Roofing

Under Safe Work Australia's Code of Practice for Managing the Risk of Falls at Workplaces, physical edge protection is mandatory for any work within two metres of an unprotected edge where a person could fall two metres or more. Edge protection must be installed before roofing work commences and must remain in place until the work is completed. Acceptable systems include guardrail systems with top rails at 900-1100mm height and mid-rails, safety mesh that prevents falls through gaps, perimeter scaffolding providing a protected working platform, or other engineered barriers that physically prevent workers from reaching the edge. Edge protection must be capable of withstanding a force of at least 200 newtons applied in any direction, must not have gaps exceeding 225mm that could allow a person to fall through, and must be installed by competent persons. Crucially, the hierarchy of control must be applied—physical edge protection is preferred over personal fall arrest systems using harnesses and lanyards, which should only be used where physical barriers are not reasonably practicable. Your SWMS must specify the type of edge protection being used, how it will be installed and maintained, who is responsible for installation and daily inspection, and what procedures apply if edge protection cannot be used in certain locations. Generic statements about 'appropriate fall protection' are inadequate—you must detail the specific systems being implemented for your particular roof configuration.

Roofing work must be immediately suspended when weather conditions create unsafe working environments. Specifically, work must stop during any rainfall as wet roof surfaces become extremely slippery, dramatically increasing fall risk on both metal and tiled roofs. Wind speeds above 40km/h make safe roofing work impossible—at this speed, roofing materials act as sails creating projectile hazards and can destabilise workers, whilst dust and debris affect visibility. All roofing work must cease during thunderstorms due to lightning strike risk for workers in elevated exposed positions, particularly when handling metal roofing materials that conduct electricity. Extreme heat conditions when Bureau of Meteorology forecasts predict temperatures exceeding 35 degrees Celsius require modified work schedules, potentially limiting work to early morning hours, or suspension entirely during extreme heat warnings. Your SWMS must specify who monitors weather conditions, how often monitoring occurs, what trigger points require work suspension, procedures for safely evacuating the roof when conditions deteriorate, and how partially completed work will be secured before evacuation. Morning inspections should include checking overnight rain, frost, or dew that may have created slippery conditions. Weather monitoring must continue throughout the work period as conditions can change rapidly, and conservative decisions to suspend work should always be supported. Never pressure workers to continue roofing work in marginal conditions—the consequences of weather-related falls are severe.

All workers conducting roofing work at heights must hold current competencies in working safely at heights, typically the nationally recognised unit RIIWHS204D (Work safely at heights) or equivalent state-based qualifications. This training covers hazard identification, hierarchy of control, use of edge protection systems, correct use of personal fall arrest equipment including harnesses and lanyards, inspection and maintenance of fall protection equipment, and emergency response procedures. Workers must also be trained in recognising and avoiding fragile roof materials, heat stress recognition and management, manual handling techniques specific to roofing materials, and safe use of ladders and roof access systems. If using fall arrest harnesses, workers must complete training in anchor point selection, attachment techniques, maintaining fall clearance distances, and suspension trauma awareness. Training must include practical competency assessment, not just theoretical knowledge—workers must demonstrate they can correctly don harnesses, inspect equipment, and attach to anchor points. Refresher training is required every two years at minimum, and additional training may be necessary when new equipment, materials, or work methods are introduced. Supervisors must hold additional qualifications in supervising high-risk work and implementing safe work method statements. Your SWMS must specify the required competencies for each role, verify that workers hold current training certificates, and establish procedures for workers who identify hazards they are not trained to manage. Keep training records readily accessible for WorkSafe inspections—failure to demonstrate current competencies can result in immediate prohibition notices halting all roofing work.

Any building constructed or renovated before December 31, 2003, should be assumed to contain asbestos until proven otherwise through testing by a licensed asbestos assessor. Roofing materials commonly containing asbestos include fibro cement sheeting (often called 'Super Six' or 'fibro'), corrugated asbestos cement roofing particularly on older homes, sheds, and industrial buildings, flat asbestos cement sheeting used for soffits and eaves, roof underlay materials, and flashing products. Visual identification alone is insufficient and dangerous—materials that appear to be standard cement sheeting may contain asbestos fibres. Before any roofing removal, renovation, or maintenance work on pre-2004 buildings, you must arrange for an asbestos inspection by a licensed asbestos assessor who will conduct sampling and testing through a NATA-accredited laboratory. The resulting asbestos register must identify the location, type, condition, and extent of all asbestos-containing materials. Never cut, drill, grind, or break suspected asbestos roofing materials without first having them professionally tested and implementing appropriate controls. If asbestos roofing is confirmed, removal of more than 10 square metres requires a licensed asbestos removalist with Class B licence minimum. Smaller quantities can be removed by competent persons following specific procedures including use of P2 respirators, wetting to suppress fibres, no cutting or power tools, proper double-wrapping for disposal, and clearance certification before reoccupation. Your roofing SWMS must include procedures for unexpected asbestos discovery, immediate work stoppage, area isolation, notification of supervisors, and engagement of licensed assessors. Workers must be trained to recognise potential asbestos materials and understand that stopping work upon discovery is mandatory, not optional.

Manual handling of roofing materials must follow the hierarchy of control, prioritising elimination and engineering controls over relying on worker technique alone. Mechanical lifting should be used wherever reasonably practicable, including roof hoists, conveyors, cranes, and material lifts that eliminate or reduce manual carrying of heavy materials to roof height. Roof tiles should be mechanically distributed across the roof using purpose-built tile conveyors or cranes with tile bundles, rather than workers carrying individual tiles up ladders. Metal roofing sheets should be lifted into position using two or more workers, particularly for sheets exceeding 4 metres in length, with mechanical assistance for longer spans. Work platforms and scaffolding should provide stable working surfaces that allow workers to adopt optimal postures without awkward reaching, bending, or twisting. Team lifting protocols are mandatory for loads exceeding 16 kilograms or for awkward shapes including ridge capping and flashing rolls. Your SWMS must specify maximum individual lift weights (typically 16kg for manual handling without assistance), require assessment of load weight before lifting, mandate team lifting for heavy or awkward loads, establish rotation schedules to prevent repetitive strain from continuous manual handling, and require regular rest breaks. Pre-work stretching and warm-up exercises reduce injury risk, whilst workers must be trained to recognise early symptoms of manual handling injuries including back pain, shoulder strain, and knee problems. Site planning should minimise distances materials are carried and eliminate carrying up and down slopes where possible. Proper PPE including steel-capped boots, gloves with good grip, and knee pads when kneeling reduces injury risk. Never pressure workers to lift loads they consider unsafe—empower workers to request mechanical assistance or additional team members for heavy lifts.