Flat roofing method statement example: torch-on warm flat roof, garage extension

HSE five steps · CDM 2015

You write this: Strip the existing failed flat roof covering and install a new warm flat roof using torch-applied (hot works) reinforced bitumen membrane to a domestic single-storey garage/kitchen extension, working from an independent scaffold with edge protection.
You get this: Northgate Flat Roofing Ltd will strip the existing failed flat roof covering and install a new warm flat roof using torch-applied (hot works) reinforced bitumen membrane to a domestic single-storey garage/kitchen extension at 18 Willow Grove, Sheffield S11 7B** (project ref NFR-3391). The work is done from an independent scaffold with edge protection. The client is Mr & Mrs Ashford. Two operatives will do the work over 3 days from Tue 23 Jun 2026 under R. Whitfield, Site Supervisor. The house stays occupied, so the occupants are kept clear of the work area, a hot works permit is issued each day and a fire watch is kept after every flame is out. Items to confirm: the age of the building and whether the client's asbestos register or management survey covers the extension roof, the type and condition of the existing roof deck, any rooflights, flues, vents or cables through the roof, how materials will be lifted to roof level, where the LPG cylinders will be kept, the route from the vehicle to the scaffold, the WC arrangement, and whether any fixings go into masonry or brick upstands were not given. R. Whitfield will confirm these with Mr & Mrs Ashford and the scaffold contractor on the pre-start walk on the morning of Tue 23 Jun 2026, before any work starts. The full postcode (given as S11 7B**) will also be confirmed so it can be passed to the emergency services. If fixings into masonry are needed, this RAMS must be updated with respirable crystalline silica dust controls before that task starts.

Generated for an example job to show the format. Make your own site-specific version and have a competent person review it.

Document details
Contractor	Northgate Flat Roofing Ltd
Author	R. Whitfield, Site Supervisor (CSCS Gold Card, NVQ Level 3 Roofing Occupations)
Client / Principal Contractor	Mr & Mrs Ashford
Site	18 Willow Grove, Sheffield S11 7B**
Project reference	NFR-3391
Start / duration	Tue 23 Jun 2026 / 3 days

1. Scope of works

Northgate Flat Roofing Ltd will strip the existing failed flat roof covering and install a new warm flat roof using torch-applied (hot works) reinforced bitumen membrane to a domestic single-storey garage/kitchen extension at 18 Willow Grove, Sheffield S11 7B** (project ref NFR-3391). The work is done from an independent scaffold with edge protection. The client is Mr & Mrs Ashford. Two operatives will do the work over 3 days from Tue 23 Jun 2026 under R. Whitfield, Site Supervisor. The house stays occupied, so the occupants are kept clear of the work area, a hot works permit is issued each day and a fire watch is kept after every flame is out. Items to confirm: the age of the building and whether the client's asbestos register or management survey covers the extension roof, the type and condition of the existing roof deck, any rooflights, flues, vents or cables through the roof, how materials will be lifted to roof level, where the LPG cylinders will be kept, the route from the vehicle to the scaffold, the WC arrangement, and whether any fixings go into masonry or brick upstands were not given. R. Whitfield will confirm these with Mr & Mrs Ashford and the scaffold contractor on the pre-start walk on the morning of Tue 23 Jun 2026, before any work starts. The full postcode (given as S11 7B**) will also be confirmed so it can be passed to the emergency services. If fixings into masonry are needed, this RAMS must be updated with respirable crystalline silica dust controls before that task starts.

