# Job Hazard Analysis: Window installation URL: https://hardhatbinder.com/en/jha/general/window-installation Last updated: 2026-10-23 Removing old windows (if replacement) and installing new vinyl, wood, or aluminum windows in framed walls on one- and two-story buildings. Work is done from inside the building, from ladders, and from exterior scaffolds. Includes carrying units, prepping and flashing the rough opening, setting and fastening, sealing, and cleanup. Buildings built before 1978 may have lead paint on old window frames. > A general example for this task. Your JHA should reflect your crew, equipment and site — review it with a competent person before work starts. ## Steps, hazards and controls ### 1. Unload windows and carry them to each opening. - **Back strain from lifting heavy or large window units (often 50–150 lb).** (Medium): Use a dolly or window cart for units over 50 lb.; Stage windows close to their openings to cut carrying distance.; Use two people for any unit over 50 lb or wider than your arm span. Lift with your legs, keep it close. - **Cuts if glass breaks while carrying.** (Medium): Keep factory corner guards and packaging on until the window is at the opening.; Carry windows upright, never flat. Store them upright against a wall on blocks.; Wear cut-resistant gloves when handling glass. - **Tripping over debris, hoses, and cords on the path.** (Low): Walk the path first and clear it before carrying.; Route cords and air hoses along walls, not across walkways. ### 2. Set up stepladders, extension ladders, or exterior scaffold. - **Falls from ladders or scaffold, especially at second-story windows.** (High): Do second-story work from inside the room or from a fully planked scaffold with guardrails instead of a ladder when possible.; Scaffold must be set on base plates and mud sills on firm ground, fully planked, with guardrails, and checked by the competent person before use each shift.; Set extension ladders at a 4-to-1 angle, extend 3 ft above the landing, and tie off or have someone foot it. Open stepladders fully and lock the spreaders.; Inspect ladders before use. Tag out any with cracked rails, bent rungs, or missing feet. - **Ladder or scaffold contacting overhead power lines.** (High): Look up before moving ladders or scaffold. Keep at least 10 ft from overhead lines.; Use fiberglass ladders, not aluminum, near any electrical source. ### 3. Remove the old window (replacement work): cut paint and caulk, pull trim, cut fasteners, and take out the sash and frame. - **Lead dust from old painted frames and trim in pre-1978 buildings.** (High): Test paint before demo. Treat it as lead if not tested.; Cover floors and ground with 6-mil plastic, close off the room, and mist surfaces before scraping. Do not dry sand, power plane, or use a heat gun over 1100°F.; Use a HEPA vacuum for cleanup. No eating, drinking, or smoking in the work area. Wash hands and face before breaks.; Wear a fit-tested respirator (P100) and disposable coveralls when disturbing lead paint. - **Cuts from broken glass and from reciprocating saw or oscillating tool blades.** (High): Tape an X across old glass with duct tape before removal so it holds together if it breaks.; Keep your free hand out of the blade path. Unplug or pull the battery before changing blades.; Wear cut-resistant gloves, safety glasses, and long sleeves. - **Old sash or frame falling out of the opening onto workers or people below.** (Medium): Barricade and flag the area below the window outside. Keep people out while removing.; Pull old units into the room, not outward. Have a second worker hold the unit while the last fasteners are cut. ### 4. Prep and flash the rough opening: check size and square, install sill pan and flashing tape. - **Fall through the open window opening on upper floors.** (High): If the sill is less than 39 in above the floor and the drop outside is 6 ft or more, install a guardrail or screw a 2x4 across the opening until the window is set.; Do not lean out past the opening. Work from scaffold outside if exterior access is needed. - **Cuts from utility knives used on flashing tape and housewrap.** (Medium): Use self-retracting utility knives. Cut away from your body.; Change blades when dull. Put used blades in a blade bank, not loose in the trash. ### 5. Set, shim, level, and fasten the new window. - **Window falling out of the opening before it is fastened.