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JHA for water heater 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 water heater 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, fire from hot works, lifting and carrying heavy loads and gas and fuel lines.

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JHA example: water heater replacement

This is a complete JHA for water heater 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.

Job Hazard Analysis (JHA)
Replace a water heater · Plumbing · Example
Document JHA-001 · Rev 1

Job steps, hazards and controls

#Job stepHazardsRisk beforeControlsRisk after
1Check access to the unit and plan the removal route through stairs, roof spaces or tight cupboards
  • Tight spaces: attics and crawl spaces
  • Lifting and carrying heavy loads
High
  • 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
  • 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. 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
Medium
2Isolate power at the electrical panel and gas or water at the meter, apply lockout/tagout
  • Electric shock from live wiring
  • Gas and fuel lines
  • Stored energy
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
  • 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 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. Elimination
  • Lock out and tag all energy sources with personal locks. Engineering (guarding)
  • 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
3Drain 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. Elimination
  • Isolate and lock off the heat source and valves, and release the pressure. Engineering (guarding)
  • Hot water and steam: see step 9 for the full controls 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
  • Plan walkways and keep them clear of materials, hoses and leads. Elimination
  • Run cords 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
4Disconnect pipes, flue and wiring, and cap the gas line
  • Gas and fuel lines
  • Electric shock from live wiring
  • Cuts from sharp edges
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 8 for the full controls 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
  • Electric shock from live wiring: see step 2 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
  • Cuts from sharp edges: see step 5 for the full controls Administrative
Medium
5Remove 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
  • 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
  • Wear cut-resistant gloves and long sleeves. PPE
Medium
6Position and secure the new unit on a level base
  • Lifting and carrying heavy loads
  • Tight spaces: attics and crawl spaces
High
  • Lifting and carrying heavy loads: see step 1 for the full controls Administrative
  • Tight spaces: attics and crawl spaces: see step 1 for the full controls Administrative
Medium
7Make pipe joins, with a hot work permit and an extinguisher at hand if soldering or brazing
  • Fire from hot works
  • Burns from hot surfaces
Critical
  • 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
  • Keep a fire watch during the work and for at least 60 minutes after you finish (NFPA 51B), longer if the permit says so. Administrative
  • Check for smoldering 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
8Reconnect gas (by a licensed gas fitter) and power (by a licensed electrician), then leak test
  • Gas and fuel lines
  • Pressure testing
  • 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)
  • 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
  • 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)
  • Pressure testing: see step 9 for the full controls Administrative
  • Electric shock from live wiring: see step 2 for the full controls Administrative
Medium
9Fill and purge air, check the relief valve, commission and set the temperature
  • Hot water and steam
  • Pressure testing
Medium
  • Turn the system off and let it cool before work. Elimination
  • Isolate and lock off the heat source and valves, and release the pressure. Engineering (guarding)
  • 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
  • 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
10Take 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. 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
Medium

PPE

Safety-toe boots (ASTM F2413)Work glovesSafety glasses (ANSI Z87.1)N95 respiratorKnee padsHard hat (ANSI Z89.1)Face shield (ANSI Z87.1)CoverallsWelding glovesCut-resistant gloves

Plant and equipment

Hand toolsProPress toolPropane torchTrailer

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 water heater 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 water 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. Check access to the unit and plan the removal route through stairs, roof spaces or tight cupboards
  2. Isolate power at the electrical panel and gas or water at the meter, apply lockout/tagout
  3. Drain the old unit, watching for scalding water and steam
  4. Disconnect pipes, flue and wiring, and cap the gas line
  5. Remove the old unit using a trolley and two people
  6. Position and secure the new unit on a level base
  7. Make pipe joins, with a hot work permit and an extinguisher at hand if soldering or brazing
  8. Reconnect gas (by a licensed gas fitter) and power (by a licensed electrician), then leak test
  9. Fill and purge air, check the relief valve, commission and set the temperature
  10. Take the old unit off site and clean up

Hazards to watch on water heater 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: attics and crawl spacesCrawling through attics, crawl spaces or tight ceilings leads to falls through the ceiling, heat stress, shocks and cuts.
Step 3, 7Burns from hot surfacesTouching hot pipes, tools, asphalt, 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.
Almost certainLikelyPossibleUnlikelyRareHow bad it could be: First aid only to FatalityBA
Highest risk on water heater 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 recordable / lost time).

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 use a ladder or stepladder?
  • Will anyone work on a roof?
  • Is there a skylight, fiberglass panel or other fragile roofing?
  • Will you use a scaffold or rolling tower?

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 water heater replacement?

OSHA expects employers to find and control hazards on every job, and many general contractors require a written JHA for water heater 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 water heater replacement?

Usually Safety-toe boots (ASTM F2413), Work gloves, Safety glasses (ANSI Z87.1), N95 respirator, Knee pads, Hard hat (ANSI Z89.1), Face shield (ANSI Z87.1), Coveralls, Welding gloves, Cut-resistant gloves. The site rules may add more, so check with the general contractor.

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Toolbox talks for this job

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

Sources