2. Sequence of works

Method statement, safe system of work

Before the start date, R. Whitfield checks the weather forecast for all 3 days. Torching does not go ahead in rain or in wind strong enough to blow the flame or lift sheets. The tasks are re-planned if the forecast is poor.
On arrival, hold a pre-start walk with Mr & Mrs Ashford. Agree the work zone, the route from the vehicle to the scaffold, the exclusion zone in the garden, where the LPG cylinders will be kept, the WC arrangement and the items to confirm listed in the scope. Record the answers.
Asbestos check before any stripping: ask Mr & Mrs Ashford for the asbestos register or management survey covering the garage/kitchen extension roof and confirm the building age. If the register does not cover the roof area, or the building is pre-2000 or its age is unknown and no survey is available, a refurbishment and demolition survey of that area is needed first (Control of Asbestos Regulations 2012, Regulation 5). Do not start stripping until this is confirmed.
Stop-work rule for the whole job: if any suspect material is found while stripping, stop work, keep everyone away from the area, tell R. Whitfield and Mr & Mrs Ashford, and do not carry on until it has been checked and cleared.
Brief both operatives on this RAMS and have them sign on. Cover the scaffold, the hot works permit, the fire watch, the LPG arrangements, the emergency plan and the stop-work rules.
Check the scaffold handover certificate and tag. Walk the scaffold and check the double guardrails, toe boards, ladder bay and gaps at eaves level. Do not alter the scaffold. If anything is missing or damaged, stop and call the scaffold contractor.
Set up the exclusion zone on the ground below the scaffold and around the work area with barriers and signs. Ask the occupants to keep children and pets away from the garden work area for the 3 days. Set up a debris chute or covered, closed skip so nothing is thrown down.
Ask the occupants to keep windows, doors and vents near the extension closed during torching, and to tell us at once if they smell smoke. Check that the smoke alarms in the kitchen and adjoining rooms are working. Tell the occupants where the fire assembly point is.
Load out materials to roof level using the agreed lifting method, a few items at a time. Keep stacks small, spread over the scaffold or deck and away from edges and from the torch. Keep PIR boards and membrane rolls apart from the LPG.
Walk the existing roof carefully. Identify rooflights, flues, vents, outlets, cables and any weak or soft areas of deck. Mark and guard any fragile areas. Use boards to spread load where the deck is suspect.
Strip the existing failed flat roof covering in small sections that can be made weathertight the same day. Cut and lift by hand, bag or bundle the waste and lower it down the chute or in bags. Do not throw anything from the roof. Keep the deck covered at the end of each day so rain cannot get into the occupied building.
Inspect the exposed deck. Report any rot, damage or loose areas to R. Whitfield. Repair or replace deck only as agreed with Mr & Mrs Ashford before carrying on.
Lay the vapour control layer, then lay the PIR insulation boards over it. Cut boards with the PIR cutter in the open air, downwind of the operatives, and bag the offcuts. Fix as the system supplier requires.
Apply bitumen primer where needed, in the open air and in small amounts. Keep lids on. No flame goes anywhere near primer until it is fully dry as the manufacturer states.
Before any flame is lit each day, the permit is completed and signed, two extinguishers are at roof level, and the fire watch person is in place. Check the cylinder, regulator, hose and flashback arrestor and leak test the joints with a proper leak detection solution.
Torch on the underlay, then the cap sheet. One operative works the torch and one acts as fire watch and assist. Keep the flame on the roll and substrate only. Keep it away from eaves timbers, soffits, fascias, the edge of the roof, the kitchen vents, rooflights, flues and the neighbour's boundary. Use hot air or manufacturer-approved methods at details close to timber if the system allows it.
Finish details, upstands, flashings and outlets. Check the laps and edges visually. Do not leave any flame unattended or any hose live while the torch is put down. Close the cylinder valve before any break and at the end of each day.
After the last flame each day, keep the fire watch for at least 60 minutes, or longer if the permit says so. Check the eaves, upstands, edges and the roof space or ceiling below for any heat, smoke or smell. Sign off the permit only when this is done.
At the end of each day, remove the cylinders from the roof and store them upright, secured, outside and away from the building, drains and ignition sources. Cover any open area of deck. Clear the roof of loose items, tools and offcuts. Tidy the work area and the access route.
On the last day, carry out a final check of the finished roof, outlets and details. Remove all waste and materials. Remove barriers and signs. Check with Mr & Mrs Ashford that the area is left tidy. The scaffold is dismantled by others.

3. Risk assessment

Built on the HSE five steps, MHSWR 1999 regulation 3 and the hierarchy of control.