** (High): One worker holds the window in place from inside while the other fastens. Never leave a window unfastened in the opening.; Keep the area below the window barricaded until the window is fastened. - **Nail gun or screw gun injuries to hands and others nearby.** (Medium): Use a sequential-trigger nail gun. Keep your hand at least 12 in from the nail point.; Never point a nail gun at anyone. Disconnect air before clearing jams.; Wear safety glasses. Use hearing protection when nailing for long periods. - **Overreaching or standing on the top cap of a stepladder to reach the head of the window.** (Medium): Pick a ladder tall enough so you never stand on the top two steps.; Keep your belt buckle between the rails. Climb down and move the ladder instead of reaching. ### 6. Seal and insulate: apply caulk, low-expansion spray foam, and install trim. - **Skin, eye, and breathing irritation from spray foam and sealants.** (Medium): Read the SDS before use. Use low-expansion window foam and low-VOC sealants.; Open windows or run a fan for fresh air in small rooms.; Wear nitrile gloves and safety glasses when foaming. - **Fire from flammable foam cans and solvent.** (Low): Keep foam cans and solvents away from heat, torches, and smoking.; Keep a fire extinguisher in the work area. ### 7. Clean up glass, old windows, packaging, and debris. - **Cuts and punctures from broken glass, nails, and blades in debris.** (Medium): Bend over or pull nails from old frames before stacking.; Sweep glass with a broom and dustpan, never by hand. Put old windows and glass straight into the dumpster.; Wear cut-resistant gloves and work boots. - **Spreading lead dust when cleaning up after old painted windows.** (Medium): Mist and fold plastic sheeting inward. HEPA vacuum, then wet wipe surfaces. Do not dry sweep lead debris.; Bag lead debris in heavy plastic bags and seal them. ## Required PPE - Safety glasses — ANSI Z87.1, at all times when cutting, nailing, foaming, or handling glass. - Cut-resistant gloves — ANSI A4 or higher when handling glass, old windows, and debris. Nitrile gloves for foam and sealants. - Hard hat — When working below scaffold or ladder work, or when overhead hazards exist. - Work boots — Sturdy boots with slip-resistant, puncture-resistant soles. Safety toe recommended. - Hearing protection — Earplugs or muffs when using saws or nail guns for extended periods. - Respirator — Fit-tested half-face with P100 filters when disturbing lead paint. Requires medical clearance and fit test. - Long sleeves and disposable coveralls — Long sleeves when handling glass. Disposable coveralls for lead paint removal. ## Training - Ladder safety training: inspection, setup, and safe climbing. - Fall protection training for working near open window openings and on scaffolds. - Scaffold user training. A competent person must inspect the scaffold each shift. - Safe use of nail guns, reciprocating saws, and oscillating tools. - Hazard communication: reading labels and SDS for spray foam, caulk, and solvents. - Lead awareness training and EPA RRP certification for work disturbing paint in pre-1978 homes. ## Emergency If someone falls or is badly cut: stop work and call 911. Give the site address and the nearest cross street. Do not move a fall victim unless they are in danger. Press a clean cloth hard on bleeding cuts. Send someone to meet the ambulance and notify the supervisor. ## Official sources - [29 CFR 1926.1053](https://www.ecfr.gov/current/title-29/section-1926.1053) — Ladders - [29 CFR 1926.451](https://www.ecfr.gov/current/title-29/section-1926.451) — Scaffolds — general requirements - [29 CFR 1926.501](https://www.ecfr.gov/current/title-29/section-1926.501) — Duty to have fall protection - [29 CFR 1926.503](https://www.ecfr.gov/current/title-29/section-1926.503) — Fall protection training requirements - [29 CFR 1926.302](https://www.ecfr.gov/current/title-29/section-1926.302) — Power-operated hand tools - [29 CFR 1926.62](https://www.ecfr.gov/current/title-29/section-1926.62) — Lead - [29 CFR 1926.59](https://www.ecfr.gov/current/title-29/section-1926.59) — Hazard communication - [29 CFR 1926.102](https://www.ecfr.gov/current/title-29/section-1926.102) — Eye and face protection --- Source: HardHat Binder, operated by Leadspire LLC. Templates to be reviewed by a competent person before use; not legal advice; not affiliated with OSHA.