Duct Work Installation Safe Work Method Statement

Installing ductwork requires lifting and positioning duct sections weighing 15-40kg at overhead heights in ceiling spaces. Rectangular duct sections are awkward to handle due to large surface areas and limited grip points. Workers must support duct weight while positioning against hangers and securing connections. Work occurs from stepladders or scaffolds with limited stable footing. Twisting, reaching, and sustained overhead holding creates shoulder, back, and neck strain. Confined ceiling spaces restrict proper lifting postures and body positioning.

Consequence: Rotator cuff injuries and shoulder damage from overhead work, lower back strain from lifting and twisting, neck strain from sustained overhead positions, crushed fingers from duct sections slipping during positioning, and chronic musculoskeletal disorders from repeated overhead manual handling.

Duct work installation requires extensive work at heights from 2 to 6 metres using stepladders, platform ladders, and mobile scaffolds. Workers must handle duct sections with both hands occupied while maintaining balance on ladders or scaffold platforms. Overreaching to position duct runs, stepping between scaffold boards, and working near ceiling penetrations creates fall risks. Cluttered work areas with duct offcuts, tools, and materials increase trip hazards on scaffold platforms.

Consequence: Serious injuries or fatalities from falls including head trauma, spinal injuries, fractures to limbs and pelvis, internal injuries from impact, and long-term disability from serious falls even from heights under 3 metres.

Sheet metal ductwork has sharp cut edges, protruding screws, and pointed corners causing laceration injuries during handling and installation. Galvanised steel edges are particularly sharp immediately after cutting or shearing. Workers may contact sharp edges when reaching inside ducts to secure connections, positioning duct sections in confined spaces, or handling damaged duct with bent edges. Flexible duct has sharp spiral wire reinforcement that can spring back and cause cuts.

Consequence: Deep lacerations requiring suturing, severed tendons in fingers or hands affecting dexterity, infection from contaminated cuts in construction environments, permanent scarring, and potential long-term loss of hand function requiring alternate employment.

Installing ductwork in roof cavities and ceiling spaces during summer months exposes workers to extreme temperatures exceeding 50°C. Inadequate ventilation compounds heat stress. Workers wear long sleeves and protective clothing for insulation handling, increasing heat load. Physical exertion from manual handling and overhead work in hot environments accelerates heat stress development. Restricted ceiling space access limits cooling air flow. Workers focused on installation tasks may not recognise heat stress symptoms.

Consequence: Heat exhaustion causing dizziness, nausea, and collapse, heat stroke requiring emergency medical treatment, dehydration affecting cognitive function and increasing error rates, impaired judgement leading to falls and other accidents, and potential fatality from severe untreated heat stroke.

Duct insulation installation involves handling fibreglass blanket insulation releasing airborne glass fibres. Cutting and fitting insulation in confined ceiling spaces concentrates fibre exposure. Ceiling cavity work disturbs accumulated construction dust and debris creating respiratory hazards. Adhesive and mastic vapours from duct sealing compound respiratory irritation. Poor ventilation in confined ceiling spaces prevents dust and vapour dispersion. Extended exposure without respiratory protection causes respiratory sensitisation.

Consequence: Respiratory irritation and coughing from fibreglass exposure, skin irritation and dermatitis from fibreglass contact, chronic bronchitis from long-term dust exposure, sensitisation to fibreglass causing allergic reactions, and potential long-term respiratory impairment from accumulated exposure.

Installing ductwork in ceiling cavities, roof spaces, and vertical service ducts requires entry to confined spaces with restricted access, limited ventilation, and difficult egress. These spaces may have oxygen deficiency from combustion equipment, accumulation of welding or soldering fumes, or displacement by heavier gases. Atmospheric hazards may not be immediately apparent. Limited access openings create rescue difficulties. Poor lighting and uneven surfaces increase trip and fall risks within confined spaces.

Consequence: Asphyxiation from oxygen-deficient atmospheres, toxic gas exposure from accumulated fumes, heat stroke in poorly ventilated hot spaces, falls and injuries from poor lighting and obstacles, difficulty in emergency rescue from restricted access, and potential fatality from confined space incidents.