Torch-applied flat roof RAMS

HSE 5-STEP · CDM 2015

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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.

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Strip of the existing failed flat roof covering and installation of a new warm flat roof to the single-storey garage/kitchen extension at 18 Willow Grove, Sheffield S11 7B**, for Mr & Mrs Ashford. The build-up comprises a vapour control layer, PIR insulation, and a two-layer torch-applied (hot works) SBS reinforced bitumen membrane. Work is carried out from an independent scaffold with double guardrails and toe boards at eaves level, on an occupied domestic property with public footpath nearby. All hot works are controlled under a daily hot works permit with a fire watch maintained after each torching session.

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, 18 Willow Grove, Sheffield S11 7B**
Project reference	NFR-3391
Start / duration	Tue 23 Jun 2026 / 3 days

1. Scope of works

2. Sequence of works

Method statement, safe system of work

Operatives arrive on site, review this RAMS, and confirm the scaffold handover certificate is in place and the working platform, guardrails, toe boards and ladder access bay are complete and inspected before access.
Introduce ourselves to the occupants, explain the works, the duration, that hot works (open flame) will be used, and agree that windows and openings near the roof are kept closed during torching. Confirm welfare and WC arrangements.
Barrier off and sign an exclusion zone at ground level beneath the work area and along the adjacent public footpath to keep the public, children and occupants clear of falling materials and the LPG storage point.
Complete and sign the daily hot works permit before any flame is lit, identifying the fire watch, extinguisher locations, combustible materials in the area and the timber roof deck and adjacent eaves/fascia as the principal fire risk.
Position LPG cylinders upright and secured at ground level in a ventilated location away from drains, gullies and ignition sources, with a spare cylinder isolated; only the cylinder in use is taken to the roof, secured upright.
Carry out a pre-use inspection of the torch, hoses, regulator and connections, leak-testing joints with leak-detection spray, and confirm the flame-out and gas shut-off procedure with both operatives.
Set out materials on the scaffold and roof, keeping loads within the platform's safe working load, storing combustible rolls and boards away from platform edges and the flame.
Strip the existing failed covering back to a sound deck, bagging waste and lowering it to ground level; never throw materials from the roof.
Inspect and prepare the timber deck, ensuring it is sound, dry, clean and free of protruding fixings before the new build-up is laid.
Prime the deck where required and allow the primer to flash off; keep the naked flame away from primer vapour until it has fully dried.
Lay and mechanically fix or bond the vapour control layer, then lay and fix the PIR insulation boards fully and tightly butted, cutting boards with a knife rather than a flame.
Torch-apply the underlay membrane, keeping the torch flame directed onto the membrane and away from the eaves, fascia, roof void and any combustible edge detail; heat only the bitumen, not the timber behind it.
Torch-apply the cap sheet, rolling and pressing laps to form a continuous watertight bond, and complete upstands, drip edges and details, using a smaller detailing torch where needed near vulnerable edges.
At each break and at the end of each torching session, shut off the torch, close the cylinder valve, bleed the hose, and begin the documented fire watch of at least one hour, checking the roof, eaves, fascia and roof void for smouldering.
Carry out a final visual and water-test check of the completed covering, laps, upstands and outlets to confirm a watertight finish.
At the end of each shift, return LPG cylinders to the secure ground-level store, remove or board the access ladder to deter unauthorised climbing, and confirm no residual heat sources remain.
On completion, remove all waste, off-cuts and packaging from site for disposal, leaving the roof, scaffold interface and grounds clean and the property secure.
Brief the occupants on the completed work, confirm the roof is watertight, and hand over any guarantee documentation.
Confirm the scaffold is clear so it can be dismantled by others, and sign out.

