Refrigerant Handling SWMS
This SWMS covers refrigerant handling activities, addressing the specific hazards, risk controls and safe work procedures required under WHS Regulation 2025. While not classified as high-risk construc
SWMS variants reference your state’s WHS legislation. Instant download after payment.
Refrigerant handling covers the recovery, charging and decommissioning of refrigeration and air-conditioning systems — connecting gauge manifolds and recovery equipment, recovering refrigerant to an approved cylinder, evacuating and charging the system, and leak-testing. The dominant hazards are oxygen displacement and asphyxiation in plant rooms and enclosed spaces, fire from flammable A2L refrigerants such as R32 and R454B, frostbite from liquid-refrigerant contact, stored-energy and high-pressure release during recovery and charging, and toxic decomposition products including hydrogen fluoride if refrigerant contacts a flame or hot surface. Refrigerant must be recovered rather than vented — venting is an offence under the Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 (Cth) — and a refrigerant handling licence issued by the Australian Refrigeration Council is required to handle refrigerant. The system, charge and pressure test follow AS/NZS 5149.
This activity is not, in itself, one of the 18 categories of high risk construction work listed in section 291 of the Work Health and Safety Regulation 2025 (NSW); it becomes high risk construction work where it is carried out in or near a confined space, or in an atmosphere that is or may become flammable or contaminated from a refrigerant release. Regardless of HRCW status, the PCBU's primary duty of care under section 19 of the Work Health and Safety Act 2011 (NSW) requires the systematic identification and control of these hazards, and many principal contractors require a SWMS for all refrigerant work as part of their WHS management plan. This document provides that auditable evidence.
Hazards identified
9 hazards covered, sorted by priority.
Asphyxiation and rapid loss of consciousness where oxygen falls below 19.5%
Fire or deflagration where a leak meets an ignition source
Impact injury, hose whip, or eye injury from a sudden release
Frostbite and cold burns to skin and eyes
Severe respiratory injury and chemical burns to the airway
Entrapment combined with an oxygen-deficient or contaminated atmosphere
Electrocution connecting or fault-finding the plant and controls
Environmental offence under the Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 and loss of licence
Musculoskeletal injury and dropped-cylinder impact
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Recover refrigerant to an approved recovery cylinder — never vent to atmosphere, which is an offence under the Ozone Protection and Synthetic Greenhouse Gas Management Act 1989.
- 2Refrigerant is handled only by a technician holding a current Australian Refrigeration Council refrigerant handling licence, working to AS/NZS 5149.
- 3Mechanical ventilation and oxygen and refrigerant monitoring in plant rooms and enclosed spaces before and during the work; withdraw and ventilate if oxygen falls below 19.5%.
- 4Eliminate ignition sources where a flammable A2L refrigerant (R32, R454B) is present; use leak detection and A2L-rated equipment and procedures.
- 5Use rated hoses, gauges and recovery equipment; do not overfill the recovery cylinder (maximum 80% by mass); isolate before disconnecting.
- 6Insulated gloves and face and eye protection against liquid-refrigerant frostbite.
- 7No open flame, smoking or hot work near refrigerant; respiratory protection where thermal decomposition is possible.
- 8Isolate and lock out the plant before electrical work, test before touch, and use a licensed electrician for the electrical connection.
- 9Move refrigerant and recovery cylinders on a cylinder trolley and store them secured and upright to AS 4332.
- 10All workers must hold a valid White Card (General Construction Induction Training, CPCCWHS1001) before entering any construction workplace in Australia.
- 11Conduct a daily pre-start toolbox talk covering the day's work scope, identified hazards, required PPE, emergency procedures, and any changes since the previous shift. Record attendance and topics in the SWMS consultation section.
- 12PPE baseline for all workers: safety eyewear compliant with AS/NZS 1337.1, Class I or Class II safety footwear with protective toecap per AS/NZS 2210.3, high-visibility clothing where required by site rules, and task-specific RPE, hearing protection, and gloves as identified in the hazard register.
- 13Display the emergency plan at the work area showing first aid kit location, emergency contacts (000, site emergency number, nearest hospital with address), evacuation routes, and assembly point. Review with all workers at pre-start.
- 14Consult workers on WHS matters affecting them per Section 47 of the WHS Act 2011 (NSW). Record the consultation in the SWMS consultation section, and obtain the HSR's acknowledgement where one has been elected.
- 15Review and update this SWMS whenever the work scope changes, after any incident or near miss, when a worker or HSR raises a WHS concern, when new hazards are identified, or at minimum every 12 months. Document the review in the revision log.
- 16Ensure all plant and equipment used has been inspected, maintained, and is fit for purpose. Conduct pre-use checks on gauges, recovery units, and safety equipment, and remove defective equipment from service.
Applicable Codes of Practice
Governs the refrigerating system, the refrigerant charge and pipework, charging and recovery, and the system pressure test.
Applies to managing the refrigerant as a hazardous chemical, including its decomposition products and the safety data sheet.
Applies where refrigerant work is carried out in a plant room or cool room that meets the confined space definition — entry permit, atmospheric monitoring, ventilation and rescue.
Isolation, lock-out and energised-work controls for the refrigeration plant and controls.
Selection, use and maintenance of respiratory protection where thermal decomposition products are possible.
Who this is for
- →Refrigeration and air-conditioning technicians recovering, charging and decommissioning refrigerant on construction and maintenance sites across NSW and other Australian jurisdictions.
- →Apprentices and trainees in the air-conditioning and refrigeration trade working under the direct supervision of a licensed tradesperson.
- →Subcontractors engaged by a Principal Contractor who require a documented SWMS for refrigerant handling before commencing work on a managed site.
- →Self-employed tradespeople operating as a PCBU who need to demonstrate compliance with WHS Act s.19 primary duty of care for their own work activities.
