Example SWMS: residential rooftop solar installation (NSW)

Hazard

Slips, trips and uneven ground on the side access path used to carry gear

Responsible: Dan Whitmore

Control measures

• Administrative controlsWalk the full access route at the pre-start and agree one path in and out
• Engineering controlsClear and cone the path; nothing is left lying across it during the day
• PPELace-up safety boots with slip-resistant soles worn on site at all times

Hazard

Bonded asbestos (ACM) sheeting disturbed in the eaves of a pre-1990 dwelling while running cable

Responsible: Dan Whitmore

Control measures

• EliminationStop work: nothing is drilled, cut or broken in any sheet suspected of containing asbestos
• Administrative controlsAny pre-1990 eaves or wall sheet is presumed to be ACM until a licensed assessor says otherwise
• Administrative controlsLicensed asbestos removalist engaged; work in that area resumes only on written clearance
• PPEP2 respirator and disposable coveralls if incidental contact cannot be avoided while withdrawing

Hazard

Worker starts on site without a verified ticket or without being briefed on this SWMS

Responsible: Dan Whitmore

Control measures

• Administrative controlsLicences and tickets sighted and recorded before anyone touches a tool
• Administrative controlsThis SWMS is read and signed by every worker at the pre-start meeting
• Administrative controlsThe apprentice works within sight and sound of the licensed electrician all day

Hazard

Householder or passer-by struck by a dropped tool, fixing or module

Responsible: Priya Raman

Control measures

• Isolation3 m mesh-fenced exclusion zone directly below the work area, signed and kept closed
• Engineering controlsTool lanyards on everything carried onto the roof; fixings kept in a closed catch bag
• Administrative controlsHouseholder briefed at the pre-start on which doors, paths and windows are out of use today

Hazard

Vehicle and pedestrian conflict while unloading modules at the kerb

Responsible: Josh Tuiletufuga

Control measures

• Engineering controlsCones out and a spotter walking the ute back into the driveway
• Administrative controlsUnload on the property side; modules are never staged across the footpath
• PPEHigh-vis worn from the moment the vehicle stops until it leaves

Hazard

Children or pets entering the drop zone during the day

Responsible: Priya Raman

Control measures

• Administrative controlsConfirm with the householder that pets are secured indoors before the ladder goes up
• IsolationSide gate closed, latched and signed for the duration of the works
• Administrative controlsAll work above stops immediately if anyone enters the zone, and does not restart until it is clear

Hazard

Fall from the roof edge — 4.8 m to the gutter line (high risk construction work)

Responsible: Dan Whitmore

Control measures

• Engineering controlsPerimeter guard rail installed to both working edges before any worker steps onto the roof
• Administrative controlsWhere rail cannot be fixed at the hip, a roof anchor and full-body harness in fall restraint, lanyard set short of the edge
• Administrative controlsNo work within 2 m of an unprotected edge under any circumstances
• PPEHarness and lanyard inspected and tagged before each use; damaged gear is destroyed, not returned to the ute

Hazard

Ladder slips, is over-reached from, or is climbed while carrying materials

Responsible: Josh Tuiletufuga

Control measures

• Engineering controlsIndustrial 150 kg rated ladder, tied off at the stiles and extending 1 m above the gutter
• Administrative controlsSet at a 4:1 pitch on firm level ground, clear of the drop zone and any door swing
• Administrative controlsThree points of contact; nothing is carried up or down by hand

Hazard

Foot through a fragile skylight or brittle roof sheet

Responsible: Dan Whitmore

Control measures

• Engineering controlsSkylight covered with a load-rated cover, fixed down and marked before roof work starts
• Administrative controlsWalk the purlin lines only; never traverse the middle of an unsupported sheet
• Administrative controlsSkylight and penetration locations identified at the pre-start walk and flagged

Hazard

Manual handling injury lifting a 22 kg module overhead from ladder height

Responsible: Priya Raman

Control measures

• SubstitutionInclined panel hoist used for every module; no module is hand-passed up the ladder
• Administrative controlsTwo-person lift on the roof, module kept below shoulder height and close to the body
• PPEGrip gloves worn for all module handling

Hazard

Load dropped from roof level into the area below

Responsible: Josh Tuiletufuga

Control measures

• IsolationExclusion zone stays closed and unattended for the whole time anything is being lifted
• Engineering controlsHoist rated for the load and inspected before use; load secured on the roof before the sling is released
• Administrative controlsNothing is lifted over an occupied area; a spotter stays at ground level for every lift

Hazard

Wind gust catches a module and turns it into a sail at height

Responsible: Dan Whitmore

Control measures

• EliminationNo module is lifted, carried or placed once wind exceeds 40 km/h — work stops
• Administrative controlsBureau of Meteorology forecast checked at the pre-start and re-checked after lunch
• Administrative controlsModules laid flat and strapped on the roof, never left leaning or standing on edge

Hazard

Fall while working near the eaves fixing rail and flashing penetrations

Responsible: Dan Whitmore

Control measures

• Engineering controlsGuard rail remains in place for the entire rail installation, not just the first course
• Administrative controlsRestraint lanyard adjusted so the worker physically cannot reach the edge
• Administrative controlsNever lean past the rail to reach a fixing — the rail is moved instead
• PPEFull-body harness worn and clipped for all work outside the rail line