Fall from height from the roof, the roof edge, the scaffold lift or the ladder bay while stripping and torching
Medium
Who / how
The two operatives, who could suffer fatal or disabling injuries from a fall
Existing controls
Independent scaffold with double guardrails at eaves level, ladder access bay and scaffold handover certificate. Work at Height Regulations 2005 apply.
L×S
3×5=15
Additional controls
Avoid working at height where possible: assemble and cut materials at ground level. Check the handover certificate and that the scaffold has been inspected within the last 7 days and after any bad weather (Work at Height Regulations 2005). Keep edge protection and toe boards in place at all times and do not remove or alter them. Keep the working platform clear of tools, hoses and stacked materials. Use the ladder bay only for access and keep the access clear. No work in high winds or wet, slippery conditions. Brief both operatives on edge protection and the rescue plan. Sound footwear with good grip is the last line of defence.
Fall through a fragile, weak or failed roof deck or an existing rooflight; overloading the deck with stacked materials
Medium
Who / how
The two operatives, from falls through the roof into the garage/kitchen extension
Existing controls
Competent operatives experienced in flat roof stripping. Work at Height Regulations 2005 apply.
L×S
3×5=15
Additional controls
Check the deck condition from the scaffold before stepping onto the roof and test as the covering is lifted. Mark and guard any rooflights, rot or soft areas. Use crawl boards or spreader boards where the deck is doubtful. Limit stacked materials to small piles spread over the supports and keep them away from weak areas. Strip in small sections, never the whole roof. Stop and tell R. Whitfield if the deck is unsound. Do not carry on until it has been repaired or made safe.
Hot works with a propane torch: fire from the flame, heat or sparks reaching roof timbers, eaves, soffits, fascias, cavities, PIR boards or the kitchen/garage below
Medium
Who / how
Operatives, Mr & Mrs Ashford, any household members, neighbours and the building itself, with risk of fatal burns and smoke inhalation
Existing controls
Hot works permit issued daily. Operatives trained in LPG and hot works.
L×S
3×5=15
Additional controls
Consider whether a cold-applied, self-adhesive or mechanically fixed method is suitable for details near timber; torch only where needed and only as the system manufacturer allows. Follow NFRC Safe2Torch guidance. Clear combustibles from the roof and the area around it. Shield or protect timber edges, eaves and vents with non-combustible shielding. Keep the flame on the roll and substrate only and away from the roof edge and timber. Do not torch while the primer is still wet. The permit is checked and signed before any flame is lit each day. Two charged extinguishers at roof level. A second person acts as fire watch whenever the torch is lit. A fire watch of at least 60 minutes (or longer if the permit says so) after the last flame, with checks at the eaves, upstands and ceiling below. No flame in wind that blows it at timber or at the edge. Flame-retardant or natural-fibre clothing is the last line of defence.
LPG (propane) cylinders, regulators and hoses: gas leak, hose damage, flashback, cylinder falling or overheating
Medium
Who / how
Operatives, occupants and neighbours, with risk of fire, explosion and serious burns
Existing controls
Operatives LPG-trained. Propane torch and hoses in use. Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) apply to the flammable gas.
L×S
2×5=10
Additional controls
Take only the cylinders needed for the day. Keep the cylinders upright and secured at ground level or on the scaffold boards, never left on the roof overnight and away from the building, drains and ignition sources. Use equipment that is in date, with regulator, hose clips and a flashback arrestor. Check hoses for cuts and wear before each use and replace damaged ones. Leak test every joint with a proper leak detection solution after connecting. Route hoses clear of walkways and edges and secure them. Close the cylinder valve at every break and at the end of the day. Brief both operatives on what to do in a leak or fire. Heat-resistant gloves are the last line of defence.
Burns from the torch flame, hot membrane, hot bitumen and heated surfaces
Medium
Who / how
Both operatives, with risk of painful burns that need hospital treatment
Existing controls
Trained operatives, one working the torch and one assisting.
L×S
4×3=12
Additional controls
Plan the torch work so the operative works backwards away from the heated area and does not kneel or lean on hot membrane. Set down the torch only in a safe place with the valve closed. Allow the membrane and tools to cool before handling. Keep a burns kit and a water supply to hand and brief both operatives on burns first aid. Rotate the torch task to limit tiredness. Heat-resistant gloves to EN 407, long-sleeved clothing and safety boots are the last line of defence.
Occupied site: the household of Mr & Mrs Ashford, their family, pets and visitors in the house and garden next to the work. Risk of smoke and fume entering the kitchen, falling objects, rain water coming through the opened roof, and unauthorised access to the scaffold.
Low
Who / how
Mr & Mrs Ashford, any children, pets and visitors, who could suffer smoke inhalation, burns, falling debris or slips on a wet floor
Existing controls
Client WC by arrangement. Scaffold and edge protection in place. Daily hot works permit.
L×S
3×4=12
Additional controls
Agree the work zone and the exclusion zone on the pre-start walk and keep the occupants out of the garden work area and off the scaffold. Barrier and sign the exclusion zone. Ask the occupants to keep windows, doors and vents near the work closed and to tell us at once if they smell smoke. Check that smoke alarms are working. Strip only the area that can be made watertight the same day and cover the deck at the end of each day. Keep tools, materials and LPG cylinders locked away or out of reach when we are off the site. Brief the occupants on the fire assembly point. Keep the occupants informed of the daily plan.
Public and other trades nearby: passers-by on the pavement or neighbouring gardens, the scaffold contractor and any other trades at the property, with dropped tools, debris or heat reaching them
Low
Who / how
Neighbours, passers-by, children, the scaffolders and any other trades, who could be hit by falling items or be affected by sparks, heat or fumes
Existing controls
