March 24, 2025

8 Best Practices for HVAC Unit Replacement Lifts

Replacing an HVAC unit with a crane? Here's what you need to know:

Plan Ahead: Assess job site conditions, including ground stability and weather.
Choose the Right Equipment: Pick a crane that matches the load, space, and time requirements.
Inspect Equipment: Check all rigging tools, chains, and lifting accessories for wear or damage.
Set Up Rigging: Use certified riggers to ensure proper load balance and secure lifting points.
Communicate Clearly: Establish hand signals or radio communication and assign a primary signaler.
Control Load Movement: Lift slowly, account for weather conditions, and use precise tools like chain hoists.
Secure the Unit: Align, level, and anchor the HVAC unit while checking ductwork and utility connections.
Document and Review: Keep records of the lift, inspect the area, and review team performance.

Quick Overview

Plan Ahead - Check site, weather, and load.
Choose Equipment - Select crane and rigging gear.
Inspect Equipment - Ensure safety and functionality.
Set Up Rigging - Balance load and secure points.
Communicate Clearly - Use signals or radios.
Control Load Movement - Lift carefully, monitor weather.
Secure the Unit - Align, level, and anchor.
Document and Review - Record details and evaluate.

These practices ensure safety and efficiency for HVAC lift projects. Stick to them to avoid accidents and complete the job right the first time.

Master HVAC Crane Lifting: Rooftop Package Unit

1. Check Job Site Conditions

Reviewing job site conditions is crucial to maintaining safety and working efficiently.

Site Access and Weather Factors

Start by evaluating the ground conditions. Outriggers should rest on stable, level ground. If needed, check the bearing pressure to ensure additional support is in place.

Weather plays a big role in lift safety:

Wind Speed: Stop operations if winds approach 20 mph. Use built-in wind indicators for real-time updates.
Temperature: Extremely cold conditions can weaken the tensile strength of rigging materials.
Lightning Risk: Immediately lower and retract booms if lightning is detected.
Rain Impact: Heavy rain can destabilize the foundation and affect equipment performance.

Once you've verified the ground and weather conditions, move on to analyzing the load weight and selecting the right crane.

Weight Analysis and Crane Size

Key factors to consider include:

Calculating the total load weight, which includes the HVAC unit, rigging gear, and any additional materials.
Choosing a crane that matches the load weight, boom length, lift radius, and site conditions.
Double-checking the crane's capacity using load charts specific to its configuration.

If weather conditions worsen, make adjustments such as:

Lowering the lift angle.
Reducing the load weight.
Decreasing the lift height.
Having a contingency plan ready.

Selecting the right crane and making necessary adjustments ensures safe and efficient operations.

2. Select and Check Equipment

Picking the Right Crane

Choosing the right crane is crucial for safely replacing an HVAC unit. The crane you select should align with the load, space, and time requirements of your project.

Here’s what to consider:

Load Capacity: Calculate the total weight, including the HVAC unit and rigging gear.
Site Conditions: Evaluate the operating space, ground stability, access routes, and any overhead obstacles.
Operation Duration: Match the crane type to the length of time it will be needed.

Different types of cranes come with specific benefits for HVAC installations:

Crane Type: All-Terrain
- Best Used For: Multiple locations
- Key Features: Combines mobility with heavy lifting
Crane Type: Carry Deck
- Best Used For: Confined spaces
- Key Features: 360-degree rotating boom
Crane Type: Boom Truck
- Best Used For: Quick installations
- Key Features: Hydraulic arm on a truck chassis
Crane Type: Rough Terrain
- Best Used For: Challenging sites
- Key Features: Superior maneuverability

Selecting a crane that meets your project’s demands ensures safe and efficient operation. Once the crane is chosen, the next step is inspecting all equipment to confirm it’s in top condition.

Equipment Safety Checks

Before every lift, inspect all equipment thoroughly. The Occupational Safety and Health Administration (OSHA) states: “Rigging equipment for material handling shall be inspected prior to use on each shift and as necessary during its use to ensure that it is safe”.

Focus on these key areas during inspections:

Rigging Equipment
Check for visible damage, ensure all fastenings and attachments are secure, and confirm that safe working load ratings and identification markings are legible.
Chains
For alloy steel chains, measure wear against allowable limits. For instance, a 3/4-inch chain should be replaced if wear exceeds 5/32 inch.
Custom Lifting Accessories
Confirm that accessories are proof-tested to 125% of their rated load, ensure safe working loads are clearly marked, and maintain proper documentation of testing results.

If any equipment shows signs of damage or wear, remove it from service immediately. Regular inspections not only prevent accidents but also ensure compliance with safety standards.

3. Set Up Rigging Correctly

Once your equipment is checked, it's time to set up the rigging to safely secure the HVAC unit.

Pick the Right Rigging Tools

Choose tools that can handle the weight of your load. This includes slings, shackles, and spreader bars designed for the unit's size and weight. Make sure each tool has a working load limit that exceeds the unit's weight and has been inspected and certified for use. Certified riggers should handle the rigging process to ensure safety. After everything is set up, check that the load is balanced.