Hazard

Cuts, struck-by and burns from rail offcuts, fixings and hot Colorbond sheeting

Responsible: Josh Tuiletufuga

Control measures

• Engineering controlsRail cut and deburred on the ground, not on the pitch
• Administrative controlsTools and fixings kept in a closed bag; nothing loose is left on the roof
• PPEGloves, safety glasses and long sleeves worn for all rail work

Hazard

Heat stress and UV exposure working on an exposed metal roof

Responsible: Priya Raman

Control measures

• EliminationRoof work rescheduled outside 11:00–15:00 whenever the forecast exceeds 35 °C
• Administrative controls600 ml of water per person per hour, shaded rest rotation every 45 minutes, buddy checks for heat symptoms
• PPEUPF 50+ long sleeves, broad-brim hat under the hard hat and SPF 50+ sunscreen reapplied every two hours

Hazard

DC electric shock — modules are live the moment they see daylight, up to about 600 V string voltage (high risk construction work)

Responsible: Dan Whitmore

Control measures

• IsolationModules stay covered and string ends stay capped until the final connection is made
• Engineering controlsMC4 connectors only, mated dry and clicked home; 1000 V DC-rated insulated tools used throughout
• Administrative controlsOnly the licensed electrical worker makes or breaks a DC connection — never the apprentice
• PPEClass 0 insulating gloves worn for all DC connection work

Hazard

Fall while positioning and clamping modules along the roof edge

Responsible: Dan Whitmore

Control measures

• Engineering controlsGuard rail stays up for the whole module install
• Administrative controlsModules landed onto the rail from above; nobody carries a module along the edge
• Administrative controlsRestraint lanyard clipped and length-checked before each row is started

Hazard

Crush or pinch injury between the module frame and the rail

Responsible: Priya Raman

Control measures

• Administrative controlsAgreed lift-and-lower calls between the two installers on every module
• Engineering controlsClamps started by hand and only then finished with the torque driver
• PPEGloves worn for all module placement

Hazard

230 V electric shock working at the main switchboard (high risk construction work)

Responsible: Dan Whitmore

Control measures

• IsolationMain switch locked out with a personal padlock and danger tag; the key stays with the person doing the work
• Administrative controlsTest before you touch — prove the tester on a known live source before and after every test
• Administrative controlsNo live work. If the board cannot be isolated, work stops and the network distributor is called
• PPEInsulated gloves and 1000 V rated hand tools for all switchboard work

Hazard

Arc flash while terminating the solar circuit into the switchboard

Responsible: Dan Whitmore

Control measures

• IsolationBoard de-energised and proven dead before any termination is started
• Engineering controlsDedicated solar circuit breaker with DC and AC isolators installed to AS/NZS 5033
• Administrative controlsOne worker at the board at a time; the apprentice observes from outside the arc zone
• PPEFace shield and natural-fibre long sleeves — no synthetics near the board

Hazard

Contact with the overhead LV service mains at the point of attachment

Responsible: Dan Whitmore

Control measures

• Administrative controls3 m exclusion maintained from the service mains, per the SafeWork NSW code of practice for work near overhead power lines
• Administrative controlsNo conductive material — rail, ladder, module or cable draw — is moved within that zone
• Engineering controlsCable route planned at the pre-start to stay on the far side of the roof from the service
• Administrative controlsIf an approach is unavoidable, a dedicated safety observer is posted and the distributor is asked to fit temporary covering

Hazard

Unexpected re-energisation while a worker is still on the array

Responsible: Dan Whitmore

Control measures

• IsolationOne nominated person holds the isolation key and is the only person who removes the tag
• Administrative controlsVerbal all-clear taken from every worker by name before anything is switched on
• Administrative controlsLockout stays on until the roof is confirmed clear of people and tools

Hazard

Fall while verifying array polarity and clamp torque on the roof

Responsible: Priya Raman

Control measures

• Engineering controlsGuard rail stays up until every rooftop check is signed off
• Administrative controlsAll rooftop testing is scheduled before edge protection comes down, never after
• PPEHarness worn in restraint for any check outside the rail line

Hazard

Mislabelled isolators leave a latent shock risk for the next worker on the property

Responsible: Dan Whitmore

Control measures

• Engineering controlsAS/NZS 5033 shock-hazard and isolation signage fitted at the array, the inverter and the main switchboard
• Administrative controlsCertificate of Compliance for Electrical Work issued and all test results recorded
• Administrative controlsHomeowner walked through the emergency shutdown procedure at handover

Hazard

Fall while dismantling edge protection — the last task of the day and the one most often rushed

Responsible: Dan Whitmore

Control measures

• Administrative controlsEdge protection comes down last, worked from the ladder or from inside the rail line — never by leaning out
• Administrative controlsDismantling is a planned task with its own toolbox talk, not something started after the crew has been told to knock off
• PPEHarness stays on and clipped until the last rail section is off the roof

Hazard

Screws, offcuts and packaging left in gutters, driveway and lawn

Responsible: Josh Tuiletufuga

Control measures

• Engineering controlsMagnet sweep of the driveway, lawn and path before the ute is loaded
• Administrative controlsGutters cleared and photographed as part of the handover pack
• Administrative controlsAll packaging and offcuts removed from site the same day

Hazard

Manual handling injury during load-out at the end of a hot day

Responsible: Priya Raman

Control measures

• SubstitutionTrolley used for the panel hoist and the ladder
• Administrative controlsLoad out in pairs, heaviest items first while the crew is still fresh
• PPEGloves and boots worn until the vehicle is loaded and closed