hand tools not power tools, and clean up with a HEPA vacuum. Engineering
  • Follow 29 CFR 1926.1101: competent person, work class, regulated area and exposure monitoring. Administrative
  • Commercial renovation and any demolition need a NESHAP asbestos inspection first, and demolition needs written notice to the state or EPA 10 working days before work starts (40 CFR 61 Subpart M). Administrative
  • Roofing felts, cement shingles and siding, roof coatings and old panel backboards can also contain asbestos. Test them or treat them as asbestos; asbestos roofing is removed intact with hand tools by trained workers (29 CFR 1926.1101(g)(8)). Administrative
  • Stop work straight away if you find suspect asbestos. Do not touch it and tell your supervisor. Administrative
  • Wear a fit-tested NIOSH-approved respirator suited to the work class, and disposable coveralls. PPE
Medium
3Remove the old unit with two people
  • Lifting and carrying heavy loads
  • Cuts from sharp edges
  • Tight spaces: attics and crawl spaces
High
  • Plan to avoid carrying: have materials delivered, and old items picked up, as close as possible to where they are used. Elimination
  • Use lighter or smaller loads: order smaller bags and shorter lengths, and drain or break down old items before moving them. Substitution
  • 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. Elimination
  • Turn the power off at the panel before entering where you can, as damaged wiring may be live. Engineering (guarding)
  • 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 attics 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
Critical
  • Check for leaks with a gas detector before and during work, and ventilate the area. Engineering
  • Only licensed gas fitters 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. Elimination
  • Move anything that can burn at least 35 feet away, or cover it with fire blankets. Engineering (guarding)
  • 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 aerial lift for longer jobs instead of a straight ladder. Substitution
  • Use Type I, IA or IAA ladders in good condition. Tag and remove any damaged ladder. Engineering
  • Set extension ladders at a 4 to 1 angle on firm, level ground, secured, and reaching 3 feet 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. Substitution
  • Keep people out of the test area with signs and barriers. Engineering (guarding)
  • 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. Elimination
  • Lock off and tag the isolation valve. Engineering (guarding)
  • Check for leaks with a gas detector before and during work, and ventilate the area. Engineering
  • Only licensed gas fitters 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 911. Administrative
Medium
6Remove old unit and clean up
  • Poor housekeeping and waste
Medium
  • Order materials to size and send packaging back where you can. Elimination
  • Put dumpsters 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

Safety-toe boots (ASTM F2413)Work glovesSafety glasses (ANSI Z87.1)N95 respiratorRubber insulating glovesArc flash PPE (NFPA 70E)Half-face respirator (P100 cartridges)CoverallsCut-resistant glovesKnee padsHard hat (ANSI Z89.1)Welding glovesFace shield (ANSI Z87.1)

Plant and equipment

Hand toolsProPress toolElectrical test meterTrailer

Permits and plans

Lockout/tagout (1926.417)Hot work permit (fire watch at least 60 minutes after, NFPA 51B)

Emergency

Call 911. Add the nearest hospital, the assembly point and the first aid / cpr person for your site.

Sign-off

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

Free JHA template for furnace replacement

Word (.docx) and PDF, Letter 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 JHA

Pre-start checklist for furnace 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 gas fitter 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 furnace replacement

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

Step 3Tight spaces: attics and crawl spacesCrawling through attics, crawl spaces or 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 asbestosIn buildings built before 1981, OSHA presumes pipe and boiler insulation, sprayed or troweled coatings, and asphalt and vinyl flooring contain asbestos, and many other older materials can too. Drilling, cutting or breaking it releases fibers that cause cancer years later.
Almost certainLikelyPossibleUnlikelyRareHow bad it could be: First aid only to FatalityBA
Highest risk on furnace replacement: Critical before controls (B), down to Medium after controls (A), on the United States 5 by 5 risk matrix (possible and fatality becomes unlikely and serious injury).

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 6 feet or more above a lower level?
  • Will anyone work on a roof?
  • Is there a skylight, fiberglass panel or other fragile roofing?
  • Will you use a scaffold or rolling tower?
  • Will you use an aerial lift (scissor lift or boom lift)?

Why JHAs get rejected

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

  • Generic steps such as "work safely" or "use PPE" with no task-specific hazards or controls.
  • No OSHA standards referenced for the hazards that have them, such as fall protection, ladders, scaffolds or silica.
  • No competent person named for fall protection, excavation, scaffolds or silica where those hazards exist.
  • Equipment listed without inspection requirements, and no training listed for the people using it.
  • Respirators listed with no respiratory protection program, medical clearance or fit test.
  • Controls rely only on PPE when engineering controls such as guardrails, wet cutting or extraction are feasible.
  • No crew sign-off, or no date and revision when the job has changed.

Questions

Do I need a JHA for furnace replacement?

OSHA expects employers to find and control hazards on every job, and many general contractors require a written JHA for furnace replacement before you start.

Who signs the JHA?

The supervisor or competent person who prepared it signs, and every crew member signs to show they were trained on the hazards and controls before the job starts. Many general contractors also sign to accept it.

How long do I keep it?

Keep this JHA on site during the job, and keep it with the training and inspection records for at least 1 year after the job (longer if your state plan or general contractor requires it). OSHA does not set a retention period for JHAs themselves.

What PPE is needed for furnace replacement?

Usually Safety-toe boots (ASTM F2413), Work gloves, Safety glasses (ANSI Z87.1), N95 respirator, Rubber insulating gloves, Arc flash PPE (NFPA 70E), Half-face respirator (P100 cartridges), Coveralls, Cut-resistant gloves, Knee pads, Hard hat (ANSI Z89.1), Welding gloves, Face shield (ANSI Z87.1). The site rules may add more, so check with the general contractor.

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

Sources