Job Hazard Analysis · Roofing

Job Hazard Analysis: Metal roof installation

Installing exposed-fastener or standing-seam metal roof panels, underlayment, trim, and ridge cap on a residential or light commercial roof. The work includes ladder access, hoisting long panels, cutting and fastening on the roof, and cleanup. Check the site before starting for overhead power lines, roof pitch, deck condition, wind, dew or frost, and heat.

Published 2026-10-23

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

Step	Hazard	Risk	Controls
1. Set up access and fall protection: place the extension ladder and install roof anchors before anyone works near an edge.	Fall from the ladder while climbing or stepping onto the roof	High	Set the extension ladder on firm, level ground at a 4-to-1 angle and extend it at least 3 ft above the roof edge. Tie off the top of the ladder to the building before climbing. Keep 3 points of contact. Carry tools in a tool belt or hoist them with a rope, not in your hands. Inspect the ladder before use. Tag and remove any ladder with cracked rails or bent rungs.
	Fall from the roof edge while installing anchors	High	Install the first anchor from the ladder or from a spot well back from the edge, and tie off right away. Fasten roof anchors into rafters or trusses per the manufacturer, not into sheathing alone. Use a full-body harness and a rope grab with a shock-absorbing lanyard, adjusted so you cannot reach the edge.
2. Hoist and stage metal panels and trim on the roof.	Contact with overhead power lines while moving long metal panels	High	Locate power lines before hoisting. Keep panels, ladders, and equipment at least 10 ft away, or have the utility de-energize or cover the lines. Assign a spotter to watch the panel ends during every lift.
	Wind catching a panel and pulling a worker off balance or off the roof	High	Stop handling panels when wind gusts make them hard to control. The foreman makes the call. Use a panel lift, telehandler, or roof conveyor for long panels when available. Carry long panels with 2 or more workers, panel on edge, and stay tied off.
	Panels sliding off the roof or falling on workers below	Medium	Stage bundles on roof jacks or a flat area and strap or screw them down temporarily. Barricade or flag the drop zone below and keep people out.
3. Install underlayment, drip edge, and eave trim.	Slipping on synthetic underlayment, dew, or frost on a pitched roof	High	Wait until dew, frost, and rain have dried before going on the roof. Install toe boards or roof jacks with planks on steep roofs. Stay tied off at all times. Wear soft-soled, slip-resistant roofing shoes.
3. Install underlayment, drip edge, and eave trim.	Falling through skylights or roof openings	High	Cover skylights and openings with secured, marked covers that can hold twice the expected load, or guard them with railing.
4. Cut panels and trim to length and shape.	Cuts from sharp panel edges and metal slivers	Medium	Cut on the ground at a sawhorse table when possible instead of on the roof. Use electric shears or a nibbler instead of an abrasive saw. They make cleaner edges and no hot sparks. Wear cut-resistant gloves and long sleeves when handling panels.
	Flying metal chips and noise from power cutting tools	Medium	Keep guards in place on all saws. Do not use a tool with a missing or broken guard. Keep other workers out of the cutting area. Wear safety glasses and a face shield when cutting, plus earplugs or earmuffs.
	Electric shock from damaged cords or tools	Medium	Plug all tools into GFCI protection. Inspect cords before each shift. Remove cords with cut jackets or missing ground pins.
5. Fasten panels with a screw gun or seam them with a seamer, working across the roof.	Fall from the roof edge or rake while fastening	High	Move your anchor and rope grab as you work so the lifeline stays nearly overhead and you cannot swing far. On low-slope roofs, use a warning line at least 6 ft from the edge with a safety monitor, or guardrails. Never unhook to reach a spot. Re-anchor instead.
	Slipping on smooth, painted metal panels	High	Walk on the panel flat over the purlins or deck, not on the ribs. Do not step on loose or unfastened panels. Remove plastic film and wipe off oil or dust before walking on panels.
	Heat stress and burns from hot metal in sun	High	Start early and schedule heavy work for cooler hours. Take shade and water breaks at least every hour in hot weather. Bring new and returning workers up to full workload over several days. Watch each other for dizziness, confusion, or stopped sweating. Wear gloves and knee pads on hot metal.
	Lightning strike while standing on a metal roof	High	Check the forecast each morning. When you hear thunder, get off the roof and into a building or vehicle. Wait 30 minutes after the last thunder before going back up.
6. Install ridge cap, rake trim, and flashing at walls and penetrations.	Fall while working at the ridge and rake edges	High	Set the anchor near the ridge so the lifeline covers the rake work. Keep your lanyard adjusted short. Use a second worker to hand up trim pieces instead of carrying them up the ladder.
	Tools and screws dropping on people below	Medium	Keep the drop zone below barricaded. Use tool lanyards and keep screws in a pouch or bucket. Wear hard hats on the ground near the building.
7. Clean up metal scraps and shavings, lower tools, and remove fall protection last.	Slipping on metal shavings and cuts from scrap	Medium	Sweep shavings off panels with a soft brush throughout the day. They cause slips and rust stains. Put scrap in a dumpster or scrap bin right away. Do not leave pieces on the roof or ground. Wear cut-resistant gloves when handling scrap.
	Fall while removing anchors and climbing down	High	Stay tied off until you are at the ladder. Remove the last anchor from the ladder or a safe spot. Lower tools with a rope. Do not throw anything off the roof.

Required PPE

Full-body harness with shock-absorbing lanyard and rope grab — At all times on the roof. Inspect before each use.
ANSI Z87.1 safety glasses — At all times. Add a face shield when cutting metal.
Cut-resistant gloves — When handling panels, trim, and scrap.
Soft-soled, slip-resistant roofing shoes — On the roof. Soles must be clean and dry.
Hard hat — On the ground near the building and in the drop zone.
Earplugs or earmuffs — When cutting with saws, nibblers, or shears.
Long sleeves and knee pads — To protect against sharp edges and hot metal.

Training

Fall protection training by a competent person: harness fit, anchors, rope grabs, and rescue.
Ladder safety training: setup, tie-off, and inspection.
Safe use of power shears, nibblers, saws, and screw guns, including guards and GFCI.
Heat illness signs, water-rest-shade plan, and lightning procedures.
Overhead power line awareness and safe clearance distances.
Forklift or telehandler operator training for anyone running lifting equipment.

Emergency

If someone falls or is hanging in a harness: stop work, call 911, and give the exact site address. Rescue a suspended worker within minutes using the planned rescue method. Do not move a fallen worker unless they are in danger; give first aid until help arrives.

Official sources

29 CFR 1926.501 — Duty to have fall protection
29 CFR 1926.502 — Fall protection systems criteria and practices
29 CFR 1926.503 — Fall protection training requirements
29 CFR 1926.1053 — Ladders
29 CFR 1926.302 — Power-operated hand tools
29 CFR 1926.102 — Eye and face protection
29 CFR 1926.416 — Electrical — general requirements
OSHA — Heat — hazard recognition and prevention

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General information, not legal advice. Templates and examples should be reviewed by a competent person before use. HardHat Binder is not affiliated with or endorsed by OSHA.