Cabinet documents showed Mr Rudd, his deputy Julia Gillard, then-treasurer Wayne Swan and then-finance minister Lindsay Tanner were warned about "critical risks" associated with the program, according to the ABC.
The documents, obtained by the ABC, did not specify whether these risks were related to safety.
"[The Department of Environment] has undertaken a risk assessment which reveals a large number of critical risks for the Energy Efficient Homes Package," the report, dated to April 6, 2009 reads.
Three workers in Queensland were electrocuted installing the insulation, and another worker in NSW died of hypothermia months later.
In a statement, a spokesman for Mr Rudd said a Royal Commission into the home insulation program showed that any assertion he was warned about safety risks, and failed to act on them, was "completely baseless and untrue".
The Energy Efficient Homes Package, otherwise known as the "Pink Batts Scheme", offered subsidised insulation as part of an economic stimulus package.
It was discontinued in February 2010 following the deaths.
In 2014, Mr Rudd told a royal commission into the program that the rollout would have been delayed if cabinet knew of any safety risks.
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"Right through until February 2010... each of the monthly reports said that the Energy Efficiency program of the government was on track," he said during the hearing.
He said he didn't know why public servants had not raised safety concerns.
The ABC said the implementation report it obtained was prepared weekly by the Office of the Coordinator-General for the Strategic Priorities and Budget Committee (SPBC), which consisted of the so-called "Gang of Four" - Mr Rudd, Ms Gillard, Mr Swan and Mr Tanner.
When Mr Rudd was questioned at the royal commission specifically about the risk assessment undertaken by the Department of Environment, he said he had "no familiarity with it", other than assuming "that's the normal thing a department would do."
