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JHA for mini split installation

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 mini split installation 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 falling from height, silica dust from concrete, brick, stone and tiles, electric shock from live wiring and fire from hot works.

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JHA example: mini split installation

This is a complete JHA for mini split 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.

Job Hazard Analysis (JHA)
Split system AC unit installation · HVAC · Example
Document JHA-001 · Rev 1

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
Critical
  • 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)
  • 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. 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
  • 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
Critical
  • 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
  • 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, side rails 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. Elimination
  • Install guardrails or edge protection on all open edges before work starts. Engineering (guarding)
  • Use a scaffold, mobile work platform or aerial lift 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
  • Provide fall protection at 6 feet or more and train workers to recognize fall hazards (29 CFR 1926.503). Administrative
  • Have a rescue plan so a worker hanging in a harness can be brought down within minutes. 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
Critical
  • Order materials cut to size, or use low-dust methods such as score and snap or a block splitter. Substitution
  • Cut outdoors or in a separate area, with other people well away and upwind. Engineering (guarding)
  • Use wet cutting or on-tool dust collection with a HEPA vacuum, as set out in Table 1 of 29 CFR 1926.1153. Engineering
  • Clean up with a vacuum or wet methods. Never dry sweep or use compressed air. Administrative
  • Have a written exposure control plan and a competent person for silica (29 CFR 1926.1153). Administrative
  • Workers who must wear a respirator 30 or more days a year get a free medical exam every 3 years (29 CFR 1926.1153(h)). Administrative
  • Wear the respirator Table 1 lists for the task: APF 10 (a fit-tested N95 or half mask) for most tasks, APF 25 (such as a loose-fitting PAPR) for tuckpointing with a handheld grinder for more than 4 hours a shift. PPE
  • Use quieter tools and methods, such as cut-to-size materials, low-noise machines and battery tools. Substitution
  • Keep noisy plant away from work areas, and use screens or distance between the noise and people. Engineering (guarding)
  • 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 at arm's length, wear 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, jewelry 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. Elimination
  • Use lighter or smaller loads: order smaller bags and shorter lengths, and drain or break down old items before moving them. Substitution
  • 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
Critical
  • 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
  • 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
Critical
  • Recover refrigerant into an approved cylinder before opening the system. Never vent it. Engineering (guarding)
  • Ventilate closed spaces and use a leak detector during the work. Engineering
  • Only EPA Section 608 certified technicians handle refrigerants. 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. 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
  • Isolate heating systems and let parts cool before you touch them. Elimination
  • 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. 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
  • Wear safety glasses or a face shield. PPE
Low
8Electrical connection by a licensed electrician, with the circuit isolated
  • Electric shock from live wiring
Critical
  • 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
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. 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)Safety glasses (ANSI Z87.1)Work glovesN95 respiratorHearing protection (earmuffs or plugs)Rubber insulating glovesArc flash PPE (NFPA 70E)Hard hat (ANSI Z89.1)Half-face respirator (P100 cartridges)Face shield (ANSI Z87.1)Welding glovesCoveralls

Plant and equipment

Power drillCore drillExtension ladderElectrical test meterHand tools

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 mini split installation

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 mini split 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 mini split 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, asphalt, 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: First aid only to FatalityBA
Highest risk on mini split installation: Critical before controls (B), down to Medium after controls (A), on the United States 5 by 5 risk matrix (likely 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 mini split installation?

OSHA expects employers to find and control hazards on every job, and many general contractors require a written JHA for mini split installation 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 mini split installation?

Usually Safety-toe boots (ASTM F2413), Safety glasses (ANSI Z87.1), Work gloves, N95 respirator, Hearing protection (earmuffs or plugs), Rubber insulating gloves, Arc flash PPE (NFPA 70E), Hard hat (ANSI Z89.1), Half-face respirator (P100 cartridges), Face shield (ANSI Z87.1), Welding gloves, Coveralls. 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