Installation of a 6.6kW residential solar PV system comprising 16 x 415W monocrystalline panels on a north-facing corrugated iron roof (25-degree pitch, single storey, ~5m to eave). Work includes mounting rail installation, panel placement and clamping, DC cabling from rooftop to inverter location, inverter installation, and connection to the switchboard. System commissioning and certification by a licensed electrician.
This SWMS does not cover battery storage installation, switchboard upgrades, or meter replacement by the network operator.
| Hazard | Inherent Risk | Control Measures | Residual Risk |
|---|---|---|---|
| Falls from roof Workers on pitched corrugated iron roof (~5m to ground) with risk of sliding or stepping off edge during panel installation |
5 x 5 = 25 Extreme |
Engineering Temporary roof anchor points (AS/NZS 1891.4 rated) installed at ridge line before any roof work commences Engineering Static line system along ridge with individual adjustable rope grabs for each worker Administrative All workers hold current Working at Heights competency; pre-start briefing on fall hazards and anchor point locations Administrative No roof work during rain, frost, or winds exceeding 40 km/h — corrugated iron becomes dangerously slippery PPE Full body harness with shock-absorbing lanyard connected to static line at all times on roof |
2 x 5 = 10 High |
| DC electrical shock Solar panels generate DC voltage when exposed to light — string voltages up to 400V DC which cannot be switched off during daylight |
3 x 5 = 15 High |
Isolation Panels covered with opaque material during wiring to reduce voltage generation; DC isolator installed and left open until final commissioning Engineering MC4 connectors used for all DC connections (touch-safe design); cable routing in UV-rated conduit Administrative Only licensed electricians to make DC and AC electrical connections; all DC work treated as live work PPE 1000V rated insulated gloves for DC wiring work; insulated tools |
2 x 5 = 10 High |
| Manual handling Lifting and carrying solar panels (~22 kg each, 1.7m x 1.0m) up ladder and across pitched roof surface |
4 x 3 = 12 High |
Engineering Panel hoist system (electric rope winch) to lift panels from ground to roof level — eliminates carrying panels up ladder Administrative Two-person lift for panel positioning on roof; panels passed one at a time, never stacked on roof Administrative Pre-task stretching; ergonomic rest breaks every 60 minutes during panel installation |
2 x 3 = 6 Medium |
| Heat stress Workers on hot metal roof surface in direct sun — roof surface temperatures can exceed 60 degrees C in summer; radiant heat compounded by PPE |
4 x 3 = 12 High |
Engineering Work scheduled for early morning start (7am) to complete roof work before peak heat Administrative Mandatory 15-minute shade breaks every 45 minutes when ambient temperature exceeds 25 degrees C; cold water available on roof Administrative Buddy system for heat stress monitoring — check for confusion, dizziness, or excessive sweating PPE Broad-brim hard hat attachment; lightweight long-sleeve UV-rated shirt |
2 x 3 = 6 Medium |
| Dropped panels Solar panels sliding off pitched roof during handling or wind gust, striking workers or property below |
3 x 4 = 12 High |
Isolation Ground-level exclusion zone around the full perimeter of the house during all roof work; no public access Engineering Panels secured to mounting rails immediately upon placement — never left unsecured on roof surface Administrative Cease panel handling if wind exceeds 30 km/h (panels act as sails); check weather forecast before starting PPE Hard hats for all ground-level personnel within exclusion zone |
1 x 4 = 4 Low |
If a worker falls and is suspended in a harness, initiate rescue within 5 minutes using the rescue plan (ladder rescue from below or rope-assisted self-rescue). If a worker falls to ground level, do not move them unless in immediate danger. Call 111 and administer first aid. Preserve the scene for investigation.
Solar panels cannot be switched off during daylight. If a worker receives a DC shock, do not touch them if they are still in contact with the circuit. Cover panels with opaque material to reduce voltage. Open the DC isolator. Call 111. Commence CPR if the person is unresponsive and not breathing.
All workers must read and understand this SWMS before commencing work. By signing below, each worker confirms they have been briefed on the hazards, controls, and emergency procedures, and agree to follow them.
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