Scaffold with edge protection and toe boards. Exclusion zone planned.
L×S
3×4=12
Additional controls
Keep an exclusion zone around the scaffold on the ground, with barriers and signs, and keep the public out. Use a debris chute or covered skip so nothing is thrown. Consider the side of the roof next to the neighbour's boundary and keep the flame and heat shielded away from it. Tell the other trades the times of hot works and keep them clear of the work area. No one works under the roof while stripping or torching is going on. Keep the access route clear. If a member of the public enters the zone, stop work until they have left.
Falling objects and debris while stripping: old felt, insulation, tools, fixings and offcuts dropped from the roof
Low
Who / how
People on the ground below, operatives on the scaffold and anyone in the garden, with risk of head and other injuries
Existing controls
Scaffold toe boards. Exclusion zone planned.
L×S
3×4=12
Additional controls
Bag or bundle the waste on the roof and lower it by chute or in bags, never throw. Keep tools in a tool belt or tethered and keep small items off the roof edge. Do not stack materials against the guardrails. Clear the area beneath the roof before work starts and keep it clear with barriers. A hard hat (EN 397) is the last line of defence for anyone entering the zone.
Disturbing unidentified asbestos-containing materials when stripping the existing roof covering and deck, in a building whose age or survey status has not yet been confirmed
Medium
Who / how
Operatives, occupants and neighbours, with risk of long-term lung disease from breathing in fibres
Existing controls
Asbestos is not flagged for this job. The building age and survey status are to be confirmed on the pre-start walk.
L×S
2×5=10
Additional controls
Before work starts, check the client's asbestos register or management survey for the roof area, and confirm the building age. If the register does not cover the area, or the building is pre-2000 or its age is not known, a refurbishment and demolition survey of the area is needed first (Control of Asbestos Regulations 2012, Regulation 5). Stop-work rule: if any suspect material is found, stop, keep people away and report to R. Whitfield and the client before carrying on. Do not break, drill or sweep suspect material. This is a check to be made, not a finding.
Fumes and dust: bitumen fume from the torch, primer vapour, PIR cutting dust and dust from stripping the old covering
Low
Who / how
Operatives and anyone downwind, including occupants through open windows and vents, with irritation of eyes, nose, throat and skin
Existing controls
Work is carried out in the open air. COSHH assessments are in this RAMS.
L×S
4×3=12
Additional controls
Follow the Control of Substances Hazardous to Health Regulations (COSHH) 2002. Where the system manufacturer allows, use a low-solvent or water-based primer. Torch only as much as needed and avoid overheating the membrane. Work upwind and keep others downwind. Cut PIR in the open air and clean up with a vacuum, never dry sweeping. Ask occupants to keep windows near the work closed. Take breaks away from the torch. Gloves, eye protection and the RPE the Safety Data Sheet specifies are the last line of defence.
Manual handling of membrane rolls, PIR boards, tins of primer, cylinders and waste bags to and from roof level
Medium
Who / how
Both operatives, with risk of back and shoulder injury or dropping loads
Existing controls
Two operatives. Manual Handling Operations Regulations 1992 apply.
L×S
4×3=12
Additional controls
Avoid carrying by hand up the ladder: use a hoist or other agreed lifting method, and if a hoist or gin wheel is used it must be in date for thorough examination and used to its limit (Lifting Operations and Lifting Equipment Regulations 1998). Order materials in manageable sizes and deliver as close as possible to the scaffold. Two-person lifts for rolls and large boards. Limit loads and take rest breaks. Keep the route clear. Gloves and safety boots are the last line of defence.
Weather: heat and UV in June, rain and wind, wet and slippery membrane and deck
Low
Who / how
Both operatives, with risk of heat illness, slips on the roof and wind blowing the flame or sheets
Existing controls
Forecast checked. Work stopped in rain.
L×S
3×3=9
Additional controls
Check the forecast each morning and agree a stop point. No torching in rain or wind that moves the flame or lifts the sheets. Start early in hot weather, take breaks in the shade and keep drinking water to hand. Cover the roof before rain. Do not walk on wet membrane. Sun protection, sun cream and sound footwear with good grip are the last line of defence.
Cuts from hook blades, knives, the PIR cutter and old fixings or nails when stripping
Low
Who / how
Both operatives, from cuts to hands and legs
Existing controls
Competent operatives using hand tools.
L×S
4×2=8
Additional controls
Use retractable or guarded blades and cut away from the body. Replace blunt blades and dispose of used ones in a sharps container. Remove or flatten old fixings as the covering is lifted. Keep the work area tidy. Cut-resistant gloves to EN 388 are the last line of defence.
Slips, trips and falls on the same level: hoses, tools, offcuts, loose membrane and uneven upstands on the roof and scaffold
Low
Who / how
Both operatives, from sprains, bruises and, near an edge, a fall
Existing controls
Scaffold boards, toe boards and guardrails. Competent operatives.
L×S
4×3=12
Additional controls
Plan the layout so hoses and cables run along the edges and away from walkways, and keep the roof clear of offcuts and waste. Bag waste as it is made. Keep the ladder bay and the walkways clear. Keep the stairs and access route to the vehicle clear. Safety boots with good grip are the last line of defence.
Existing roof penetrations and services: flues, vents, extractor outlets, soil pipes, rainwater outlets and any electrical cables or fittings at roof level
Low
Who / how
Operatives and occupants, from fire, fume entry, blocked flues or electric shock if a cable is damaged
Existing controls
Roof walked and checked before stripping.
L×S
2×4=8
Additional controls
Identify and mark every penetration and any cable on the pre-start walk. Ask Mr & Mrs Ashford to turn off or avoid using any appliance that vents through the roof during torching. Do not cut into or strip around any cable or flue until it has been identified and made safe (Electricity at Work Regulations 1989). Protect outlets and vents from the flame. Protect rainwater outlets from debris. Report any damage to the client.

