Risk Assessment and Safe System of Work for Roof Replacement Activities

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This risk assessment covers roof replacement activities from initial site set-up through removal of existing roof coverings, installation of new roofing materials, edge work, material handling, access and egress, temporary weather protection, and demobilisation. It includes work at height, fragile roof surfaces, skylights and roof openings, scaffolding, ladders, manual handling, falling materials, weather-related risks, PPE selection and use, contractor competence, and emergency rescue arrangements. The assessment applies to employees, subcontractors, visitors, and any other persons who may be affected by roofing operations. Exclusions: structural design of the roof, permanent building maintenance outside the roofing scope, and unrelated trades unless they interface with the roofing work area. The assessment assumes that a site-specific fall protection work plan and task briefing are prepared before work starts and updated if conditions change.

2. Risk Assessment Methodology

A task-based job hazard analysis approach is used to identify hazards, evaluate the initial risk using a 5x5-style qualitative matrix, and apply controls in accordance with the hierarchy of controls: elimination, substitution, engineering controls, administrative controls, and PPE. Risk ratings are expressed consistently as Low, Medium, High, or Extreme based on the combined likelihood and severity of harm. The assessment should be reviewed against actual site conditions, roof pitch, access arrangements, weather, and the competence of the workforce before and during the job.

3. Risk Matrix Reference

The following matrix is used to evaluate risk levels based on likelihood and severity:

		Likelihood
Rare	Unlikely	Possible	Likely	Almost Certain
Severity	Catastrophic	Low	Low	Low	Medium	Medium
Major	Low	Low	Medium	Medium	High
Moderate	Low	Medium	Medium	High	High
Minor	Medium	Medium	High	High	Extreme
Negligible	Medium	High	High	Extreme	Extreme

4. Hazard Identification and Risk Evaluation

1. Falls from roof edges, leading edges, and unprotected sides during roof stripping, installation, and edge detailing.

Potential Consequences: A fall from height can cause fatal injuries, traumatic brain injury, spinal injury, fractures, or permanent disability. Falls are a leading cause of construction fatalities and are especially severe on roof work.

Affected Persons: Roofing operatives, supervisors, subcontractors, and any person working near the roof edge.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Catastrophic	Extreme

Control Measures

• Eliminate exposure where possible by completing preparatory work from the ground or using prefabricated components.
• Use engineering controls such as guardrails, scaffolds, aerial lifts, or properly installed edge protection where practicable.
• Install a site-specific fall protection system before work begins, including PFAS, restraint, or other approved systems appropriate to roof pitch and task.
• Use administrative controls including a written fall protection work plan, pre-start briefing, exclusion zones, and 100% tie-off rules where required.
• Provide and enforce PPE including full body harnesses, compatible lanyards/lifelines, helmets, safety footwear, and high-visibility clothing.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Catastrophic	High

2. Fragile roof surfaces, including deteriorated decking, skylights, roof lights, and openings that may not support body weight.

Potential Consequences: A person may fall through the roof, resulting in fatal or life-changing injuries. Falling through openings can also expose workers below to struck-by hazards from the falling person or materials.

Affected Persons: Roof workers, maintenance staff, subcontractors, and persons below the work area.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Eliminate access to fragile areas where possible by planning work from below or using alternative access methods.
• Substitute fragile components with safer temporary coverings or pre-installed protected access routes.
• Install covers, guardrails, or PFAS protection around skylights and openings before roof work starts.
• Clearly mark and secure all covers so they cannot be displaced by wind, equipment, or workers.
• Brief all workers on the location of fragile areas and prohibit stepping on unverified surfaces.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Catastrophic	High

3. Unsafe access and egress from the roof, including ladder misuse, poor ladder positioning, and climbing while carrying tools or materials.

Potential Consequences: Falls during ascent or descent can cause serious injury or death. Poor access also increases the chance of slips, trips, and dropped objects.

Affected Persons: Roofers, labourers, supervisors, and delivery personnel.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Major	High

Control Measures

• Eliminate unnecessary roof access by staging materials and tools at the point of use where possible.
• Use properly selected and inspected ladders or scaffold access systems suitable for the task.
• Ensure ladders are secured, extend sufficiently above the landing point, and are used in accordance with manufacturer instructions.
• Require workers to maintain three points of contact and keep hands free when transitioning to or from the roof.
• Prohibit carrying bulky loads up ladders; use hoists, tool belts, or controlled lifting methods instead.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

4. Scaffold failure, improper scaffold erection, incomplete platforms, or unsafe use of scaffold access around roof edges.

Potential Consequences: Collapse, falls from height, struck-by injuries, and serious injury to workers or persons below.

Affected Persons: Scaffold users, roofers, scaffold erectors, and nearby workers.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Eliminate scaffold use where a safer alternative access method is available and practical.
• Ensure scaffolds are designed, erected, altered, and dismantled only by competent persons.
• Provide full decking, guardrails, toe boards, safe access, and load limits appropriate to the work.
• Inspect scaffolds before first use, after alteration, and after adverse weather or impact.
• Restrict scaffold loading to the rated capacity and keep materials evenly distributed.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	High

5. Manual handling of roofing materials such as tiles, sheets, battens, insulation, and waste during lifting, carrying, and positioning on the roof.

