Job Hazard Analysis · HVAC

Job Hazard Analysis: Attic equipment service

Service of a furnace, air handler, or evaporator coil installed in a residential or light-commercial attic. Work includes accessing the attic by pull-down or portable ladder, moving across joists and insulation, locking out power, servicing components (filters, condensate drain, blower, burner, controls, refrigerant checks), and cleanup. Attics can exceed 130°F in warm weather. Expect blown-in fiberglass or cellulose, exposed nails, low clearance, and possible gas piping and 120/240V circuits.

Published 2026-10-23

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

Step	Hazard	Risk	Controls
1. Plan the job and set up access to the attic	Heat stress in a hot attic	High	Schedule attic work for early morning when possible. Set a portable fan at the attic hatch blowing fresh air in, and bring a work light. Set work/rest cycles: limit attic time to 15–20 minutes, then cool down below. Drink 1 cup of water every 15–20 minutes. Use a buddy system and check on the worker in the attic every 10 minutes. New or returning workers start with shorter shifts.
1. Plan the job and set up access to the attic	Falls from the attic pull-down ladder or portable ladder	Medium	Inspect the pull-down ladder hinges, bolts, and rungs before use. If it is loose or damaged, use your own fiberglass extension or stepladder instead. Extend a portable ladder 3 ft above the hatch landing or secure a grab point, and set it on firm, level floor. Keep 3 points of contact. Hoist tools and parts in a bag or hand them up; do not carry them while climbing.
2. Move across the attic to the unit	Stepping off joists and falling through the drywall ceiling	High	Use the existing catwalk. If there is none, lay 2x10 boards or plywood across at least 3 joists to make a walkway. Light the path with a work light; locate joists before each step. Never step on insulation between joists.
	Head and scalp cuts from roofing nails and rafters	Medium	Move slowly and stay low under sloped rafters. Wear a bump cap and long sleeves.
	Fiberglass or cellulose dust in eyes, skin, and lungs	Medium	Disturb insulation as little as possible; keep the fan blowing so dust does not drift into your face. Wear safety glasses, gloves, long sleeves, and an N95 respirator (voluntary use, read the info sheet).
3. Shut off and lock out power and gas	Electric shock from the 120V or 240V unit circuit	High	Turn off the service switch at the unit and the breaker at the panel. Apply your personal lock and tag. Test for zero voltage with a meter at the unit terminals; check the meter on a live source first. Watch for a second circuit feeding the condenser or accessories.
3. Shut off and lock out power and gas	Gas leak at the furnace gas valve or flex connector	Medium	Close the appliance gas shutoff before opening the burner compartment. If you smell gas, stop, do not flip switches, get everyone out, and call the gas utility.
4. Service the unit (filter, blower, drain, burner, controls)	Cuts from sheet metal panel edges and coil fins	Medium	Set removed panels flat on the platform with edges away from you. Wear cut-resistant gloves when handling panels and coils.
	Mold and biological growth in the drain pan and condensate line	Low	Use a wet/dry vac to clear the drain instead of blowing by mouth. Wear nitrile gloves and wash hands before eating or drinking.
	Skin and eye contact with coil cleaner or chemicals	Medium	Use a non-acid, low-odor coil cleaner when possible. Read the label and SDS before use; keep ventilation running. Wear chemical splash goggles and nitrile gloves.
	Hot burner, heat exchanger, and flue surfaces	Low	Let the furnace cool at least 10 minutes after shutdown before touching burner parts. Wear leather gloves when handling flue pipe.
5. Check refrigerant pressures and test run	Refrigerant frostbite or eye injury from hose connections	Medium	Use low-loss fittings on gauge hoses; point the port away from your face. Wear safety glasses and gloves when connecting or removing gauges.
5. Check refrigerant pressures and test run	Contact with moving blower or live terminals during test run	High	Reinstall all panels and guards before restoring power. Only the worker who placed the lock removes it, after telling everyone. Take live readings only with insulated meter leads, one hand, and no jewelry.
6. Clean up, remove tools, and exit the attic	Falls when climbing down with tools or old filters	Medium	Lower tools and trash in a bag or hand them to your buddy. Face the ladder and keep 3 points of contact.
6. Clean up, remove tools, and exit the attic	Tripping on tools and debris left in the work area	Low	Bag old filters and debris; do a final tool count before leaving the attic. Close the attic hatch and fold the ladder up when done.

Required PPE

Safety glasses — ANSI Z87.1 at all times in the attic; chemical goggles when using coil cleaner.
Bump cap — Worn in the attic to protect from nails and rafters.
Gloves — Cut-resistant for sheet metal; nitrile for chemicals and drains; leather for hot parts.
N95 filtering facepiece — For insulation dust; voluntary use unless the competent person requires it.
Long-sleeve lightweight shirt — Protects skin from fiberglass; choose breathable fabric for heat.
Work boots — Slip-resistant soles for ladders and joists.
Knee pads — When kneeling on joists or platforms.

Training

Ladder safety training by a competent person.
Lockout/tagout procedure for HVAC disconnects and breakers.
Heat illness recognition, prevention, and first aid.
Hazard communication: reading SDS and labels for coil cleaners and refrigerants.
EPA Section 608 certification for anyone handling refrigerant.
Respirator voluntary-use information for N95 users.

Emergency

If a worker shows heat stroke signs (confusion, collapse, hot skin): stop work, call 911 and give the site address, get the worker out of the attic to a cool area, and cool them fast with water and fans until help arrives. For a fall or shock, call 911 and do not move an injured worker unless they are in danger.

Official sources

OSHA — Heat — hazard recognition and prevention
29 CFR 1926.1053 — Ladders
29 CFR 1926.417 — Lockout and tagging of circuits
29 CFR 1926.416 — Electrical — general requirements
29 CFR 1926.21 — Safety training and education
29 CFR 1926.95 — Criteria for personal protective equipment
29 CFR 1910.1200 — Hazard communication (GHS)
29 CFR 1910.134 — Respiratory protection program

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General information, not legal advice. Templates and examples should be reviewed by a competent person before use. HardHat Binder is not affiliated with or endorsed by OSHA.