Risk assessment: hazards, who may be harmed, controls and residual risk
Hazard	Who / how	Existing controls	L×S	Additional controls	Residual
Fall from height from the roof, the roof edge, the scaffold lift or the ladder bay while stripping and torching	The two operatives, who could suffer fatal or disabling injuries from a fall	Independent scaffold with double guardrails at eaves level, ladder access bay and scaffold handover certificate. Work at Height Regulations 2005 apply.	3×5=15	Avoid working at height where possible: assemble and cut materials at ground level. Check the handover certificate and that the scaffold has been inspected within the last 7 days and after any bad weather (Work at Height Regulations 2005). Keep edge protection and toe boards in place at all times and do not remove or alter them. Keep the working platform clear of tools, hoses and stacked materials. Use the ladder bay only for access and keep the access clear. No work in high winds or wet, slippery conditions. Brief both operatives on edge protection and the rescue plan. Sound footwear with good grip is the last line of defence.	Medium
Fall through a fragile, weak or failed roof deck or an existing rooflight; overloading the deck with stacked materials	The two operatives, from falls through the roof into the garage/kitchen extension	Competent operatives experienced in flat roof stripping. Work at Height Regulations 2005 apply.	3×5=15	Check the deck condition from the scaffold before stepping onto the roof and test as the covering is lifted. Mark and guard any rooflights, rot or soft areas. Use crawl boards or spreader boards where the deck is doubtful. Limit stacked materials to small piles spread over the supports and keep them away from weak areas. Strip in small sections, never the whole roof. Stop and tell R. Whitfield if the deck is unsound. Do not carry on until it has been repaired or made safe.	Medium
Hot works with a propane torch: fire from the flame, heat or sparks reaching roof timbers, eaves, soffits, fascias, cavities, PIR boards or the kitchen/garage below	Operatives, Mr & Mrs Ashford, any household members, neighbours and the building itself, with risk of fatal burns and smoke inhalation	Hot works permit issued daily. Operatives trained in LPG and hot works.	3×5=15	Consider whether a cold-applied, self-adhesive or mechanically fixed method is suitable for details near timber; torch only where needed and only as the system manufacturer allows. Follow NFRC Safe2Torch guidance. Clear combustibles from the roof and the area around it. Shield or protect timber edges, eaves and vents with non-combustible shielding. Keep the flame on the roll and substrate only and away from the roof edge and timber. Do not torch while the primer is still wet. The permit is checked and signed before any flame is lit each day. Two charged extinguishers at roof level. A second person acts as fire watch whenever the torch is lit. A fire watch of at least 60 minutes (or longer if the permit says so) after the last flame, with checks at the eaves, upstands and ceiling below. No flame in wind that blows it at timber or at the edge. Flame-retardant or natural-fibre clothing is the last line of defence.	Medium
LPG (propane) cylinders, regulators and hoses: gas leak, hose damage, flashback, cylinder falling or overheating	Operatives, occupants and neighbours, with risk of fire, explosion and serious burns	Operatives LPG-trained. Propane torch and hoses in use. Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) apply to the flammable gas.	2×5=10	Take only the cylinders needed for the day. Keep the cylinders upright and secured at ground level or on the scaffold boards, never left on the roof overnight and away from the building, drains and ignition sources. Use equipment that is in date, with regulator, hose clips and a flashback arrestor. Check hoses for cuts and wear before each use and replace damaged ones. Leak test every joint with a proper leak detection solution after connecting. Route hoses clear of walkways and edges and secure them. Close the cylinder valve at every break and at the end of the day. Brief both operatives on what to do in a leak or fire. Heat-resistant gloves are the last line of defence.	Medium
Burns from the torch flame, hot membrane, hot bitumen and heated surfaces	Both operatives, with risk of painful burns that need hospital treatment	Trained operatives, one working the torch and one assisting.	4×3=12	Plan the torch work so the operative works backwards away from the heated area and does not kneel or lean on hot membrane. Set down the torch only in a safe place with the valve closed. Allow the membrane and tools to cool before handling. Keep a burns kit and a water supply to hand and brief both operatives on burns first aid. Rotate the torch task to limit tiredness. Heat-resistant gloves to EN 407, long-sleeved clothing and safety boots are the last line of defence.	Medium
Occupied site: the household of Mr & Mrs Ashford, their family, pets and visitors in the house and garden next to the work. Risk of smoke and fume entering the kitchen, falling objects, rain water coming through the opened roof, and unauthorised access to the scaffold.	Mr & Mrs Ashford, any children, pets and visitors, who could suffer smoke inhalation, burns, falling debris or slips on a wet floor	Client WC by arrangement. Scaffold and edge protection in place. Daily hot works permit.	3×4=12	Agree the work zone and the exclusion zone on the pre-start walk and keep the occupants out of the garden work area and off the scaffold. Barrier and sign the exclusion zone. Ask the occupants to keep windows, doors and vents near the work closed and to tell us at once if they smell smoke. Check that smoke alarms are working. Strip only the area that can be made watertight the same day and cover the deck at the end of each day. Keep tools, materials and LPG cylinders locked away or out of reach when we are off the site. Brief the occupants on the fire assembly point. Keep the occupants informed of the daily plan.	Low
Public and other trades nearby: passers-by on the pavement or neighbouring gardens, the scaffold contractor and any other trades at the property, with dropped tools, debris or heat reaching them	Neighbours, passers-by, children, the scaffolders and any other trades, who could be hit by falling items or be affected by sparks, heat or fumes	Scaffold with edge protection and toe boards. Exclusion zone planned.	3×4=12	Keep an exclusion zone around the scaffold on the ground, with barriers and signs, and keep the public out. Use a debris chute or covered skip so nothing is thrown. Consider the side of the roof next to the neighbour's boundary and keep the flame and heat shielded away from it. Tell the other trades the times of hot works and keep them clear of the work area. No one works under the roof while stripping or torching is going on. Keep the access route clear. If a member of the public enters the zone, stop work until they have left.	Low
Falling objects and debris while stripping: old felt, insulation, tools, fixings and offcuts dropped from the roof	People on the ground below, operatives on the scaffold and anyone in the garden, with risk of head and other injuries	Scaffold toe boards. Exclusion zone planned.	3×4=12	Bag or bundle the waste on the roof and lower it by chute or in bags, never throw. Keep tools in a tool belt or tethered and keep small items off the roof edge. Do not stack materials against the guardrails. Clear the area beneath the roof before work starts and keep it clear with barriers. A hard hat (EN 397) is the last line of defence for anyone entering the zone.	Low
Disturbing unidentified asbestos-containing materials when stripping the existing roof covering and deck, in a building whose age or survey status has not yet been confirmed	Operatives, occupants and neighbours, with risk of long-term lung disease from breathing in fibres	Asbestos is not flagged for this job. The building age and survey status are to be confirmed on the pre-start walk.	2×5=10	Before work starts, check the client's asbestos register or management survey for the roof area, and confirm the building age. If the register does not cover the area, or the building is pre-2000 or its age is not known, a refurbishment and demolition survey of the area is needed first (Control of Asbestos Regulations 2012, Regulation 5). Stop-work rule: if any suspect material is found, stop, keep people away and report to R. Whitfield and the client before carrying on. Do not break, drill or sweep suspect material. This is a check to be made, not a finding.	Medium
Fumes and dust: bitumen fume from the torch, primer vapour, PIR cutting dust and dust from stripping the old covering	Operatives and anyone downwind, including occupants through open windows and vents, with irritation of eyes, nose, throat and skin	Work is carried out in the open air. COSHH assessments are in this RAMS.	4×3=12	Follow the Control of Substances Hazardous to Health Regulations (COSHH) 2002. Where the system manufacturer allows, use a low-solvent or water-based primer. Torch only as much as needed and avoid overheating the membrane. Work upwind and keep others downwind. Cut PIR in the open air and clean up with a vacuum, never dry sweeping. Ask occupants to keep windows near the work closed. Take breaks away from the torch. Gloves, eye protection and the RPE the Safety Data Sheet specifies are the last line of defence.	Low
Manual handling of membrane rolls, PIR boards, tins of primer, cylinders and waste bags to and from roof level	Both operatives, with risk of back and shoulder injury or dropping loads	Two operatives. Manual Handling Operations Regulations 1992 apply.	4×3=12	Avoid carrying by hand up the ladder: use a hoist or other agreed lifting method, and if a hoist or gin wheel is used it must be in date for thorough examination and used to its limit (Lifting Operations and Lifting Equipment Regulations 1998). Order materials in manageable sizes and deliver as close as possible to the scaffold. Two-person lifts for rolls and large boards. Limit loads and take rest breaks. Keep the route clear. Gloves and safety boots are the last line of defence.	Medium
Weather: heat and UV in June, rain and wind, wet and slippery membrane and deck	Both operatives, with risk of heat illness, slips on the roof and wind blowing the flame or sheets	Forecast checked. Work stopped in rain.	3×3=9	Check the forecast each morning and agree a stop point. No torching in rain or wind that moves the flame or lifts the sheets. Start early in hot weather, take breaks in the shade and keep drinking water to hand. Cover the roof before rain. Do not walk on wet membrane. Sun protection, sun cream and sound footwear with good grip are the last line of defence.	Low
Cuts from hook blades, knives, the PIR cutter and old fixings or nails when stripping	Both operatives, from cuts to hands and legs	Competent operatives using hand tools.	4×2=8	Use retractable or guarded blades and cut away from the body. Replace blunt blades and dispose of used ones in a sharps container. Remove or flatten old fixings as the covering is lifted. Keep the work area tidy. Cut-resistant gloves to EN 388 are the last line of defence.	Low
Slips, trips and falls on the same level: hoses, tools, offcuts, loose membrane and uneven upstands on the roof and scaffold	Both operatives, from sprains, bruises and, near an edge, a fall	Scaffold boards, toe boards and guardrails. Competent operatives.	4×3=12	Plan the layout so hoses and cables run along the edges and away from walkways, and keep the roof clear of offcuts and waste. Bag waste as it is made. Keep the ladder bay and the walkways clear. Keep the stairs and access route to the vehicle clear. Safety boots with good grip are the last line of defence.	Low
Existing roof penetrations and services: flues, vents, extractor outlets, soil pipes, rainwater outlets and any electrical cables or fittings at roof level	Operatives and occupants, from fire, fume entry, blocked flues or electric shock if a cable is damaged	Roof walked and checked before stripping.	2×4=8	Identify and mark every penetration and any cable on the pre-start walk. Ask Mr & Mrs Ashford to turn off or avoid using any appliance that vents through the roof during torching. Do not cut into or strip around any cable or flue until it has been identified and made safe (Electricity at Work Regulations 1989). Protect outlets and vents from the flame. Protect rainwater outlets from debris. Report any damage to the client.	Low

