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When your employees are expected to work on the rooftop, fall protection isn’t optional—it’s the law. The leading edge of a roof is inherently dangerous and installing a safety railing is one of the smartest things you can do to keep your workers safe in this high-risk environment. But roof fall protection doesn’t stop there. In fact, there are all kinds of trip and fall hazards on industrial rooftops and it's important to protect workers with the appropriate equipment—whether that means passive protection like a metal guardrail and/or hatch and skylight guards, or active protection like a safety harness and horizontal lifeline system.
According to OSHA regulations, employers must provide fall protection at the unprotected leading edge of a rooftop, floor, or other walking or working surface. A leading edge is considered an "unprotected side and edge" during periods when it is not actively or continuously under construction. But there are other things to consider beyond the leading edge. Since roofs often have HVAC equipment and other essential systems, skylights, hatchways, ladders, and uneven levels, it's essential to address all these potential fall hazards as well.
OSHA defines a low-slope roof as a roof having a slope of less than or equal to 4 inches (10.16 cm) of vertical rise for every 12 inches (30.48 cm) horizontal length. In some instances, a metal guardrail system can be placed around the leading edge, however, this isn't always feasible. When a guardrail can’t be used, warning line systems, safety monitors, and personal fall protection devices are required for workers.
If your rooftop has a slope of 4.5 inches (11.43 cm) or more for every 12 inches (30.48 cm) of horizontal length, it's considered a steep-slope roof. Because of the slope, you'll need to make sure that there's adequate protection for workers, so they don't slide off the roof towards the edge. A safety-net system, or a personal fall arrest system must be in place, even for temporary roof work.
Oftentimes, HVAC machinery is installed close to the roof edge, which creates a potential fall hazard for HVAC maintenance workers as well as anyone performing other duties on the roof. If the equipment is within 15 feet (4.57 meters) of the leading edge, you're required to provide fall protection. While a metal guardrail may be adequate in some cases, the slope of the roof, along with other factors must be taken into consideration. For HVAC systems that are extremely close to the edge, it may also be wise to use a parapet rail along with a horizontal lifeline system or other form of personal fall protection.
When walking or working on the rooftop, employees can encounter obstacles and potential fall hazards like skylights and hatches. These are often overlooked but can still result in injury, as well as damage your building, equipment, and the people below. A skylight protection system serves as both warning and as protection from impact without diminishing its intended purpose: as a source of natural light. For roof hatches and ladders, a guard or a safety railing with a swing gate makes a smart choice to protect workers from falling and also serves as a means of access control.
If your employees must move from level to level on the rooftop, you need to make sure they're safe while doing so. A safety railing may not provide enough protection, especially if the different levels need to be accessed by a ladder or stairs, or if they make accessing the work area difficult. In these instances, a horizontal lifeline system may be a smarter choice. OSHA regulations also require the use of a fall arrest system for workers who are climbing or descending a ladder - something to keep in mind if this is how your various roof levels are accessed.
It is sometimes necessary to store equipment and supplies on the rooftop, especially during construction, repairs, or maintenance operations. While these are important to the work to being done, they also create a trip and fall hazard for workers as they go about their business. A non-penetrating metal guardrail system or warning line system placed around the equipment and supplies will provide protection without compromising the roofing material or the movement of workers.
The type of material your rooftop is covered in can have a dramatic effect on the safety of your employees. Some surfaces become slippery when wet, which can be dangerous even on a mildly sloped roof. When this is the case, it's wise to provide employees with a personal fall arrest system that's tied off to a solid anchorage point on the roof. Extra care should be taken during periods of heat, when your employees may experience heat-related symptoms, or high winds, when they may lose their footing. Either a metal guardrail system and/or a horizontal lifeline system could (and should) be used, but if the weather seems questionable, it’s best to call off the rooftop work for the day.
Even with the best roof fall protection systems in place, there’s also the human factor to contend with. Since safety begins at the top of your organization, it's up to you to make sure your workers are following safety protocols. That begins with training on rooftop hazards, best practices, and the proper use of fall protection systems and it continues with refresher courses and accountability for every worker.
While OSHA regulations dictate the need for roof fall protection, it is up to you to determine which system, or combination of systems, is best for your application. A thorough inspection of the rooftop is a vital first step in making this important decision. This should be completed by an individual with experience and expertise in rooftop fall protection. The truth is, you can never be too careful - and as the old saying goes, it’s better to be safe than sorry. Bringing in a competent person, third-party safety expert, or trusted vendor can help you determine the right system for the job at hand.
When it comes to protecting workers on your industrial rooftop, there are many options available to you. If you're having a tough time deciding which systems and devices are right for you, contact BlueWater. Our roof fall protection experts will help guide you through the process of choosing the right systems for your application.