Rooftop HVAC Unit Maintenance Safety Checklist

Is the roof hatch structurally sound, free from rust/corrosion, and able to support 300 lbs? (OSHA 1910.27(d)(1))

Does the roof hatch latch securely in the open position to prevent accidental closure? (ANSI A14.8)

If a fixed ladder is used, are rungs free from damage, secure, and spaced 12 inches apart? (OSHA 1910.27(b)(1))

Does the fixed ladder extend at least 42 inches above the landing surface? (OSHA 1910.27(d)(3))

If using a portable ladder, is it set at a 4:1 ratio (base distance to height)? (OSHA 1926.1053(b)(5)(i))

Is the portable ladder secured at the top and bottom to prevent movement? (OSHA 1926.1053(b)(6))

Is the pathway from the access point to the RTU clear of obstructions (e.g., debris, tools, equipment)?

Is the roof surface dry and free from slip hazards (e.g., oil, ice, water)?

Is there adequate lighting (minimum 10 foot-candles) along the access route and around the RTU? (ANSI/IES RP-7)

Is there a clear and unobstructed emergency egress route from the RTU location?

Is a dedicated disconnect switch present and readily accessible for the RTU? (NEC 440.14)

Does the disconnect switch operate smoothly and completely cut off power to the RTU? (NFPA 70E)

Has a written Lockout/Tagout procedure been followed, including identification of all energy sources? (OSHA 1910.147(c)(4))

Has a qualified person performed the Lockout/Tagout procedure? (OSHA 1910.147(c)(6))

Is a personal lockout device (lock and tag) properly applied to the disconnect switch? (OSHA 1910.147(d)(4))

Has voltage been verified as zero using a calibrated voltage meter after lockout? (NFPA 70E)

Have all capacitors been properly discharged using a suitable discharge tool and verified with a meter before touching any components? (NFPA 70E)

Is the RTU properly grounded, and is the grounding conductor intact and securely connected? (NEC 250)

Are all electrical panels and components properly labeled with voltage and hazard warnings? (NEC 110.16)

Has an arc flash risk assessment been performed, and are appropriate PPE requirements documented? (NFPA 70E)

Are leading edges within 6 feet of the RTU protected by guardrails, safety nets, or personal fall arrest systems? (OSHA 1926.501(b)(1))

Are guardrails at least 42 inches high with a mid-rail and toe board? (OSHA 1926.502(b)(2))

Has the full-body harness been inspected for damage (cuts, tears, abrasions) prior to use? (ANSI Z359.11)

Has the lanyard been inspected for damage (cuts, burns, chemical exposure) prior to use? (ANSI Z359.11)

Is the anchorage point capable of supporting 5,000 lbs per employee attached? (OSHA 1926.502(d)(15))

If using a self-retracting lifeline (SRL), is it functioning properly and within its inspection date? (ANSI Z359.12)

Is there sufficient fall clearance below the anchorage point to prevent contact with lower levels? (OSHA 1926.502(d)(16))

Is there a documented rescue plan in place in case of a fall? (OSHA 1926.502(d)(20))

If using a controlled access zone, is it clearly marked and limited to authorized personnel? (OSHA 1926.502(g))

If using a warning line system, is it at least 6 feet from the edge and flagged every 6 feet? (OSHA 1926.502(f)(2))

Is a properly fitted hard hat worn at all times on the roof? (ANSI Z89.1)

Are safety glasses or goggles worn to protect against debris and chemical splash? (ANSI Z87.1)

Are appropriate gloves worn for the task (e.g., electrical-rated gloves, cut-resistant gloves)? (ANSI/ISEA 105)

Are safety-toe boots with slip-resistant soles worn? (ASTM F2413)

Is high-visibility clothing (e.g., vest or jacket) worn to increase visibility? (ANSI/ISEA 107)

Is hearing protection worn when working near noisy equipment (above 85 dBA)? (OSHA 1910.95)

If performing electrical work, is arc-rated clothing worn according to the arc flash hazard assessment? (NFPA 70E)

Is respiratory protection required for refrigerant handling or other tasks, and is it properly fitted and maintained? (OSHA 1910.134)

Is all PPE in good condition, clean, and properly stored?

Have all personnel been trained on the proper use, care, and limitations of their PPE?

Is refrigerant recovery equipment certified and in good working order? (EPA 608)

Is a proper refrigerant recovery procedure followed to prevent venting to the atmosphere? (EPA 608)

Are refrigerant cylinders properly labeled, secured, and in good condition (no rust or damage)? (DOT 49 CFR Part 178)

Are refrigerant cylinders filled to no more than 80% of their capacity? (DOT 49 CFR Part 173.304)

If lifting heavy components (e.g., compressors), is the lifting equipment (crane, hoist) rated for the load? (OSHA 1926.1400)

Has the lifting equipment been inspected prior to use, and is it free from defects? (OSHA 1926.1400)

Are proper lifting techniques used to avoid musculoskeletal injuries when handling compressors? (NIOSH Lifting Equation)

If hot work (welding, cutting) is required, is a hot work permit obtained and followed? (NFPA 51B)

Is a fire extinguisher readily available and inspected within the last year? (OSHA 1910.157)

Is the work area kept clean and free from trip hazards?