Skylight Installation

The two most critical risks are falls from the roof edge and falls through the roof opening being created. Falls from height caused 24 worker fatalities nationally in 2024. Falls through skylights have resulted in fines of $40,000-$270,000 across Australian states. Additional significant risks include cutting near electrical wiring in ceiling cavities (solar cables remain live), working in extreme heat in roof spaces (60°C+), and handling heavy skylight units at height.

Full body harness (AS/NZS 1891.1:2020 + AS/NZS 1891.4:2025) connected to a rated anchor point (15kN minimum) is required at all times on the roof. Temporary edge protection (guardrails per AS/NZS 4994.1:2023 + AS/NZS 4994.2:2023) must be installed around the roof opening BEFORE cutting begins and maintained until the skylight is fully installed. Temporary hole covers (rated 75kg+, secured, marked "HOLE BELOW") must cover the opening whenever work pauses. Safety mesh (AS/NZS 4389:2015) should be installed under any fragile roof surfaces that workers must traverse.

NEVER step on or near existing skylights or polycarbonate roof panels. These are fragile surfaces that can fracture without warning under body weight, causing falls of 4-9 metres. Multiple prosecutions confirm this: a QLD worker fell 4.8m when polycarbonate broke, a WA worker fell 4.1m through an unguarded skylight, and an apprentice fell 9.2m through a skylight in 2015. All existing skylights must be marked with warning barriers maintaining a 2m exclusion perimeter.

Ceiling cavities contain electrical wiring for lights, outlets, and air conditioning. Critically, solar array cables remain LIVE even when the main switchboard is turned off. Older buildings (1970s-80s) may have deteriorated wiring insulation with exposed conductors. All electrical circuits in the work area must be isolated at the switchboard and verified with a voltage tester before cutting. A licensed electrician should be consulted if wiring condition is unknown or solar panels are present.

Yes, for any building constructed before 1990. These buildings are presumed to contain asbestos until proven otherwise. Asbestos may be present in roof cladding, ceiling materials, pipe insulation, and eave linings. The building's asbestos register must be checked before any roof or ceiling cavity work. If asbestos is identified or suspected, STOP WORK and engage a licensed asbestos assessor. Cutting through asbestos-containing materials generates carcinogenic fibres causing mesothelioma and lung cancer.

Ceiling cavities in Australian buildings can exceed 60°C in summer, with extreme conditions reaching 80°C or higher under dark metal roofs. Workers must not enter ceiling cavities above 40°C. Schedule cavity work for early morning (coolest temperatures). Limit continuous work to 30 minutes maximum, then exit for cool-down breaks. A second person must be stationed at the cavity access point at all times during entry, with verbal check-ins every 10 minutes.

AS/NZS 4285:2019 is the primary standard for skylights and roof windows, covering product performance, safety, installation requirements, and maintenance. AS 1562.1:2018 covers integration into metal roof cladding systems. AS 1288:2021 covers safety glazing requirements. For fall protection: AS/NZS 1891 (harness systems), AS/NZS 4994.1:2023 + AS/NZS 4994.2:2023 (edge protection), and AS/NZS 4389:2015 (safety mesh). All skylights must be installed per the manufacturer's instructions.

Physical cover or safety mesh in place before the cut completes, not after — that's the rule that prevents the prosecutions cited above. Practical sequence: deploy the safety mesh under the cut line before the saw starts; cut the opening; lift the offcut out the moment it separates; fit a temporary cover (plywood crawl board, rigid sheet, or factory-supplied opening protection) immediately. The Model Code of Practice on Managing the Risk of Falls in Housing Construction governs the broader fall plan: physical fall prevention before fall arrest, and the opening is a fall-through hazard the second the saw breaks through.

Australian regulators have issued significant fines: NSW $270,000 (worker fell 4m through skylight, 2022), WA $140,000 combined (worker fell 4.1m, 2021), QLD $60,000 combined (worker fell through skylight, 2022), VIC $40,000 (worker fractured spine, 2023). Courts consistently find that verbal instructions like "be careful" are not control measures. Physical barriers, harness systems, and edge protection are the minimum required.

Stop all roof work when surfaces are wet from rain, dew, or frost (extreme slip hazard on metal and tile roofs). Stop work in wind gusts exceeding 40 km/h (general roof work) or 30 km/h when handling large skylight panels (sail effect). Stop work if ambient temperature exceeds 38°C or if any worker shows heat stress symptoms. Check weather forecast before starting and monitor conditions throughout the day. Metal roof surfaces can exceed 70°C in direct sun.