Metal Roof Installation — Safe Work Method Statement
Safe Work Method Statement for the installation of metal roofing (Colorbond, corrugated iron, and metal deck) including material handling, roof access, sheet fixing, and edge protection management in compliance with Australian WHS legislation.
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Metal roof installation — including Colorbond, corrugated steel, and trapezoidal metal deck sheeting — is HRCW under Schedule 3 of the model WHS Regulations wherever workers are at risk of falling more than 2 metres. For virtually all residential and commercial roof installations in Australia, this threshold is met. The SWMS must be prepared before any worker accesses the roof and must address the full sequence of work from material delivery and hoisting through to ridge cap installation and final inspection.
There is no specific licence for metal roof installation itself, but workers performing the work as a trade are typically qualified roof plumbers (Certificate III in Roof Plumbing, CPC32920) for concealed fix systems, or carpenters for exposed fix systems. Where roof plumbing work is involved — including flashings, gutters, downpipes, and penetration sealing — a plumbing licence is required in most jurisdictions. The material must be installed to comply with AS 1562.1 (Design and installation of sheet roof and wall cladding — Metal) and manufacturer installation instructions, which often specify fastener types, spacings, and lap requirements.
Fall prevention is the critical control. Options include perimeter scaffolding with guardrails at eave height, proprietary edge protection systems rated to AS 4994, travel restraint systems using certified roof anchor points per AS/NZS 5532, or fall arrest systems. Travel restraint is preferred over fall arrest — the objective is to prevent a fall occurring rather than to arrest one. Roof anchor points must be installed by a competent person and rated for the intended loads. Any roof anchor used for work-positioning must have a current inspection record.
Sheet metal presents additional hazards beyond falls — freshly cut edges are razor-sharp and cut-resistant gloves rated to AS/NZS 2161.3 are essential. Metal sheets are large, sail in wind, and can become projectiles; wind speed limits for handling large panels must be specified in the SWMS. Thermal burns from hot metal in direct sunlight and UV exposure are summer-specific hazards requiring administrative controls.
This SWMS applies in all Australian states and territories. Western Australia adopted the model WHS laws in 2022. Victorian users must also comply with the OHS Regulations 2017.
Personal Protective Equipment
High Risk Construction Work Types
- •Work at height involving the risk of falling more than 2 metres
- •Work on or near energised electrical installations or services
Risk Assessment
1.Roof access and edge protection installation
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Fatal fall from roof edge or through unprotected openings | Catastrophic | Before commencing work on any roof above 2 metres, a fall prevention plan must be in place. Preferred controls in order: (1) install perimeter scaffolding with guardrails and toe-boards before accessing the roof; (2) install purpose-built edge protection guardrails (minimum 900 mm high) at all open edges; (3) use a fall-arrest system consisting of a certified full-body harness connected to an engineered anchor point via a shock-absorbing lanyard or SRL. Harness and lanyard must be inspected before each use. Lifelines and anchor points must be installed by a competent person and must have a minimum 15 kN rating. All roof openings (penetrations, skylights, voids) must be covered with a secured load-rated cover or guarded. No workers on roof without fall protection. | Moderate | Site Supervisor / Roofer |
| Contact with overhead powerlines during roof access or material lifting | Catastrophic | Before commencing, identify all overhead powerlines in the vicinity of the work area. Contact the distribution network service provider (DNSP) to confirm voltage and to arrange exclusion zone requirements. Maintain a minimum safe approach distance of 3 metres from powerlines (up to 66 kV). If work cannot be performed within safe distances, request the DNSP to de-energise, insulate, or relocate the line. Use a spotter when craning or lifting sheet material near powerlines. Do not use metal ladders near powerlines. | Moderate | Site Supervisor / DNSP |
2.Lifting and positioning metal roofing sheets
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Manual handling injury from awkward lifting of long metal sheets | High | Metal roofing sheets can be up to 12 metres long and have sharp edges. Use a crane or roof sheet elevator to lift packs of sheets to roof level — do not manually carry long sheets up ladders. Sheets must be lifted in bundles using manufacturer-approved lifting lugs and correctly rated slings. If manual carrying is required for short distances on the roof, assign two workers per sheet for lengths over 4 metres. Handle sheets parallel to their length to reduce wind loading. Wear cut-resistant Level 3 gloves when handling all sheet edges. Bend down or tape sharp cut edges immediately after cutting. | Moderate | Roofer / Dogger |
| Sheet blown off roof in windy conditions creating falling object hazard | High | Monitor weather conditions before and during roofing operations. Suspend lifting and placing of sheet metal when wind speeds exceed 40 km/h or as directed by the site supervisor. Secure all delivered sheets to the roof or to the ground immediately after delivery using straps or clamps — never leave unsecured sheets unattended on a roof. When sheets are laid but not yet fastened, use temporary holding clips or brick weights to prevent displacement. Establish and enforce a ground-level exclusion zone directly below the roofing work area. | Low | Roofer / Site Supervisor |
3.Cutting and trimming metal roofing sheets
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Laceration from sheet metal edges during cutting and handling | High | Use electric or pneumatic metal-cutting shears, nibbler, or a cold saw for cutting roofing sheets — never use an angle grinder with an abrasive disc on profiled roofing sheets due to heat and edge quality. Wear cut-resistant Level 3 gloves at all times when handling cut sheets. Immediately bend back or file sharp cut edges after cutting. Do not walk over cut sheet edges. Use a purpose-built sheet bending tool or brake to fold cut edges where required. Dispose of metal off-cut waste in a designated metal waste skip. | Low | Roofer |
4.Fastening and sealing roofing sheets
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Eye injury from fastener projectiles during screw gun use | Moderate | Wear safety glasses or goggles when using screw guns and roofing fastener guns at all times. Inspect screw bits and drive adaptors before use. Ensure fasteners are loaded correctly and the tool's nose guide is used for depth control. Do not operate roofing screw guns in the direction of other workers. Inspect all fastener heads after installation to confirm washers are correctly seated and the screw has not over-driven through the sheet. | Low | Roofer |
| Heat stress from sun exposure while working on reflective metal roofing | High | Metal roofing surfaces can reach 70–80°C in direct Australian summer sun. Schedule roof work for early morning (before 10:00 AM) and late afternoon (after 3:00 PM) during hot weather. Provide shaded rest areas at ground level for regular cool-down breaks every 45 minutes. Ensure workers maintain adequate hydration (at least 250 mL of water every 20 minutes in hot conditions). Wear long-sleeved UV-protective shirts and sunscreen. Monitor workers for signs of heat exhaustion. Issue a heat alert when temperature exceeds 35°C. | Moderate | Roofer / Site Supervisor |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.