Ensure Load Balance

Identify the unit's center of gravity and pinpoint the best lifting points. Perform a test lift to confirm stability. If the load is uneven, adjust the rigging by moving the attachment points. Double-check all components and confirm the load is balanced before moving forward. Don’t forget to account for factors like wind or uneven ground that could impact stability.

4. Set Up Team Communication

Effective communication is essential for safe and smooth HVAC lifts. Setting up clear protocols helps avoid accidents and ensures everything runs efficiently.

Signal Methods

Hand signals are the go-to way to communicate with crane operators during HVAC lifts. It's crucial for every team member to know and consistently use standard hand signals. Posting a signal chart at the site can help keep everyone on the same page.

Here are the basics for effective signaling:

Primary Signaler: Only one person should be designated as the main signaler. Make them easy to spot with unique clothing or a badge.
Clear Visibility: The signaler must always have an unobstructed view of both the crane operator and the load.
Signal Clarity: Signals should be clear and easy to see, with hands always visible. Be mindful of lighting conditions.

If hand signals aren’t practical - due to distance, poor visibility, or weather - use dedicated radio frequencies instead. While the primary signaler oversees communication, any team member is authorized to give a STOP signal, which must be followed immediately.

Make sure these protocols are discussed and agreed upon during the pre-lift planning session.

Team Planning Meeting

A thorough planning meeting with all team members is the cornerstone of a safe and efficient lift. Key topics to cover include:

Lift Plan: Share and review the documented lift procedures.
Roles and Responsibilities: Clearly assign tasks and establish the chain of command.
Communication Protocols: Decide on primary and backup communication methods.
Emergency Procedures: Go over safety protocols and how to handle emergencies.
Weather and Environment: Discuss conditions that might delay or halt the lift.

During the meeting, confirm everyone’s roles and responsibilities. Running through a lift sequence rehearsal can help catch potential issues and ensure everyone is comfortable with the process.

5. Control Load Movement

Smooth Lifting Methods

Precise load control starts with the right tools and techniques. For heavy equipment like compressors weighing around 450 pounds, chain hoists and falls offer better control. Chains are especially effective for precise positioning since they don't stretch like lifting straps.

"I've come to find that most lifting straps have a degree of stretch to them which can make precise positioning difficult... The chain doesn't stretch." – Jeremy Smith, Senior Refrigeration Tech

When using eyebolts, follow these guidelines: opt for shouldered eyebolts, keep angular forces within 45° of the eye's plane, and tighten bolts to the correct torque to prevent bending.

In tight spaces, the "trapeze" method is useful. This involves combining lifting eyes, shackles, and chains to create a balanced system. For trapeze lifts, raise the load gradually to clear obstacles, inspect all attachment points frequently, move slowly, and stay in constant communication with your team.

Weather conditions also play a critical role in lifting operations, requiring specific precautions to ensure safety.

Weather Safety Steps

Weather can impact lifting safety in significant ways. Here’s a quick guide to managing operations under various conditions:

Weather Condition: High Winds
- Action Required: Suspend operations
- Safety Threshold: Winds near or above 20 mph
Weather Condition: Lightning
- Action Required: Lower boom and clear the area
- Safety Threshold: Any lightning present
Weather Condition: Heavy Rain
- Action Required: Pause operations and protect equipment
- Safety Threshold: When visibility is compromised
Weather Condition: Cold Weather
- Action Required: Reduce load weights and check equipment capacity
- Safety Threshold: Below freezing temperatures
Weather Condition: Fog
- Action Required: Reduce lifting and slewing speeds
- Safety Threshold: When visibility is limited

For extreme weather scenarios:

Install wind speed indicators on cranes to monitor conditions in real-time.
Use salt or grit to improve traction on icy surfaces.
Set up temporary shelters to protect equipment during rain.
Verify that all equipment is rated for cold-weather use.

Ground stability can also shift during bad weather. For example, rain can saturate the soil, affecting the stability of mobile cranes. Always reassess site conditions before resuming operations once the weather clears.

Modern tools like wireless headsets (starting at $490 for a two-person setup) can ensure clear communication even when hand signals are hard to see due to weather. This is especially helpful in maintaining safety and coordination during challenging conditions.

6. Place and Secure Units

Check Unit Position

Make sure the HVAC unit is properly aligned on its mounting points with the weight evenly distributed. Double-check that the curb is aligned correctly to prevent vibration and ensure efficient operation.

For rooftop setups, leave at least 36 inches of clearance around service panels and 48 inches for condenser coil access. This spacing allows for adequate airflow and makes maintenance easier down the line.

Before securing the unit permanently, review these key points:

Leveling: Use digital levels at multiple spots to confirm the unit is even.
Ductwork alignment: Ensure all connection points line up correctly.
Utility access: Verify that service panels are easy to reach.
Vibration isolation: Check that pads or spring mounts are installed and functioning as intended.

Once everything checks out, you can move forward with securing the unit.