4. COSHH assessment

Built on COSHH 2002 regulations 6 and 7 and HSE guidance L5.

Check each entry against the supplier's Safety Data Sheet before work starts. Take workplace exposure limits from HSE EH40/2005.

SBS reinforced bitumen torch-on membrane (underlay and cap sheet), including the fume made when it is heated

Task or use: Torch-applied underlay and cap sheet to the new warm flat roof; handling hot membrane and offcuts
Route of exposure: Inhalation of fume, skin contact with hot or warm bitumen, eye contact with fume or splashes.
Who could be harmed: The two operatives and anyone downwind, including occupants through open windows. Burns to skin and irritation of the eyes, nose and throat.
Hazards: Hot bitumen can cause severe burns. Fume from heated bitumen can irritate the eyes, nose and throat. The exact hazards depend on the product, so check section 2 of the supplier's Safety Data Sheet. Do not assume them.
Controls: Substitute where the system manufacturer allows: use a cold-applied, self-adhesive or hot-air welded method at details near timber, so less flame is used.
Torch only as much as is needed and avoid overheating the membrane, to limit fume.
Work in the open air, upwind of the operatives, and keep others downwind and the kitchen windows closed.
Limit the time on the torch by rotating the task between the two operatives and take breaks away from the fume.
Let offcuts and hot membrane cool before handling or bagging. Follow COSHH 2002 and HSE's COSHH guidance (L5).
PPE: Heat-resistant gloves to EN 407
Long-sleeved, non-synthetic or flame-retardant clothing
Eye protection to EN 166
Safety boots
RPE only as the Safety Data Sheet specifies
Storage and disposal: Store rolls upright or flat on pallets, dry, out of direct sun and away from LPG and ignition sources. Let offcuts cool, bag them and remove them with the other roof waste through a licensed waste carrier.
First aid and spillage: For a burn, cool it under running water for at least 20 minutes, do not pull hot bitumen off the skin, cover with a clean non-fluffy dressing and get medical help for anything more than a small burn. For fume, move to fresh air. Follow section 4 of the Safety Data Sheet. Pick up and bag any bitumen drips once cool and keep them out of drains.
Health surveillance: None is expected for this short job. Report any skin problems to R. Whitfield.
Check against the Safety Data Sheet: Before work starts, get the Safety Data Sheet for the underlay and the cap sheet. Confirm the hazards in section 2, the PPE and RPE in section 8, the first aid in section 4 and the storage and disposal advice. Check workplace exposure limits in HSE EH40/2005.