- →WHS managers, site supervisors, and safety coordinators reviewing subcontractor SWMS documentation during pre-start and ongoing compliance checks.
What you receive
- ✓Editable Microsoft Word document (.docx) fully compatible with Microsoft Word 2016 and newer, Google Docs, and LibreOffice Writer.
- ✓Title page with editable fields for PCBU name, ABN, site address, project name, principal contractor details, and document revision date.
- ✓Signed approval block with signature lines for PCBU representative, Principal Contractor (if applicable), and nominated site supervisor.
- ✓Hazard register containing 9 hazards specific to refrigerant handling — each with a documented consequence, inherent risk rating (using a 5x5 likelihood-consequence matrix), hierarchy-of-control measures, and residual risk rating after controls are applied.
- ✓Control measures listed in hierarchy-of-control order with cross-references to the specific WHS Regulation section, Code of Practice, or Australian Standard that mandates or recommends each control.
- ✓Worker consultation record section per WHS Act s.47 for documenting consultation with workers and HSRs on the content of this SWMS.
- ✓Worker sign-on register (blank, single page, expandable) for recording daily worker acknowledgement of the SWMS content, hazards, and required controls.
- ✓Applicable legislation and Codes of Practice schedule pre-populated for NSW with a state-variance reference table covering VIC (OHS Act 2004), QLD, SA, WA, TAS, NT, and ACT.
- ✓Emergency procedure template with fields for emergency contacts, nearest hospital, first aid officer, evacuation assembly point, and incident reporting procedure.
- ✓Revision log for documenting SWMS reviews, amendments, and version history.
Worked example
A two-person refrigeration crew is engaged to decommission a packaged air-conditioning unit and recover its R32 charge before a tenancy strip-out at a commercial building in Parramatta, NSW. Before starting, the licensed technician reviews this SWMS: the unit sits in a small rooftop plant room, so the dominant hazards are oxygen displacement in the enclosed space, the flammability of the A2L refrigerant, and the stored energy in the charged system. The plant room is ventilated and an oxygen and refrigerant monitor is set at the entrance; ignition sources are removed and a leak check is run before any work. The refrigerant is recovered to an approved recovery cylinder using a rated recovery unit, the cylinder is filled to no more than 80% by mass, and at no point is refrigerant vented. The three-phase supply is isolated and locked out by a licensed electrician who tests before touch before any electrical disconnection. Liquid-refrigerant lines are handled with insulated gloves and face protection to prevent frostbite. The crew signs on to the SWMS at pre-start, the recovery and isolation records are kept, and the recovered refrigerant is sent for reclaim under the technician's Australian Refrigeration Council licence.
Related legislation
- Work Health and Safety Act 2011 (NSW) — Section 19 primary duty of care; Section 47 consultation with workers; Sections 35-38 notifiable incidents.
- Work Health and Safety Regulation 2025 (NSW) — Section 291 (the 18 categories of high risk construction work), Section 299 (preparation and content of a SWMS where the work is HRCW), Section 302 (review of a SWMS).
- Work Health and Safety Regulation 2025 (NSW) — Part 4.3 (Confined Spaces, Sections 62-77) where refrigerant work is carried out in a plant room or cool room that is a confined space.
- Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 (Cth) and Regulations — recovery and reclaim of refrigerant and the prohibition on venting; refrigerant handling licence administered by the Australian Refrigeration Council.
- AS/NZS 5149 — Refrigerating systems and heat pumps: safety and environmental requirements.
Frequently asked questions
What specific hazards does this Refrigerant Handling SWMS cover?
This SWMS identifies and assesses 9 hazards specific to refrigerant recovery, charging and decommissioning, including oxygen displacement and asphyxiation, flammable A2L refrigerant ignition, high-pressure and stored-energy release, frostbite from liquid refrigerant, and toxic decomposition products such as hydrogen fluoride. Each hazard is documented with a realistic worst-case consequence, an inherent risk rating using a 5x5 likelihood-consequence matrix, control measures ordered by the hierarchy of controls, and a residual risk rating after controls are applied.
Is refrigerant handling high risk construction work?
Not in itself. Refrigerant handling is not one of the 18 categories of high risk construction work listed in Section 291 of the WHS Regulation 2025 (NSW). It becomes high risk construction work where it is carried out in or near a confined space, such as a plant room or cool room, or in an atmosphere that is or may become flammable from an A2L refrigerant release. A SWMS is still good practice and is commonly required by principal contractors regardless of HRCW status, and it is mandatory once the work meets one of those triggers.
Do I need a refrigerant handling licence?
Yes. Handling refrigerant requires a current refrigerant handling licence issued by the Australian Refrigeration Council, and refrigerant must be recovered and reclaimed rather than vented to atmosphere. Venting is an offence under the Ozone Protection and Synthetic Greenhouse Gas Management Act 1989. The SWMS records the licensed technician and the recovery method.
How does it manage flammable A2L refrigerants?
Lower-GWP refrigerants such as R32 and R454B are mildly flammable (A2L). The SWMS requires ignition sources to be eliminated, leak detection to be used, the space to be ventilated, and A2L-rated equipment and procedures to be followed under AS/NZS 5149. Where the work is in a confined plant room, the flammable-atmosphere trigger also makes it high risk construction work.
Can I use this SWMS in states other than NSW?
Yes, with amendments. The SWMS includes a state-variance reference table covering all Australian jurisdictions. For QLD, SA, TAS, NT, ACT and WA the core WHS framework is similar and the amendments are minor. Victoria requires more significant amendment because it operates under the Occupational Health and Safety Act 2004 and Regulations 2017 and uses different terminology (Compliance Codes rather than Codes of Practice). The refrigerant handling licence and the Ozone Protection Act apply nationally.