# Job Hazard Analysis: Flat roof membrane (TPO/EPDM) URL: https://hardhatbinder.com/en/jha/roofing/flat-roof-membrane Last updated: 2026-10-23 Install single-ply TPO or EPDM membrane on a low-slope roof: material hoisting, warning lines and opening covers, insulation boards with screws and plates, bonding adhesive, hot-air welding or seam tape, edge metal and flashing, and cleanup. Includes work near unprotected roof edges, skylights, and rooftop HVAC units, often in sun and heat. > A general example for this task. Your JHA should reflect your crew, equipment and site — review it with a competent person before work starts. ## Steps, hazards and controls ### 1. Set up ladder access, the ground zone, and hoist materials to the roof. - **Fall from the extension ladder while climbing to the roof.** (High): Use a hoist, forklift, or conveyor for materials. Never carry rolls or boards up the ladder.; Set the ladder at a 4-to-1 angle, extend it at least 3 ft above the roof edge, and tie it off at the top.; Inspect the ladder before use. Tag out any ladder with cracked rails or broken rungs.; Keep 3 points of contact and face the ladder when climbing. - **Materials falling from the roof edge or hoist onto workers below.** (High): Barricade the hoisting area and drop zone with caution tape and signs.; Keep everyone out from under a hoisted load. Use a tag line to control it.; Wear a hard hat in the ground zone and at the hoist. - **Overloading the roof deck or rolls and boards blowing off in wind.** (Medium): Spread loads out and stage them over beams or near walls, not at mid-span.; Keep materials at least 6 ft back from the edge and weight down loose boards and rolls. ### 2. Install perimeter fall protection and cover skylights and roof openings. - **Fall from the unprotected roof edge while setting stanchions and warning line.** (High): Set the warning line at least 6 ft back from the edge, flagged every 6 ft, before other work starts.; Anyone between the warning line and the edge must be on a personal fall arrest system, behind guardrail, or watched by a designated safety monitor where allowed.; Use roof anchors rated for fall arrest and installed per the manufacturer. - **Fall through a skylight, roof hatch, or open deck hole.** (High): Cover every skylight and hole with a cover that holds at least twice the load on it. Screw it down so it cannot shift.; Mark each cover 'HOLE' or 'COVER' in bright paint.; Never sit, stand, or step on a skylight. ### 3. Prep the deck and install insulation boards with screws and plates. - **Back and shoulder strain from lifting insulation bundles and membrane rolls.** (Medium): Use a roof cart or dolly to move bundles and rolls.; Use two people for full membrane rolls. Lift with your legs, not your back. - **Trips over boards, fastener boxes, hoses, and cords.** (Medium): Keep walk paths clear. Run cords and hoses along the same route, away from the edge.; Pick up packaging and scraps as you go. - **Heat illness from sun, hot roof surface, and reflected heat off white TPO.** (High): Start early and schedule the heaviest work for the cooler hours.; Provide cool water on the roof and drink a cup every 15–20 minutes. Set up shade for breaks.; Ease new and returning workers into full shifts in the heat. Watch each other for dizziness, cramps, or confusion.; Stop roof work when lightning or high wind moves in and get off the roof. ### 4. Roll out membrane and apply bonding adhesive (fully adhered systems). - **Breathing solvent vapors from bonding adhesive, primer, or cleaner.** (Medium): Use low-VOC or water-based adhesive when the roof spec allows it.; Coordinate with the owner to shut down or cover rooftop air intakes near adhesive work.; Read the SDS before use and keep cans closed when not pouring.; Work upwind. Wear the respirator the SDS calls for if vapors build up. - **Fire from flammable solvent adhesive and its vapors.** (High): No smoking, open flames, or grinders near adhesive. Post 'No Smoking' signs.; Keep a charged fire extinguisher within 50 ft of the adhesive area.; Bring up only what you need for the day. Store extra cans closed and in the shade. - **Wind catching unrolled membrane and pulling a worker off balance toward the edge.** (Medium): Stop unrolling sheets when wind is strong enough to lift them.; Weight down or fasten each sheet right after it is positioned. Never stand between a loose sheet and the edge. - **Slips on wet adhesive, dew, or frost on the membrane.** (Medium): Plan the adhesive layout so you work toward a dry exit, not into a corner.; Wait for dew or frost to dry. Wear soft-soled, slip-resistant boots. ### 5. Weld TPO seams with the hot-air welder or prime and tape EPDM seams. - **Burns from the hot-air welder nozzle and fresh seams.** (Medium): Set hand welders on their stand when not in use. Never lay a hot welder on the membrane or insulation.; Let the nozzle cool before changing tips. Wear leather or heat-resistant gloves. - **Electric shock from damaged cords, wet connections, or the generator powering the robotic welder.