Bitumen primer

Task or use: Primer applied to the deck or substrate before the membrane is laid
Route of exposure: Inhalation of vapour, skin contact, eye contact and ingestion from dirty hands.
Who could be harmed: Both operatives and anyone downwind. Irritation of skin and eyes, headache or dizziness from vapour depending on the product, and a fire risk near the torch.
Hazards: The hazards depend on the product, so check section 2 of the supplier's Safety Data Sheet. Many primers give off flammable vapour, so no flame is used near it until it is fully dry.
Controls: Substitute a water-based or low-solvent primer if the membrane manufacturer allows it.
Use only the amount needed for the area and keep lids on between uses.
Apply in the open air with no ignition source and no torch work until it is dry as the manufacturer states.
Use a brush or roller, not a spray, and keep others away from the area while it dries.
Follow COSHH 2002 and HSE's COSHH guidance (L5).
PPE: Chemical-resistant gloves as the Safety Data Sheet specifies
Eye protection to EN 166
Long-sleeved clothing
RPE only as the Safety Data Sheet specifies
Storage and disposal: Keep in closed original containers, upright, in the vehicle or a secure area outside, away from heat, the LPG and ignition sources. Keep wet rags in a closed metal container until removed. Empty tins and rags go to a licensed waste carrier as the Safety Data Sheet says. Do not pour any into drains.
First aid and spillage: Eyes: rinse with clean water for at least 10 minutes and get medical help. Skin: wash with soap and water. Swallowed: do not make the person sick and get medical advice. Follow section 4 of the Safety Data Sheet. Spillage: remove ignition sources, soak up with sand or absorbent, bag it and keep it out of drains.
Health surveillance: None is expected for occasional use over 3 days. Report any skin problems to R. Whitfield.
Check against the Safety Data Sheet: Before work starts, get the Safety Data Sheet for the primer and confirm hazards (section 2), glove and RPE specification (section 8), drying time, flash point and fire advice, first aid and disposal. Check workplace exposure limits in HSE EH40/2005.

LPG (propane)

Task or use: Fuel for the propane gas torch used to apply the torch-on membrane
Route of exposure: Inhalation of leaked gas, skin contact with escaping liquid gas, and fire or explosion if gas builds up near an ignition source.
Who could be harmed: The operatives, the occupants and neighbours. Fire, explosion and burns, and cold burns from liquid gas on skin.
Hazards: Propane is an extremely flammable gas under pressure. A leak can cause fire or explosion, and gas can displace air in low or enclosed areas. Liquid gas on skin causes cold burns. Check section 2 of the supplier's Safety Data Sheet for the supplier's hazard details. Fire and explosion risk is also covered by DSEAR 2002.
Controls: Take only the cylinders needed for the day.
Use regulators, hoses and flashback arrestors that are in date, in good condition and leak tested at every joint after connecting.
Keep cylinders upright, secured and away from the edge, the roof timber and ignition sources.
Close the cylinder valve at every break and at the end of the day. Never leave the torch lit and unattended.
Store cylinders outside, away from the building, drains and the primer, and do not leave them on the roof overnight.
Follow COSHH 2002 and HSE's COSHH guidance (L5).
PPE: Heat-resistant gloves to EN 407
Eye protection to EN 166
Safety boots
Flame-retardant or natural-fibre clothing
Storage and disposal: Keep cylinders upright, secured, in a ventilated place outside and away from the building, drains and ignition sources, with valves closed. Return empty or unused cylinders to the supplier. Never dispose of them as scrap.
First aid and spillage: In a leak: if safe, close the valve, remove all ignition sources, keep people away and call 999 if the leak cannot be stopped. For a cold burn, flush with lukewarm water, do not rub, cover loosely and get medical help. For flame burns, cool under running water for at least 20 minutes and call 999 for anything serious. Follow section 4 of the Safety Data Sheet.
Health surveillance: None is expected.
Check against the Safety Data Sheet: Before work starts, get the supplier's Safety Data Sheet for the LPG and confirm the hazards (section 2), the safe use and storage (sections 7 and 8), the first aid and the emergency advice. Check workplace exposure limits in HSE EH40/2005.

PIR insulation board cutting dust

Task or use: Cutting PIR insulation boards to fit the warm flat roof, using the PIR cutter and hand tools
Route of exposure: Inhalation of dust, skin and eye contact with dust and board edges.
Who could be harmed: The operatives and anyone close by. Irritation of the eyes, nose, throat and skin.
Hazards: Dust and fibres from cut insulation can irritate the skin, eyes and airways. The hazards depend on the product, so check section 2 of the supplier's Safety Data Sheet. The boards are also combustible, which matters near the torch.
Controls: Eliminate cutting where possible: order boards in sizes or tapers that need little cutting.
Cut by scoring and snapping or with a hand cutter, not a power saw, and cut in the open air, downwind and away from others.
Bag offcuts straight away, and clean up with a vacuum fitted with a suitable filter, never by dry sweeping or with compressed air.
Keep the cut boards and offcuts away from the torch and the flame.
Follow COSHH 2002 and HSE's COSHH guidance (L5).
PPE: Gloves
Eye protection to EN 166
Long-sleeved clothing
Disposable respirator as the Safety Data Sheet specifies, if dust is still present
Storage and disposal: Store boards flat, dry and covered, off the ground and away from the LPG and ignition sources. Bag offcuts and dust and remove them through a licensed waste carrier.
First aid and spillage: Eyes: rinse with clean water for at least 10 minutes. Skin: wash with soap and water. Breathing irritation: move to fresh air. Follow section 4 of the Safety Data Sheet. Clean up dust by vacuum, not by sweeping.
Health surveillance: None is expected for this short job. Report any skin or breathing problems to R. Whitfield.
Check against the Safety Data Sheet: Before work starts, get the Safety Data Sheet or product data for the PIR boards and confirm the hazards (section 2), the PPE and RPE specification (section 8), the fire advice and the disposal route. Check workplace exposure limits in HSE EH40/2005.

