Work-related accidents, in particular falls from roofs, can lead to severe injuries and even fatalities. Unfortunately, these incidents are common in the construction industry due to the inherent hazards associated with working at heights and inadequate safety measures. Many employers overlook or neglect safety regulations set by organizations like the Occupational Safety and Health Administration (OSHA), contributing to a concerning rise in fatal work injuries, with falls remaining the leading cause.
According to the latest data from the Census of Fatal Occupational Injuries by the Bureau of Labor Statistics, fatal work injuries in the United States increased by 8.9 percent in 2021, compared to the previous year, with falls remaining the leading cause of work-related deaths in construction.
Global safety cultures
In the United States, the responsibility for rooftop safety typically falls on the employer. However, due to infrequent job site visits, temporary and portable safety systems are often used. Conversely, in many other parts of the world, building owners are accountable for providing permanent fall protection for the building’s lifespan. Fortunately, there is a rising trend in the United States toward adopting permanent installations for improved safety.
The role of metal roofs
Metal roofs, recognized for their durability, sustainability, and versatility, present unique challenges in terms of safety. The surface of a metal roof can be quite slippery, posing a potential fall hazard, leading to serious injury for workers and liability for a business. Add adverse weather conditions like rain or snow and it increases the risk for any worker.
Rooftop access is essential for various tasks such as installing rooftop equipment or accessories such as HVAC, service walkways, solar and snow retention; conducting inspections; performing maintenance; or servicing equipment. Even experienced contractors and installers—who spend hours on metal rooftops—are not immune to accidents, underscoring the importance of reliable safety systems.
In addition to protecting the company and its employees, OSHA has established many requirements professionals must follow, so it is important to select a fall protection system that complies with its regulations.
Types of fall protection
According to OSHA, fall-arrest systems are crucial for preventing workers from free-falling more than six feet or contacting a lower level. In many cases, this requires guardrails, which include anchors as secure attachments for the system.
Guardrails
Guardrails, which act as passive barriers, are installed around the roof perimeter to prevent falls. When correctly installed, guardrails offer reliable protection and can save costs on frequent inspections. Guardrails used for fall protection must withstand a 90 kg (200 lb) force in any outward or downward direction within 50 mm (two in.) of the top rail extremity.
Walkways
Walkways are essential for larger commercial settings to ensure safe access to equipment and systems on the roof. For example, the Apple Park headquarters building in California features 9.7 km (six miles) of walkways in conjunction with a 7.4 MW rooftop solar array.
Anchor points
Anchor points serve as secure attachments for fall-arrest systems, limiting falling distances and providing a lifeline for workers, and can be a single secure attachment. In this instance, a body harness connects to the anchor, limiting the falling distance if a worker descends over the edge. In other situations, anchor points may incorporate one or multiple attachments and can also be paired with travel-restraint lanyards designed to prevent access to the area where a fall hazard occurs.
Another option providing greater mobility is a horizontal lifeline. This system includes multiple anchor points and a connection cable. The anchor points can be installed on a temporary or permanent basis and require some training for proper use.
For fall-arrest systems, OSHA requires the anchorage strength to either be “capable of supporting at least 5,000 lb per person attached or designed, installed and used under the supervision of a qualified person, as part of a complete personal fall-arrest system that maintains a safety factor of at least two.”
Fall-restraint (or travel-restraint) systems must “withstand 3,000 lb or twice the maximum expected force needed to keep the worker from accessing the fall-hazard area.”
Ensuring secure fall protection
Ensuring the efficacy of fall protection systems involves meticulous planning and engineering, considering factors such as load capacities, roof profiles and materials, and attachment solutions.
Given the weight loads involved, it is vital to ensure rooftop attachments can safely and reliably support the anchors, guardrails, or walkways. The only way to safeguard this reliability is to use attachments that are properly load tested, including a factor of safety. After that, engineer the fall protection system using the tested design load information. Each situation is unique, and the way an attachment performs on one type of roof is no guarantee it will perform the same way on another. For this reason, consult attachment load tests performed for the specific roof type and profile. In addition, these tests should be certified through an independent third party, to ensure the results are accurate. Once the exact values are determined, the system can be engineered to withstand the appropriate loads designated by OSHA.
When installing fall protection systems, it is imperative not to compromise the integrity of the metal roof. For a standing seam roof, opt for clamps specifically designed to fit the seam profile, produced in an audited facility with quality assurance standards for product consistency. Ensure the clamps are made from corrosion-resistant metals and are metallurgically compatible with the roof material. Additionally, it is critical to know the reputation of the manufacturer to ensure the system is verified, as well as engineered and tested for the loads it must withstand on the specific roof profile.
Non-penetrating clamps, relying on mechanical interlocks for superior holding strength, are preferable to avoid unnecessary roof penetrations. For permanent fall protection systems, opt for clamps that have the durability to last the life of the roof, backed by the manufacturer’s warranty.
Key takeaways
Safeguarding workers from falls on metal roofs demands a multifaceted approach, encompassing robust fall protection systems and adherence to stringent safety regulations.
OSHA enables various fall protection strategies, including anchor points, guardrails and walkways. When selecting rooftop clamps, prioritize those that are independently load-tested to the specific project, seam-profile specific, corrosion-resistant, non-penetrating to protect the roof, and from a reputable manufacturer with independent quality assurances.
By investing in tested and proven attachment solutions for fall protection, companies can ensure the safety and confidence of their workers, even in challenging environments.
Rob Haddock, president of the Metal Roof Advisory Group and CEO/founder of S-5!, brings more than five decades of industry expertise to the field of metal roofing. With a background spanning contracting, roof forensics,check for extra space and building envelope science, Haddock is a respected authority in the field. S-5! manufactures reliable clamp and bracket attachments for metal roofs. Trusted by premier fall protection companies globally, S-5!’s products undergo rigorous certified load testing and adhere strictly to international safety standards For more information, visit www.S-5.com.