Safety Confirmation

Follow strict safety protocols during the final steps of securing the unit:

Keep the unit supported by the crane until all checks are completed. Use the table below as a guide:

Verification Point: Mounting Hardware
- Required Action: Tighten all bolts
- Pass Criteria: Meets manufacturer specs
Verification Point: Seismic Restraints
- Required Action: Inspect anchor points
- Pass Criteria: All restraints are secured
Verification Point: Electrical Connections
- Required Action: Check conduit alignment
- Pass Criteria: No strain on connections
Verification Point: Condensate Lines
- Required Action: Verify proper slope
- Pass Criteria: Minimum 1/4 inch per foot
Verification Point: Unit Level
- Required Action: Measure at multiple points
- Pass Criteria: Within 1/8 inch tolerance

For permanent anchoring, use grade-8 hardware that matches the specific requirements of the installation. Remove all temporary rigging and auxiliary supports before disconnecting the crane.

Finally, do a thorough walkthrough to clear away any debris and take detailed photos to document the completed installation.

7. Complete Post-Lift Tasks

Check Unit and Area

Take a close look at the HVAC unit and its surroundings. Here's what to focus on:

Electrical Connections: Make sure all connections are secure, properly insulated, and meet the voltage specs provided by the manufacturer.
Workspace Cleanliness: Clear away any debris or temporary materials to ensure proper airflow and easy access for servicing.
Safety and Clearance: Double-check that all safety features specific to the unit are functioning and that the area meets clearance guidelines.

Document the Lift

Keep thorough records following OSHA standards (29 CFR 1926 Subpart CC). Here's what to document:

Equipment Records
- Required Details: Serial numbers, inspection dates
- Purpose: Track compliance
Safety Protocols
- Required Details: Procedures and safety measures
- Purpose: Protect against liability
Installation Photos
- Required Details: Before/after images, connections
- Purpose: Aid future maintenance
Load Calculations
- Required Details: Weight distribution, rigging
- Purpose: Verify technical accuracy

Use a detailed post-lift inspection checklist and maintain both digital and physical records. Ensure you back up these records to comply with OSHA requirements. Include photos of critical areas, like key connection points and safety features.

These records not only ensure compliance but also serve as a valuable reference for future inspections and maintenance, helping to keep the equipment in good working order.

8. Maintain Team Skills

Review Team Performance

Regular evaluations are essential to ensure safety and efficiency during HVAC lifts. These reviews, combined with clear communication protocols, help improve overall safety for lifting operations.

Focus on:

Equipment handling: Assess how well team members operate and maintain equipment.
Communication: Evaluate how effectively the team communicates during lifts.
Problem-solving: Review how unexpected situations are managed.
Safety adherence: Check compliance with established safety procedures.
Time management: Analyze workflow and task completion efficiency.

Best practices for implementation:

Daily Briefings: Begin each day with a quick team meeting to discuss tasks and potential challenges.
Monthly Reviews: Go over incident reports, including near-misses, to identify areas for improvement.
Quarterly Training: Conduct drills on emergency procedures and introduce new techniques or updates.

Required Certifications

Keeping certifications up-to-date is a must for HVAC lift operations. Certifications like EPA, ICE, and NATE are standard for HVAC professionals.

OSHA Crane Operator
- Requirements: Written and practical exams
- Renewal Period: Every 5 years
EPA Certification
- Requirements: Pass a technical knowledge test
- Renewal Period: No expiration
NATE Certification
- Requirements: Written exam and field experience
- Renewal Period: Every 2 years
ICE Certification
- Requirements: Technical and practical evaluations
- Renewal Period: Annual renewal

Key OSHA 1926.1427 guidelines:

Employers must cover certification or licensing costs for employees.
Operators-in-training must always work under direct supervision.
Additional restrictions apply for high-risk tasks, such as working near power lines, hoisting personnel, using multiple pieces of equipment, or operating over shafts.

To stay organized, maintain a training matrix to track certification expiration dates. Schedule renewal courses ahead of time and keep both digital and physical records for audit purposes. This ensures compliance and helps avoid any last-minute issues.

Conclusion

Key Takeaways

HVAC lifts require careful planning and strict safety measures. To ensure smooth operations, focus on these essentials:

Conducting a detailed site evaluation
Choosing the right equipment
Employing certified operators
Maintaining clear communication within the team
Keeping thorough documentation

By sticking to these steps, you can handle HVAC lift projects safely and efficiently.

Reach Out to L&M Crane

L&M Crane brings over 40 years of experience to HVAC lift projects in Long Island, the Five Boroughs, and New Jersey. Their services include:

Equipment Options - From boom trucks to 600-ton cranes
Service Areas - Long Island, Five Boroughs, Greater NY Area, NJ
Storage Availability - Indoor and outdoor facilities for HVAC units
Additional Services - Help with permits, technical drawings, and signage

"We streamline processes to increase positive workflow and promote exceptional job site safety." - L&M Crane

L&M Crane offers project analysis, equipment recommendations, and certified crews, with 24/7 support for urgent installations. Get in touch with L&M Crane for your HVAC lift needs.