Solar Installation SWMS: Cheatsheet with 20 hazard & controls (Free PDF)
Covers rooftop and ground-mount panel installation, DC and AC cabling, inverter connection and battery storage for residential and commercial solar PV systems. No signup, no email required.
Hazards & controls
1. Falls from height while working on the roof during panel and racking installation
- ✓ Harness and anchor point used for work above 2 metres
- ✓ EWP or scaffold used for roof access, not ladders alone
- ✓ Edge protection installed where practical before elevated work begins
- ✓ No work on wet or unstable roof sheeting
2. Contact with energised DC electrical parts (arc flash or shock)
- ✓ Panels covered or shaded during work where practical to reduce live voltage
- ✓ DC isolators used and tested before touching cabling
- ✓ Insulated tools used for all DC work
- ✓ Work performed only by a licensed and accredited solar installer
3. Contact with energised AC electrical parts at the switchboard
- ✓ Isolate and lock out/tag out supply before work starts
- ✓ Test before touch on every circuit, every time
- ✓ Arc-rated PPE worn for switchboard work
4. Manual handling injury from lifting and positioning solar panels
- ✓ Team lift used for all panel lifting and positioning
- ✓ Mechanical aid (hoist or conveyor) used where roof pitch and access allow
- ✓ Correct manual handling technique briefed at toolbox talk
5. Falling objects and struck-by incidents below roof work
- ✓ Exclusion zone maintained below all elevated panel and racking work
- ✓ Tools tethered or lanyarded when working at height
- ✓ Toe boards fitted to scaffold and elevated platforms
6. Roof collapse or structural failure from additional panel and racking load
- ✓ Roof structure assessed for load capacity before fixing racking
- ✓ Engineer sign-off obtained for non-standard roofs or heavy battery/inverter mounting
- ✓ Panel load distributed across the roof per the racking design
Show all 20 hazards & controls
7. Fire from DC arc faults caused by poor or damaged connections
- ✓ MC4 connectors correctly matched and torque-checked, not just eyeballed
- ✓ Cable runs protected from abrasion, pinch points and UV degradation
- ✓ DC isolators correctly rated for the array voltage and current
- ✓ Connections visually inspected, and thermal-checked where available, before energising
8. Contact with asbestos in older roof sheeting during racking penetration
- ✓ Suspect material identified and left undisturbed until tested
- ✓ Licensed asbestos removalist engaged if asbestos is confirmed
- ✓ Work stopped and area isolated if suspect material is found
9. Electric shock from working on wet panels or a wet roof
- ✓ No work on wet panels or roof surfaces
- ✓ RCD protection confirmed before use of test equipment
- ✓ Work stopped and postponed in wet weather
10. Struck by mobile plant or delivery vehicles during panel and battery delivery
- ✓ Exclusion zone maintained around unloading and staging areas
- ✓ Spotter used for reversing delivery vehicles
- ✓ Site traffic management plan followed
11. Heat stress and UV exposure working on exposed roofs in summer
- ✓ Hydration breaks scheduled during hot conditions
- ✓ Work rescheduled to cooler parts of the day where practical
- ✓ Sun-protective clothing, hat and sunscreen worn
- ✓ Shade provided for breaks
12. Falls through fragile roofing materials such as skylights or deteriorated sheeting
- ✓ Fragile areas identified and marked before work starts
- ✓ Crawl boards or mesh used to distribute load over fragile sections
- ✓ No stepping directly on skylights or roof lights
13. Thermal runaway, chemical burns or fire during battery storage system installation
- ✓ Battery installed to manufacturer specification and ventilation requirements
- ✓ Battery handled and connected per manufacturer procedure
- ✓ Fire extinguisher rated for lithium battery fires available on site
14. Wind loading on large panel surfaces during lifting and placement
- ✓ Work stopped in high wind conditions per manufacturer or engineer limits
- ✓ Panels secured immediately after positioning, not left loose
- ✓ Additional restraint used for panels in exposed or elevated locations
15. Cuts and lacerations from sharp panel edges and racking components
- ✓ Gloves worn when handling panels and racking
- ✓ Panel and racking edges checked before handling
- ✓ Offcuts and sharp fixings cleared from the work area
16. Noise exposure from drills and power tools during racking installation
- ✓ Hearing protection worn for all high-noise tools
- ✓ Task rotation used to limit individual exposure duration
17. Trip hazards from cables, tools and racking components on the roof
- ✓ Cables routed and secured away from walkways
- ✓ Work area kept clear of tools and offcuts throughout the day
- ✓ Site cleaned up at the end of each shift
18. Working alone on isolated residential roof jobs
- ✓ Check-in procedure maintained with the office or supervisor
- ✓ Mobile phone carried and charged at all times
- ✓ Lone work avoided for roof access or isolation tasks
19. Contact with overhead powerlines during EWP, scaffold or panel delivery near the roofline
- ✓ Overhead clearance checked before EWP or scaffold is erected
- ✓ Spotter used when working near powerlines
- ✓ No-go zone agreed with the energy authority for work near high-voltage lines
20. Damage to existing underground services during ground-mount array trenching
- ✓ Dial Before You Dig search completed before excavation
- ✓ Hand digging used within the exclusion zone of marked services
- ✓ Service locator used to confirm cable and pipe routes
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Solar Installation SWMS Cheatsheet
All 20 hazards & controls for rooftop and ground-mount solar pv installation, dc/ac cabling and battery storage, laid out as a printable one-pager for your site file.
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Frequently asked questions
What is a SWMS?
A Safe Work Method Statement (SWMS) is a legally required document for high-risk construction work. It sets out the job steps, the hazards involved, and the controls you'll use to manage them before work starts.
Do I need a SWMS for rooftop and ground-mount solar pv installation, dc/ac cabling and battery storage?
If the work falls into one of the 18 high-risk construction work categories under the WHS Regulations, a SWMS is mandatory before work can start. This template is pre-mapped to the categories that typically apply to solar installation work of this kind.
Is this template really free?
Yes. Join with your Google account in 10 seconds, no card required, and it's saved to your account ready to customise, publish and get signed by your crew online.
Can I use this template as-is?
Treat it as a starting point, not a finished document. Every site is different — add your site-specific hazards, confirm the controls suit the actual job, and have it reviewed before workers sign it.
This template is a starting point only. Review and adapt it for your actual site conditions before use — it is not a substitute for a competent person's own risk assessment.