Potential Consequences: Musculoskeletal injuries, strains, sprains, fatigue-related errors, loss of balance, and increased fall risk.

Affected Persons: Roofers, labourers, and delivery operatives.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Eliminate unnecessary manual lifting by using mechanical hoists, cranes, or material lifts where feasible.
• Substitute heavy or awkward loads with smaller, modular, or pre-cut materials where possible.
• Use team lifts, staged deliveries, and planned material routes to reduce carrying distances and roof congestion.
• Provide manual handling training and task-specific lifting plans for awkward or repetitive loads.
• Use gloves and suitable footwear to improve grip and reduce hand and foot injuries.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

6. Falling materials, tools, debris, and roof components striking workers below or adjacent to the work area.

Potential Consequences: Head injuries, eye injuries, fractures, lacerations, damage to property, and secondary falls caused by being struck or startled.

Affected Persons: Workers below, roofers, visitors, occupants, and the public.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Major	High

Control Measures

• Eliminate overhead exposure by excluding persons from the drop zone and sequencing work to avoid simultaneous access below.
• Install toe boards, debris nets, brick guards, catch platforms, or covered exclusion zones where appropriate.
• Use tool lanyards, secured containers, and controlled material staging to prevent items from sliding or being dropped.
• Establish barricaded drop zones and warning signage around the perimeter and access points.
• Require hard hats and eye protection for all persons entering controlled work areas.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

7. Adverse weather conditions including rain, wind, frost, ice, lightning, heat, and reduced visibility affecting roof stability and worker footing.

Potential Consequences: Slips, trips, falls from height, loss of control of materials, heat stress, cold stress, and reduced effectiveness of fall protection systems.

Affected Persons: Roof workers, supervisors, and anyone exposed to the roof work area.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Catastrophic	Extreme

Control Measures

• Suspend roof work during wet, windy, icy, or lightning conditions when safe work cannot be assured.
• Monitor weather forecasts and site conditions before and during the shift.
• Use anti-slip footwear and maintain dry, clear walking surfaces where work continues.
• Adjust work sequencing to avoid exposed edge work during deteriorating weather.
• Provide shaded rest, hydration, warm-up breaks, and cold-weather controls as required by conditions.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	High

8. Inadequate contractor competence, poor supervision, or failure to follow the safe system of work and fall protection requirements.

Potential Consequences: Incorrect installation or use of fall protection, unsafe access, missed hazards, increased likelihood of serious injury or fatality, and non-compliance with legal duties.

Affected Persons: All workers on site, including subcontractors and supervisors.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Eliminate unqualified work by verifying competence before mobilisation and restricting tasks to trained personnel.
• Require proof of relevant training, experience, and authorisation for roof work, scaffold use, ladder use, and rescue roles.
• Use competent supervision and daily coordination meetings to confirm the work sequence and controls.
• Implement a permit-to-work or authorisation process for high-risk roof activities.
• Stop work immediately if unsafe behaviour, missing controls, or changing conditions are identified.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Major	Medium

9. Failure or misuse of personal fall arrest, restraint, or positioning equipment, including incorrect anchorage, damaged components, or poor fit.

Potential Consequences: A fall may not be arrested correctly, leading to severe injury, suspension trauma, or death. Equipment failure can also create false confidence and unsafe behaviour.

Affected Persons: Roof workers using fall protection systems.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Eliminate defective equipment from service and replace it before use.
• Use only compatible, manufacturer-approved components and anchor points suitable for the roof structure and task.
• Inspect harnesses, lanyards, lifelines, connectors, and anchors before each use and after any event that may affect integrity.
• Train workers to fit, adjust, connect, and use fall protection correctly, including 100% tie-off where required.
• Maintain a rescue plan for any worker who may be suspended after a fall.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	High

5. General Control Measures

• Implement a written site-specific fall protection work plan and task briefing before roof work begins.

The plan should identify roof hazards, access routes, fall protection methods, rescue arrangements, overhead protection, and responsibilities. Update it whenever the roof layout, weather, crew, or work sequence changes.

• Establish controlled access zones and exclusion areas around the roof perimeter and drop zones.

Use barriers, signage, and supervision to keep unauthorised persons away from edge work, material hoisting areas, and areas below overhead work.

• Require competent supervision and verification of worker competence for all high-risk roofing tasks.

Confirm training, experience, and authorisation for scaffold use, ladder use, fall protection, material handling, and rescue duties before work starts.

• Inspect all access equipment, fall protection equipment, and temporary works before use and after adverse events.

Checks should cover ladders, scaffolds, anchors, harnesses, lanyards, covers, guardrails, and any equipment exposed to impact, weather, or wear.

• Maintain good housekeeping and material staging on the roof.

Keep walkways clear, secure loose materials, remove waste promptly, and stage materials away from edges and openings to reduce trip and drop hazards.

