Complete replacement of an aging built-up bituminous membrane roof system on a single-storey industrial warehouse (~800m2 roof area, flat with slight fall to internal gutters). Work involves stripping the existing membrane and insulation, inspecting and repairing the structural steel deck, installing new rigid insulation boards, and laying a torch-on modified bitumen membrane system. Includes flashing to parapet walls, penetrations, and internal gutter detailing.
This SWMS does not cover internal ceiling works, structural steel replacement (requires separate engineering SWMS), or removal of any asbestos-containing materials (requires licensed asbestos removal contractor).
| Hazard | Inherent Risk | Control Measures | Residual Risk |
|---|---|---|---|
| Falls from roof edge Workers at or near the parapet edge (~6m to ground) during stripping, installation, and material handling activities |
5 x 5 = 25 Extreme |
Engineering Scaffold with guardrails erected around full building perimeter, extending 1m above roof level as edge protection Engineering Where scaffold gaps exist (e.g., loading areas), temporary guardrail systems installed on parapet Administrative All workers hold current Working at Heights competency; daily pre-start on fall hazards PPE Full body harness with lanyard connected to roof anchor when working within 2m of any unprotected edge or opening |
2 x 5 = 10 High |
| Falls through fragile surfaces Workers stepping on deteriorated deck sections, skylights, or translucent roof sheeting concealed under existing membrane |
4 x 5 = 20 Extreme |
Elimination All skylights and fragile panels identified and marked on roof plan before work commences; existing drawings reviewed Engineering Crawl boards placed over all identified fragile areas; safety mesh installed below skylights from inside the building Administrative Supervisor to inspect exposed deck sections progressively during stripping — no worker to step on unsupported areas PPE Fall-arrest harness connected to independent anchor point when working near identified fragile areas |
2 x 5 = 10 High |
| Weather exposure Rain causing slip hazards on membrane surface; wind lifting loose material; UV exposure during extended outdoor work |
4 x 3 = 12 High |
Isolation Maximum 100m2 of deck exposed at any time — remaining roof keeps building weathertight Engineering Temporary tarps secured over exposed sections at end of each day and when rain is forecast Administrative Monitor weather forecasts daily; cease all roof work during rain, lightning, or winds exceeding 40 km/h PPE Non-slip footwear with soft rubber soles; sunscreen and UV-protective clothing |
2 x 3 = 6 Medium |
| Manual handling Lifting and carrying insulation boards, membrane rolls (~30 kg), and gas bottles up scaffold and across roof |
4 x 3 = 12 High |
Engineering Materials crane-lifted to roof level in bulk; distributed across roof using trolley on crawl boards Administrative Two-person lift for membrane rolls and gas bottles; team rotation to distribute physical load Administrative Pre-task warm-up stretches; scheduled rest breaks every 90 minutes |
2 x 3 = 6 Medium |
| Hot bitumen burns Torch-on membrane application using open-flame gas torches; contact with molten bitumen causing severe burns |
4 x 4 = 16 High |
Substitution Use self-adhesive membrane at details and penetrations where torch application creates fire risk (e.g., near timber) Engineering Fire extinguisher within 5m of all torching operations; fire blanket available Administrative Only trained and experienced roofers to operate gas torches; hot work permit for torching near combustible substrates PPE Leather gloves, long-sleeved cotton clothing, and safety boots; no synthetic fabrics near torch operations |
2 x 4 = 8 Medium |
If a worker falls through the roof into the building, call 111 immediately. Do not move the casualty unless in immediate danger. If suspended in harness externally, initiate rescue within 5 minutes using scaffold platform access. Administer first aid and monitor for spinal injury.
Extinguish using available dry chemical extinguisher if safe to do so. If fire cannot be controlled within 60 seconds, evacuate all workers from the roof immediately via scaffold. Close gas cylinder valves at ground level. Call 111. Notify the building manager to evacuate occupants in adjacent units.
All workers must read and understand this SWMS before commencing work. By signing below, each worker confirms they have been briefed on the hazards, controls, and emergency procedures, and agree to follow them.
Describe your roofing project and get a complete SWMS with edge protection and fragile surface controls in under 60 seconds.
Get Started Free