Metal Roofing Installation

Temporary edge protection compliant with AS/NZS 4994.1:2023 and AS/NZS 4994.2:2023 must be installed before any roof access. This typically includes guardrails minimum 900mm high around the full perimeter. Where roof pitch exceeds 26 degrees, infill panels are also required. Full body harnesses (AS/NZS 1891.1:2020) connected to certified single-point anchor devices to AS 5532:2025 (supersedes AS/NZS 5532:2013) are required when installing/dismantling edge protection or working beyond its protection, such as at ridge level.

All workers require a Construction Induction Card (White Card) and Working at Heights training (RIIWHS204E). Workers using fall arrest harnesses need harness user training including rescue procedures. Metal roof installers should have training in AS 1562.1 requirements and manufacturer specifications for the products being installed. For buildings constructed before 1990, Asbestos Awareness training is also required. Scaffolding licences are needed for erecting scaffold over 4m.

Metal roofing has several unique hazards compared to tile roofing: sharp edges causing severe cuts and lacerations, metal sheets acting as sails in wind, hot metal surfaces causing burns in summer (can exceed 70°C), extremely slippery surfaces when wet or dewy, and conductive sheets increasing electrical contact risk near powerlines. Metal roofing requires cut-resistant gloves, careful attention to weather conditions, and stricter approach distances to overhead powerlines.

Nibblers or power shears are the preferred cutting method as they produce a clean cut without damaging the coating or creating excessive heat. Aviation snips are suitable for flashings and small cuts. Angle grinders should only be used as a last resort as they damage protective coatings, create hot sparks (fire risk), produce metal swarf (eye injury risk), and are noisier. All cut edges should be deburred and touched up with matching paint to prevent corrosion.

Impact drivers are specifically NOT recommended for metal roofing by the Metal Construction Association (MCA). The hammering action over-torques fasteners, crushing the EPDM washer seal and causing leaks. Impact drivers can also chip paint coatings and break screw heads. Use a screw gun (Tek gun) with adjustable clutch and depth-sensing nosepiece at 2000-2500 RPM for proper fastener installation with controlled torque.

Work must cease when: roof surface is wet, frosty, dewy, or icy (metal becomes extremely slippery), sustained wind exceeds 25 km/h or gusts exceed 40 km/h (sheets become uncontrollable), temperature exceeds 35°C or during heat wave warnings (heat stress risk), during or immediately after rain. Wait for dew to dry (typically 1-2 hours after sunrise) before accessing metal roof surfaces.

AS 1562.1:2018 "Design and installation of sheet roof and wall cladding - Metal" is the primary standard for metal roofing. SA HB 39:2015 "Installation code for metal roof and wall cladding" provides complementary installation guidance. These standards cover minimum pitch requirements, fastening patterns, weatherproofing, thermal movement, and wind load requirements. Compliance with AS 1562.1 is mandatory for all new building projects under the National Construction Code.

The minimum pitch depends on the profile type. Corrugated iron typically requires at least 5 degrees, profiles like Trimdek need around 2-3 degrees, and standing seam systems can go as low as 1 degree with proper drainage design. Using the wrong pitch for a profile is a common mistake that leads to water ingress and non-compliance with AS 1562.1. Always check manufacturer specifications for the specific product being installed.

Victoria operates under the OHS Act 2004 and OHS Regulations 2017 (not WHS). WorkSafe Victoria has specific compliance codes for prevention of falls in housing and general construction. Victoria has "No Go Zones" for overhead powerlines - work within 3m requires electricity company permission, and work between 3m and 6.4m requires a trained Spotter. For scaffolding within No Go Zones, contact the distribution company for a permit as Spotters are not considered adequate.

In Queensland, work at heights above 2 metres (or 3 metres for housing construction) triggers SWMS requirements. However, for falls between 2m and 3m in housing construction, a risk assessment must still be conducted. Construction work over 2m is classified as high-risk construction work requiring a SWMS, which must be prepared before work starts, given to the principal contractor, and reviewed if conditions change.

In South Australia, high-risk construction work requiring a SWMS is currently triggered at falls greater than 3 metres - higher than most other Australian jurisdictions which use 2 metres. However, from 1 July 2026, SA will align with national model regulations and the threshold will change to 2 metres. Fall protection must still be provided for any work where there is a risk of falling, regardless of height, based on risk assessment.

Metal sheets are highly conductive and increase electrical risk. Maintain minimum approach distances: 3m for low voltage lines, 4m when handling conductive materials like long metal sheets. Use the Look Up and Live app to identify powerline locations. Never carry sheets toward powerlines - always parallel. If work is required within safe distances, contact the supply authority (Ausgrid, Energex, SA Power Networks, etc.) to request isolation or tiger tails. Never assume powerlines are de-energised.