6. Emergency Preparedness

• A site-specific rescue plan must be in place before any worker is exposed to fall arrest or suspension hazards. The plan should identify how a suspended worker will be reached, lowered, or recovered quickly without exposing rescuers to additional fall risk.
• Emergency arrangements must include communication methods, emergency contact procedures, access for emergency services, and clear directions to the work location. The crew must know who raises the alarm and who coordinates the response.
• First aid provision must be suitable for the size and risk of the roofing job, including trauma response capability for falls from height and struck-by incidents.
• If a fall occurs, work must stop, the area must be secured, and the rescue plan must be activated immediately. Do not move an injured person unless there is an immediate danger such as fire, collapse, or further falling objects.
• Emergency drills or tabletop reviews should be carried out so the crew understands anchor rescue methods, ladder access for responders, and the sequence for contacting emergency services.

7. Training Requirements

• Work at Height and Fall Protection Training: All roof workers must be trained to recognise fall hazards, understand roof-specific protection methods, and use the selected fall protection system correctly. Training should cover the limitations of each system and the need for continuous compliance with the safe system of work.
  • Hazard recognition on roofs, edges, openings, and fragile surfaces.
  • Correct use of restraint, arrest, guardrails, and warning systems.
  • 100% tie-off and transition procedures where applicable.
• Ladder and Scaffold Safety Training: Workers who use ladders or scaffolds must be trained in safe erection, inspection, positioning, access, loading, and use. Training should emphasise stable setup, safe climbing practices, and the prohibition on unsafe improvisation.
  • Pre-use inspection and defect reporting.
  • Safe access and egress.
  • Load limits and platform housekeeping.
• Manual Handling and Material Staging Training: Workers must be trained to handle roofing materials safely, use team lifts or mechanical aids, and stage materials to avoid overloading the roof or creating trip hazards. Training should address fatigue, awkward loads, and maintaining balance near edges.
  • Use of hoists and mechanical aids.
  • Team lifting and communication.
  • Safe staging away from edges and openings.
• Emergency Rescue and Incident Response Training: The crew must be trained on the site rescue plan, alarm raising, first aid escalation, and the actions required if a worker falls, becomes suspended, or is injured by falling materials. Rescue training should be practical and role-specific.
  • Who initiates rescue and who calls emergency services.
  • How to isolate the area and protect rescuers.
  • How to respond to suspension trauma risk.
• Competence and Supervisor Briefing: Supervisors and competent persons must be trained to verify controls, monitor changing conditions, and stop work when the roof, weather, or equipment conditions become unsafe. They must also ensure that subcontractors understand the site rules before starting work.
  • Daily briefing and change-of-condition review.
  • Verification of training and authorisation.
  • Authority to stop unsafe work.

8. Monitoring and Review

Review Frequency: Review before the job starts, weekly during the project, and immediately after any incident, near miss, significant weather change, design change, or change in work method.

Monitoring Type	Frequency	Responsible Party	Description
Pre-Start Inspection	Before each shift and after any significant weather event	Competent supervisor	Inspect roof condition, access equipment, edge protection, skylight covers, anchors, scaffolds, ladders, housekeeping, and weather conditions before work begins. Confirm that the rescue plan and exclusion zones are in place.
Active Work Observation	Continuous during roof work	Supervisor or competent person	Monitor worker behaviour, tie-off compliance, material staging, ladder use, and adherence to the work sequence. Stop work if unsafe acts, missing controls, or changing conditions are observed.
Equipment Inspection	Before each use and after any impact or suspected damage	Each user and competent person	Check harnesses, lanyards, connectors, anchors, ladders, scaffold components, covers, and other temporary works for wear, damage, instability, or deterioration. Remove defective items from service immediately.
Formal Safety Review	Weekly and after any incident or near miss	Site management and competent supervisor	Review incidents, near misses, weather interruptions, control effectiveness, and any changes to the work scope. Update the risk assessment and safe system of work as needed.
Subcontractor Compliance Check	At mobilisation and periodically during the job	Principal contractor or site manager	Verify that subcontractors are competent, briefed, and following the same roof safety rules, including fall protection, exclusion zones, and rescue arrangements.

9. Special Circumstances

• Wet, windy, icy, or poor-visibility conditions increase the likelihood of slips, loss of balance, and failure to control materials. Roof work should be paused or rescheduled when conditions make safe work impracticable.
• Night work or reduced-light operations require enhanced lighting, stricter supervision, and careful control of access routes, edges, and drop zones because visibility and depth perception are reduced.
• Lone working on roofs should be avoided. If it cannot be avoided, additional controls are required, including communication checks, rescue readiness, and tighter supervision.
• Steep-pitch roofs, fragile roofs, and roofs with multiple levels or complex geometry require task-specific controls because movement, anchorage, and rescue become more difficult.
• Simultaneous work by other trades, occupants, or delivery personnel can increase struck-by and interface risks. Coordinate sequencing and isolate the work area before roof operations begin.

Approval and Sign-off

This risk assessment has been reviewed and approved by:

Assessor: _________________________ Date: __________

Manager/Supervisor: _________________________ Date: __________

Safety Representative: _________________________ Date: __________

This risk assessment must be reviewed review before the job starts, weekly during the project, and immediately after any incident, near miss, significant weather change, design change, or change in work method. or when significant changes occur.

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