10 Essential HVAC Safety Tips: Hazards to Avoid When Weather is Extreme

Electrical HVAC dangers

Installation and repair of air conditioning systems, heat pumps, and thermostats all require electrical wiring knowledge. Techs must de-energize HVAC equipment before performing routine inspections, tests, repairs, and other procedures.

Avoid electrical accidents by:

• Turning off power to the corresponding circuit in the breaker panel. 

• Using proper lockout and tag procedures to ensure no one tries to turn on the power while you’re working.

• Before performing work, test the circuit with a meter properly rated for the type of circuit you’re testing to determine if it’s still energized.

For more electrical safety tips, visit the National Fire Protection Association’s National Electric Code and Electrical Safety Requirements for Employee Workplaces.

Extreme weather conditions

When home heating systems run nonstop in winter, customers are more likely to see their equipment malfunction and call your company for emergency service.

While extreme hot or cold weather can pose mechanical difficulties for HVAC units, it also presents dangerous conditions for technicians who must work for extended periods of time in frigid or sweltering temperatures. Here's some weather-related tips to ensure your technicians remain safe outdoors, in cold or heat:

Winter safety tips:

• Dress properly with insulated coats, hats, boots, gloves (and store dry backups in the truck).

• Stay hydrated.

• Take extra precautions to ensure ladders remain secure on wet or icy ground.

• Perform winter HVAC vehicle maintenance to minimize break-downs.

• Follow winter driving safety, especially on ice and in snowfall.

Summer safety tips:

• Drink plenty of fluids to avoid dehydration.

• Take appropriate breaks to prevent heat stroke. 

• Monitor interior truck temperatures. 

• Dress for the heat, but still wear protective equipment.

Chemical exposure

Qualified technicians work with a variety of chemicals that can cause serious burns, such as refrigerants, cleaning liquids, solvents, and gases. 

Even though manufacturers classify many refrigerants as safe, the toxicity of certain chemicals may increase when exposed to heat—ultimately posing a health hazard to technicians. 

It’s crucial for techs to undergo proper HVAC safety training before working with these chemicals. Exercise caution and always gear up with reliable protective personal equipment (PPE), including safety glasses, protective footwear, and HVAC work gloves. 

A type of pressurized gas cylinder commonly found in the back of a technician’s truck is R-410A refrigerant. When these types of gas cylinders are exposed to extreme summer temperatures, one bump on the road can send them shooting off like a rocket. For proper handling and storage, the American Welding Society (AWS) recommends the following:

• Secure cylinders upright with a chain or strap in a proper cylinder cart.

• Ensure valves are completely closed and any protection devices are secured.

• Keep cylinders in a ventilated location, free from excessive heat and electrical circuits.

• Ensure safety measures, such as caps or guards, are securely installed.

• Use a cart or hand truck. Do NOT drag or roll cylinders.

Inadequate equipment

Equipment inventory might not be the first thing that comes to mind when you think about HVAC accidents, but it increases safety.

Techs should perform inventory to make sure their trucks are stocked with the right tools and equipment before they head out to a job. This ensures they don't substitute the wrong tool for the job, compromising safety and quality of work. Regular tool inventory also allows techs to discover and remove any worn or broken tools.

Determining the type of tools needed for the next job makes it easy to hit the ground running upon arrival. Practice a routine check of prevention and awareness before you even depart for the job.

>>Related: HVAC Van Organization: Tips & Strategies for Better Efficiency

Respiratory risks

The most common health risks for HVAC technicians include respiratory-related dangers. Many homes contain dirty air filters that act as a Petri dish for mold, bacteria, and fungus. A faulty pilot light and heat exchangers leaking on a gas furnace can result in carbon monoxide poisoning.

Wear an industrial-grade face mask to avoid inhaling these lingering dangers, particularly when you’re in close proximity and for extended periods of time. Sometimes, the job requires a higher-grade mask, such as a cartridge-style mask or even a self-contained breathing mask, especially if the job is in a contaminated and confined space. Learn more about the Occupational Safety and Health Administration (OSHA) respiratory safety standards.

Ladder liability

Ladder violations ranked fifth in OSHA's top-10 workplace safety violations, underscoring the importance of following proper ladder regulations. Choose the right ladder and adequately secure it to prevent one of the most common occupational fatalities and injuries.

When engaging in ladder work:

• Always maintain three-point contact. Either both feet with at least one hand or both hands with at least 1 foot on the ladder at all times.

• Place the base of the ladder a quarter of its working length from the dwelling to achieve the safest angle.

• Make sure the extension or straight ladder extends at least 3 feet above the point of support.

• Ensure all locks are properly engaged on an extension ladder.

Dangerous driving

All of your tools can be pristine and properly stored. You can be fully outfitted with every item of PPE. You can safely climb a ladder and follow every precautionary step when dealing with electrical or chemical hazards. But none of that matters if you never make it to the job.

Daily driving becomes a mundane reality for virtually all HVAC technicians. But driving with care not only positively reflects on your company (because let’s face it—that van is really just a moving billboard), but it saves lives on the road.

To stay safe on the road:

• Optimize scheduling, so techs don't rush from one job to the next.

• Avoid weather-related road closures, traffic delays, and other last-minute hiccups with HVAC dispatch software.

• Use HVAC customer experience software, so customers know exactly when techs will arrive.

Unprofessional conduct

It’s an act of trust when a homeowner invites a technician into their home, and nothing screams unprofessional like an untrained technician. As a business owner, ensure all of your technicians receive proper HVAC safety training to recognize hazards and establish proper protocols to ensure the safety of both technicians and customers.

Go one step further to help homeowners by educating them on a recommended tune-up schedule for their cooling systems and check-ups for furnace maintenance, so they won't be faced with a mechanical breakdown when they need it the most. Routine tests of carbon monoxide detectors, changing air filters to remove buildup and ensure proper airflow through ductwork, and replacing furnace filters ultimately contribute to improved indoor air quality in your customers' homes. 

A simple warning if techs notice a space heater plugged into an extension cord or placed too close to furniture could go a long way towards keeping customers safe in their own homes.

Health concerns

When HVAC techs enter homes, they touch thermostats, air conditioners, furnaces, water heaters, and other equipment.

While there were fewer health risks before COVID-19, the ongoing pandemic pushed health and safety concerns to the forefront, including additional safety guidelines.

When scheduling a visit, businesses should confirm with the client and the technician about any possible exposure to COVID-19, and take proper precautions if needed. Ideally, all transactions that can be completed virtually (like receipts and payments) can be done in advance or upon job completion to limit contact. 

After the job is finished, employees should wash their hands, or sanitize them until they can, as recommended in workplace guidelines. Any employee showing symptoms or facing health concerns should not be working. Following cautionary steps can ensure the technicians, and their customers, stay fully protected.

Proper HVAC PPE

Always wear proper personal protective equipment (PPE) to avoid HVAC accidents. The Refrigeration School Inc. recommends the following PPE:

• Steel-toed work boots

• Full-coverage clothing

• Thick HVAC work gloves

• Hard hat

• Safety goggles

• Face shield

• Respirator

• Earplugs

Evaluate each worksite for common HVAC safety hazards. You can often remedy slippery surfaces, fall dangers, and electrical risks before starting the job.

Technicians should make personal safety a priority in the field. Don’t take shortcuts. And if techs have gaps in safety knowledge or training, they should speak to their supervisor to find an effective solution. HVAC safety training should be a routine practice—it’s never too late to start.