Taking the time to understand all relevant safety standards is a basic requirement for any industrial technician performing work on flat roofs. However, it's hard for every roofer, HVAC technician, and other employee under their watch to always know which regulatory standards always apply to them.
To help you choose highly effective and user-friendly rooftop fall protection systems and equipment for your teams, we have outlined the most important questions about maintaining flat roof safety with properly executed guard rail systems, access gates, hatch coverings, temporary roof safety railings and other essential rooftop fall protection equipment.
What's Considered a Flat Roof?
Flat roofs are sometimes called low-slope roofs, which OSHA 1926.500 defines as any roof with a slope that rises/lowers four inches or less for every 12 inches of horizontal distance (aka 4:12 or 4/12). Generally, if your roof contains regularly maintained equipment or other reasons to expect regular rooftop activity, it's necessary to secure the edges, dangerous equipment and any other potential fall hazard.
Most flat roof fall protection standards relate to edge safety. You can prevent fall hazards at the perimeter by investing in the highest-quality guard rail system available.
Guard rail systems are necessary when any work is performed within six feet of a flat roof's leading edge. The only exception is when safety managers opt for a combination of personal fall arrest systems (i.e., harnesses and lanyards), safety nets, and related safety devices. While regulations can make some distinction for types of work with lower protection standards, it’s safest to protect the edge of a flat roof if you can.
Safety managers must take additional measures for flat roof fall protection where access ladders and stairways are concerned:
External ladders require a temporary break in guardrails while causing workers to pass within six feet of the edge. The solution is a parallel railing enclosure that passes six feet away from the ladder, where workers access the enclosure through a gate tightly aligned with the surrounding guardrails.
Internal stairways should have guardrails wherever the stairway isn't already enclosed, along with gate access. In most cases, the gate must leave a 20-inch platform (past the swung-open gate) in front of the stairway. This both physically arrests falls and gives workers a moment to pause and scan for tripping hazards before descending.
Hatches don't always require covers, but when used, they must be strong enough to stop falls and remain firmly situated over the opening. A hatch railing/gate system is required, to give workers time to visually gauge the roof's condition and/or detect trip hazards. This also gives them time to adjust to changing light conditions when ascending or descending.
Internal openings are defined as any gap at least 18 inches wide that opens to a drop of 30 inches or more. These areas essentially require the same considerations as for leading edges.
Some flat roof fall risks relate less to height and more to tripping hazards. Changes in elevation by even several inches could be more dangerous when heavy equipment is involved. In fact, OSHA’s leading edge definition includes any "walking/working surface" and an "unprotected side and edge" not actively under construction (see OSHA 1926.500 once more).
Always double-check the OSHA or CCOHS regulations in your area to achieve total certainty before any work or decisions about fall protection measures. In addition to minimum standards, they often include guidelines for maximizing fall protection, even when not strictly required.
When exposed to the elements, workers are often subject to weather hazards including wind, lightning and even glare, as many flat roofing systems are designed for high reflectivity. Whether or not your location isn’t subject to regulations for such hazards, encourage your staff to use proper eyewear, footwear and other weather-appropriate attire. If necessary, consider postponing flat roof activity until more favorable conditions.
For works in progress, you still need to take robust fall protection measures – more, in fact. Temporary roof safety railings shouldn't be considered any less important than permanent fall protection devices. The best temporary guard rails are those built to withstand the same amount of force as their permanent equivalents while still being easy to install. Here, the key factor is versatility without sacrificing effectiveness.
Exceptions are rare, but usually include types of work that don't require standard fall protection systems. These are limited to "controlled access zones," where a flagged control line or similar components, plus a safety monitor, are considered adequate for restricting leading edge access. Essentially, limited types of masonry are the only work allowed in a controlled access zone, because the work usually needs to be performed on leading edge side of guardrails.
What about irregular railing heights or protrusions into the railing's pathway, such as ductwork, variations in parapets, and permanent rooftop equipment that extends past the edge? For such cases, there are semi-custom guard rail systems designed to accommodate corners, edge extensions and other abnormal obstacles. These uniquely shaped guard rails include:
Note that some flat roof materials, such as corrugated metal, also require specialty equipment or installation methods, where your choice in rooftop fall protection systems can make or break a roof's warranty coverage. Connecting with the most dependable manufacturer of fall protection safety equipment is the best way to ensure you're equipped to handle these situations and more.
From temporary roof safety railings and specialty guardrail designs to widescale permanent solutions, BlueWater® continually defines the standards for flat roof fall protection. The cost of a single fall far exceeds that of even the most cutting-edge rooftop fall protection systems, and workforces everywhere deserve nothing less than the most reliable fall protection equipment on the market.
If you have more questions about rooftop fall protection systems on low slope roofs, don't hesitate to contact BlueWater. Part of the Tractel family, we have extensive experience serving the workplace safety needs of industries throughout the world. Our experienced fall safety experts are standing by to help you maximize your fall protection methods and match you with the most reliable and compliant system.