5. Plant & equipment

Propane gas torch with regulator, hoses and flashback arrestor
LPG cylinders (propane), secured and stored upright
Two charged fire extinguishers kept at roof level for the hot works
Hand tools, hook blades and knives
Felt roller
PIR insulation cutter
Debris chute or covered skip, barriers and signs
Independent scaffold and edge protection (by others), with handover certificate
Hoist or other agreed lifting method (to be confirmed), thoroughly examined if it is lifting equipment (LOLER 1998)
Leak detection solution, burns kit and first aid kit

6. Materials / COSHH

SBS reinforced bitumen torch-on membrane (underlay and cap sheet), PIR insulation boards, vapour control layer, bitumen primer and LPG (propane). The detail for the membrane and fume, the primer, the LPG and the PIR cutting dust is in the separate COSHH assessments. Safety Data Sheets for each product must be on site before work starts.

7. PPE

Safety helmet to EN 397 when working below or near others, or where there is a risk of falling objects
Safety boots to EN ISO 20345 with good grip and heat-resistant soles
Heat-resistant gloves to EN 407 for torch work
Cut-resistant gloves to EN 388 for stripping and cutting
Eye protection to EN 166
Long-sleeved, non-synthetic or flame-retardant clothing
High-visibility clothing
Sun protection and sun cream
RPE only as the Safety Data Sheets specify (disposable respirator for dust, with a face-fit test where required)

8. Competence & training

R. Whitfield, Site Supervisor, holds a CSCS Gold Card and an NVQ Level 3 in Roofing Occupations and is the competent person for this job. The operatives are NVQ Level 3 Roofing Occupations trained, CSCS carded, LPG and hot works trained, and hold a first aid at work qualification. Copies of the cards and certificates are available to the client on request. Both operatives are briefed on this RAMS on the first morning and sign on to confirm they have read and understood it. Anyone new to the job is briefed before starting.

9. Permits

Hot works permit, issued and signed each day before any flame is lit, with a fire watch of at least 60 minutes after the last flame (or longer if the permit says so)
Scaffold handover certificate, checked before work starts and kept with the RAMS
Asbestos register or management survey (or refurbishment and demolition survey) confirmed for the roof area before stripping starts

10. Access & egress

Access to the roof is by the independent scaffold ladder bay with double guardrails at eaves level. Operatives use the ladder bay only, do not climb the scaffold frame and do not carry heavy loads up the ladder. The route from the vehicle to the scaffold is agreed with Mr & Mrs Ashford on the pre-start walk and kept clear. The garden work area is barriered off and the occupants are kept clear. In an emergency, the escape route is down the ladder bay and to the fire assembly point agreed on the pre-start walk.

11. Welfare

A client WC is available by arrangement with Mr & Mrs Ashford, to be confirmed on the pre-start walk. Operatives use vehicle-based provisions for rest, drinking water and hot drinks. Water and soap are available to wash hands and any bitumen contact off the skin before eating, drinking or smoking. In hot weather, drinking water is kept to hand and breaks are taken in the shade.

12. First aid

Both operatives hold a first aid at work qualification. A first aid kit and a burns kit are kept in the vehicle and on the scaffold, with clean water available. Cool burns under running water for at least 20 minutes and do not pull hot bitumen off the skin. Any injury, near miss or fire is reported to R. Whitfield and recorded in the accident book.

13. Emergency procedures

Fire: raise the alarm, shut off the LPG cylinder valve if it is safe to do so, get everyone down from the roof and out to the assembly point on the front drive, ask the occupants to leave, call 999 and only use an extinguisher if it is safe and trained to do so. Gas leak: close the valve if safe, remove ignition sources, keep people away and call 999 if it cannot be stopped. Fall or serious injury: do not move the casualty unless there is immediate danger, call 999 and give first aid. Site address for the emergency services is 18 Willow Grove, Sheffield, with the full postcode to be confirmed on the pre-start walk. If suspect material is found, stop, keep people away and report it.

14. Environmental

Old roof covering, insulation and offcuts are bagged, lowered by chute and removed by a licensed waste carrier in line with the duty of care. Do not burn waste. Bitumen, primer and fuel must not get into drains or rainwater outlets, which are protected during the work. Keep the work area tidy and sweep up daily using a vacuum for dust. Limit fume and smell by keeping torching to what is needed and tell neighbours the work times. Return LPG cylinders to the supplier. Keep noise and working hours reasonable for the neighbours.

This document was AI-generated as a drafting aid. It is not a substitute for professional health & safety advice. It must be reviewed, verified and made site-specific by a competent person before use, briefed to all operatives, and updated when site conditions or the method change. The provider accepts no liability for use of this document on site.

Flat roofing method statement: what it covers

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