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❄️ HVAC Safety

Topic: Refrigerant handling, confined spaces, electrical hazards, sheet metal safety, lifting, brazing, and temperature extremes Duration: 8–10 minutes Required: OSHA 29 CFR 1926 Subpart P (Confined Space), 1910.94 (Ventilation), 1926 Subpart K (Electrical)

The Stats​

  • Refrigerant exposure causes frostbite, asphyxiation, and chemical burns — hundreds of incidents annually
  • Confined space fatalities in HVAC include air handlers, plenums, and ductwork — approximately 90 deaths per year across industries
  • Electrical contact remains a leading cause of construction fatalities — HVAC work involves high-voltage equipment
  • Falls from overhead work (ladders, roofs, equipment) account for roughly 1 in 3 construction deaths
  • Musculoskeletal injuries from lifting condensers and air handlers (100–500+ lbs) are common — improper lifting causes over 30% of HVAC-related injuries

OSHA requires: Confined space entry procedures, proper refrigerant handling certification (EPA 608), lockout/tagout, and fall protection when working 4+ feet above ground.

Refrigerant Handling & Exposure​

Hazards​

HazardEffect
Skin contactFrostbite, severe burns
InhalationDizziness, asphyxiation, cardiac arrest
Eye contactCorneal damage, blindness
Cylinder ruptureExplosion, flying debris

Safe Practices​

  • EPA 608 Certified — Only trained personnel handle refrigerants
  • PPE — Safety glasses, chemical-resistant gloves, long sleeves
  • Ventilation — Work in well-ventilated areas; never in confined spaces without proper ventilation
  • Release — Never vent refrigerant; recover and reclaim per EPA regulations
  • Storage — Store cylinders upright, secured, away from heat and ignition sources

Confined Space Entry (Air Handlers, Plenums, Ductwork)​

Before Entering​

  • Permit required — Assess for permit-required confined space (oxygen deficiency, toxic gases, engulfment)
  • Atmosphere test — Oxygen 19.5–23.5%, no flammables or toxics
  • Entry permit — Complete permit; attendant posted outside
  • Rescue plan — Non-entry rescue preferred; know retrieval procedure
  • Lockout/tagout — All energy sources (fans, dampers) isolated

Inside the Space​

  • Communication — Constant contact with attendant
  • Ventilation — Continuous ventilation if needed
  • Exit — Know the nearest exit; evacuate immediately if conditions change

Electrical Hazards (High Voltage)​

HVAC equipment often has 208V, 240V, 480V, or higher. One mistake can be fatal.

  • Lockout/tagout — Always isolate power before servicing
  • Verify dead — Use a properly rated meter; test before touch
  • Qualified person — Only qualified electricians work on live circuits
  • Dry conditions — Never work on electrical when wet or in damp areas
  • GFCI — Use GFCI for portable tools and temporary power

Sheet Metal Cuts, Overhead Work & Falls​

Sheet Metal Safety​

  • Gloves — Cut-resistant gloves when handling sheet metal
  • Edge protection — Deburr sharp edges; use edge protectors
  • Proper tools — Use snips, shears, and cutters correctly; keep blades sharp

Overhead Work & Falls​

  • Fall protection — Harness and lanyard when working 4+ feet above ground or on roofs
  • Ladder safety — 3-point contact; extend 3 feet above landing; secure at top
  • Scaffolding — Use guardrails when available
  • Roof work — Watch for skylights, roof edges, and fragile surfaces

Lifting Heavy Equipment (Condensers, Air Handlers)​

DoDon't
Use mechanical lifting (crane, hoist, forklift) when possibleManually lift units over 50 lbs alone
Team lift with clear communicationTwist or bend while lifting
Use proper rigging and slingsWork under suspended loads
Plan the path — clear obstaclesRush the lift
Bend knees, keep load closeReach or overhead lift

Brazing & Soldering Safety​

  • Hot work permit — Obtain if required
  • Fire watch — Have fire extinguisher and watch for sparks
  • Ventilation — Avoid breathing solder flux and brazing fumes
  • PPE — Safety glasses, gloves, long sleeves
  • Flammables — Keep away from oxygen and acetylene cylinders

Working in Extreme Temperatures​

Attics & Roofs (Heat)​

  • Hydration — Drink water before thirst
  • Breaks — Shade breaks every 15–20 minutes in extreme heat
  • Sunscreen — Protect exposed skin
  • Recognize symptoms — Dizziness, headache, nausea = stop work, cool down

Mechanical Rooms & Cold​

  • Layered clothing — Remain dry
  • Frostbite — Watch fingers, toes, ears in cold
  • Warm-up breaks — Take breaks in heated areas when possible

Discussion Questions​

  1. Where on this job will we enter confined spaces (plenums, air handlers)? What's our entry procedure?
  2. Who is EPA 608 certified for refrigerant work? What PPE do we use?
  3. How are we lifting the condenser/air handler today? What's the lift plan?
  4. What fall protection do we need for the roof work or equipment access?

Today's Commitment​

"I will follow confined space and lockout procedures, use proper PPE for refrigerant and sheet metal work, and never work above 4 feet without fall protection."

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