** (High): Plug all welders and tools into GFCI protection.; Inspect cords and plugs every day. Remove any with cut jackets, missing ground pins, or taped splices.; Keep connections out of standing water. Use heavy-duty cords sized for the welder load. - **Fire from the hot nozzle near insulation facers, wood nailers, or adhesive vapors.** (Medium): Do not weld until adhesive solvents have flashed off.; Do a fire watch of welded areas before leaving the roof. ### 6. Install edge metal, termination bar, and flashings at the perimeter and curbs. - **Fall from the roof edge while working outside the warning line.** (High): Wear a full-body harness connected to a rated roof anchor with a lanyard or self-retracting lifeline short enough to keep you from going over.; Inspect the harness and lanyard before each use. Remove any with cuts, burns, or a deployed shock pack.; Have a rescue plan ready to reach a suspended worker within minutes. - **Cuts from sheet metal edges, snips, and hook knives.** (Medium): Use a self-retracting utility knife where possible and cut away from your body.; Wear cut-resistant gloves when handling and cutting metal. - **Flying fragments and noise from drills, pneumatic nailers, and metal cutting.** (Low): Keep tool guards in place and point nailers away from people.; Wear safety glasses at all times and hearing protection while using loud tools. ### 7. Clean up, lower debris, and take down fall protection. - **Debris thrown or blown off the roof hitting people below.** (High): Lower debris in bins with the hoist or use an enclosed chute to the dumpster. Never throw it off the roof.; Keep the ground zone barricaded until the roof is cleaned. - **Fire from adhesive-soaked rags and open cans left on the roof.** (Medium): Put solvent rags in a closed metal can and remove it from the roof daily.; Close and lower leftover adhesive and primer cans to proper storage. - **Fall from the edge when removing warning lines and opening covers.** (High): Remove edge protection last, while tied off to an anchor. Leave skylight covers in place until the owner says otherwise. ## Required PPE - Safety glasses — ANSI Z87.1 at all times; tinted lenses for glare off white TPO. - Hard hat — In the ground zone, at the hoist, and anywhere overhead work is going on. - Full-body harness with lanyard or self-retracting lifeline — Whenever working between the warning line and the roof edge. - Gloves — Cut-resistant for metal and knives; nitrile for adhesives and primers; leather or heat-resistant for welding. - Soft-soled, slip-resistant work boots — At all times on the roof; soft soles protect the membrane. - Hearing protection — Earplugs or muffs when running generators, nailers, or cutting metal. - Respirator — Organic vapor cartridge respirator only if the SDS or vapor levels require it; fit testing and medical clearance required first. - Sun protection clothing — Light-colored long sleeves and a hard hat sun shade in hot weather. ## Training - Fall protection training by a competent person: warning lines, harness use, anchors, and rescue. - Ladder safety training: setup, inspection, and climbing. - Hazard communication training on the adhesives, primers, and cleaners used, including how to read the SDS. - Heat illness training: signs, water, rest, shade, and what to do when someone gets sick. - Hands-on training on the hot-air welder per the manufacturer before running seams. - Fire extinguisher use for crew working with flammable adhesives. - Forklift or hoist operator training for anyone running material-lifting equipment. ## Emergency If someone falls: stop work, call 911, and give the exact site address. Do not move the injured person unless they are in danger; give first aid until help arrives. If a worker is hanging in a harness, start the rescue plan right away. Send someone to meet the ambulance at the street. ## Official sources - [29 CFR 1926.501](https://www.ecfr.gov/current/title-29/section-1926.501) — Duty to have fall protection - [29 CFR 1926.502](https://www.ecfr.gov/current/title-29/section-1926.502) — Fall protection systems criteria and practices - [29 CFR 1926.503](https://www.ecfr.gov/current/title-29/section-1926.503) — Fall protection training requirements - [29 CFR 1926.1053](https://www.ecfr.gov/current/title-29/section-1926.1053) — Ladders - [29 CFR 1926.59](https://www.ecfr.gov/current/title-29/section-1926.59) — Hazard communication - [29 CFR 1926.152](https://www.ecfr.gov/current/title-29/section-1926.152) — Flammable liquids - [29 CFR 1926.404](https://www.ecfr.gov/current/title-29/section-1926.404) — Wiring design and protection - [OSHA](https://www.osha.gov/heat-exposure) — Heat — hazard recognition and prevention --- Source: HardHat Binder, operated by Leadspire LLC. Templates to be reviewed by a competent person before use; not legal advice; not affiliated with OSHA.