Refrigeration System Installation SWMS

Refrigeration system installation involves mounting condensing units, evaporators and pipework, brazing copper refrigerant lines, pressure testing, evacuating and charging systems with fluorinated or hydrocarbon refrigerants, and terminating high and low voltage electrical connections. The work regularly requires access to plant rooms, ceiling voids and rooftops, hot works with oxy-acetylene, handling of pressurised gas cylinders and connection to live switchboards. Failures include refrigerant asphyxiation in confined plant rooms, cold burns from liquid refrigerant, fire from brazing near combustibles, electric shock during commissioning, and falls from height at rooftop condenser locations.

Under the Work Health and Safety Regulation 2025 (NSW), section 291 classifies work in or near a confined space, work on or near pressurised gas distribution mains or piping, and work on or near energised electrical installations as high risk construction work. Section 299 therefore requires a Safe Work Method Statement prepared before the work commences, applying the hierarchy of controls in section 36 and consultation obligations under section 47 of the WHS Act 2011 (NSW).

Hazards identified

12 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Eliminate live electrical work — isolate, lock out and tag the switchboard, verify dead with a tested voltage indicator, and only energise for commissioning under a documented energisation permit in accordance with AS/NZS 4836 and AS/NZS 3000.
2. 2Substitute oxy-acetylene brazing with pre-formed press-fit refrigeration fittings (e.g. copper press system rated to refrigerant pressures) where design permits, eliminating hot works and open flame.
3. 3Engineer confined space controls for plant rooms: mechanical ventilation to achieve minimum 5 air changes/hr before entry, continuous oxygen and refrigerant monitoring, and permit-controlled entry per AS 2865 Confined spaces.
4. 4Install refrigerant leak detection (fixed sensors set to 25% of the practical limit for the refrigerant charge) in plant rooms and machinery spaces in accordance with AS/NZS 5149.3 Refrigerating systems and heat pumps — Safety and environmental requirements.
5. 5Perform all pressure testing with dry oxygen-free nitrogen (never oxygen) to the design pressure specified in AS/NZS 5149.2, using a regulated manifold with an in-line pressure relief device set below the weakest component rating.
6. 6Establish a 3 metre hot works exclusion zone, remove or shield combustibles, station a charged 4.5 kg dry chemical extinguisher and fire blanket, and maintain a fire watch for 60 minutes post-brazing per the SafeWork NSW Welding processes Code of Practice.
7. 7Handle refrigerants only under an ARC RTA/RHL licence (Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 (Cth)); recover refrigerant with a rated recovery unit before opening any charged system.
8. 8Control falls at rooftop and elevated locations using guardrailed access, EWPs or a compliant fall arrest system anchored to certified anchors per AS/NZS 1891 series, with a documented rescue plan.
9. 9Manage silica and asbestos: obtain an asbestos register before penetrations; use on-tool H-class LEV extraction for core-drilling and cutting per the SafeWork NSW Code of Practice — Managing the risks of respirable crystalline silica from engineered stone in the workplace and general silica guidance.
10. 10PPE baseline for all tasks: safety glasses to AS/NZS 1337.1, cryogenic/chemical gloves when handling liquid refrigerant, leather gauntlets and shade 5 goggles for brazing, hearing protection, and Type 5/6 coveralls where refrigerant oil contact is foreseeable.
11. 11Emergency preparedness: SDS on site for every refrigerant and brazing gas, eye-wash accessible, refrigerant recovery cylinders segregated, and an evacuation route posted for the plant room.
12. 12Only workers holding a General Construction Induction (CPCCWHS1001 — White Card), a current NSW electrical licence for electrical connections, and ARCtick authorisation for refrigerant handling may perform this work. The SWMS must be consulted on with all workers under section 47 of the WHS Act 2011 (NSW) and reviewed under section 302 of the WHS Regulation 2025 (NSW) on any change, incident or control failure.

Applicable Codes of Practice

High-Risk Construction Work triggered

Worked example

A mechanical contractor is installing a 40 kW VRF system across three floors of a commercial tenancy in Parramatta. The outdoor units are craned to the rooftop, refrigerant piping is routed through core-drilled slab penetrations to fan coil units in the ceiling void, and the system is terminated at an existing MSB in a Level 1 plant room. Before mobilisation the contractor issues this SWMS, obtains the building asbestos register (confirming no ACM in the penetration zones), and holds a pre-start with the two RAC mechanics and the licensed electrician. Rooftop work is controlled via existing guardrails and a boom lift for the crane rigging. The plant room is classified a confined space; ventilation and continuous O₂/refrigerant monitoring are established under a permit. Pressure testing is completed with OFN to 4.15 MPa, followed by vacuum and R32 charging under ARCtick authorisation. The MSB is isolated and proven dead for terminations; commissioning under live conditions is performed by the electrician with insulated tools and rated PPE.

Related legislation

• Work Health and Safety Act 2011 (NSW)
• Work Health and Safety Regulation 2025 (NSW)
• Electricity (Consumer Safety) Act 2004 (NSW)
• Home Building Act 1989 (NSW) — licensing of refrigeration and electrical work
• Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 (Cth) — ARCtick refrigerant handling
• Dangerous Goods (Road and Rail Transport) Act 2008 (NSW) — transport of refrigerant and gas cylinders

Frequently asked questions