3. Risk assessment

HSE 5-STEP · MHSWR 1999 REG 3 · HIERARCHY OF CONTROL

Risk assessment: hazards, who may be harmed, controls and residual risk
Hazard	Who / how	Existing controls	L×S	Additional controls	Residual
Fire from torch-applied (hot works) flame igniting the timber deck, eaves, fascia, roof void or combustible materials.	Operatives, occupants, neighbours and property. Fire can cause severe burns, smoke inhalation, fatality and extensive property damage, and may spread unseen into the roof void.	Hot works trained operatives. Timber deck and combustible edges identified. Fire extinguishers carried. Torch and hoses inspected before use.	3×5=15	Eliminate where practicable by using self-adhesive or cold-applied membrane for vulnerable detailing and edges instead of a naked flame. Where torching is required, direct the flame onto the bitumen only and never at the timber, eaves or void; use a heat-resistant board between the flame and any combustible edge. Complete a daily hot works permit. Maintain a suitable fire extinguisher and water within arm's reach. Post a documented fire watch of at least one hour after each torching session and again before leaving site, checking the deck, eaves, fascia and roof void for smouldering. Stop all torching at least one hour before leaving site.	Medium
LPG (propane) leak, cylinder handling, and flashback/explosion from the gas torch, hoses and regulator.	Operatives, occupants, public. Explosion or flash fire causing severe burns, blast injury or fatality; asphyxiation in low-lying areas from escaping gas.	Cylinders stored upright. Torch equipment inspected. Operatives trained in torch use.	2×5=10	Store cylinders upright and secured at ground level in a ventilated position away from drains, gullies, basements and ignition sources, keeping only the cylinder in use on the roof (DSEAR 2002). Fit a hose with a flashback arrestor and check the regulator, hose and connections for damage before use, leak-testing joints with leak-detection spray, never a flame. Turn gas off at the cylinder, not just the torch, at every break, and bleed the hose. Never lay a lit torch down; use the torch stand. Know and rehearse the emergency gas shut-off. Transport and secure cylinders upright in a ventilated vehicle.	Low
Fall from height from the flat roof edge, from the scaffold, or through a fragile or opened-up deck.	Operatives. Falls from height are a leading cause of serious injury and fatality in roofing.	Independent scaffold with double guardrails and toe boards at eaves level. Ladder access bay. Scaffold handover certificate.	3×5=15	Provide collective edge protection: confirm the scaffold guardrails and toe boards are complete and inspected to the Work at Height Regulations 2005 before any roof access. Do not access the roof until the scaffold handover certificate is in place. Treat any opened-up or suspect deck area as fragile, cover and cordon it, and never step onto an unsupported deck. Keep the working platform clear and tidy to prevent trips near the edge. Prohibit work at height in high winds or when the surface is icy. Report any scaffold defect and prohibit use until corrected.	Medium
Manual handling of felt/bitumen rolls, PIR insulation boards, LPG cylinders and waste up to and from the roof.	Operatives. Musculoskeletal injuries to the back, shoulders and hands; injuries from dropped loads.	Manual handling trained operatives. Loads assessed before lifting.	3×3=9	Reduce handling at height by ordering smaller/lighter roll formats and raising materials in stages rather than carrying full loads up the ladder. Use a hoist, gin wheel or telehandler by others to raise heavy or bulk materials to the platform rather than manual carrying. Team-lift bitumen rolls and cylinders; keep loads within individual limits under the Manual Handling Operations Regulations 1992. Adopt good lifting technique, avoid twisting, and store materials at working height to avoid repeated bending. Wear gloves to protect against pinch points.	Low
Burns and hot bitumen contact from the torch flame, heated membrane and hot tools.	Operatives. Contact burns to hands, arms and face; eye injury from radiant heat.	Trained operatives. Awareness of hot surfaces and flame direction.	3×3=9	Keep hands and body clear of the flame path and of freshly torched, molten bitumen until it has cooled. Use the correct roller and detailing tools so hands are not placed near the heated lap. Allow hot tools to cool on a heat-resistant surface. Provide cool running water on site for burn first aid. Wear heat-resistant gauntlet gloves, long sleeves and eye protection when torching. Never adjust the torch or clear a blockage while lit.	Low
Falling materials, tools, hot off-cuts or waste striking people below, including the public on the adjacent footpath.	Occupants, public, children and other operatives at ground level. Head injuries, burns from hot material, serious injury.	Toe boards to the scaffold platform. General awareness of people below.	3×4=12	Establish and barrier a signed exclusion zone at ground level beneath the work area and along the public footpath, and keep it clear during roof works. Lower all waste and materials in bags or by hoist; never throw anything from the roof. Fit toe boards and, where required, brick guards or netting to the platform. Store loose materials and cylinders away from the platform edge. Suspend overhead work if the public cannot be excluded. Wear head protection at ground level beneath the works.	Low
Smoke, bitumen fumes and hot-works emissions, and working on an occupied domestic property.	Operatives (respiratory irritation), occupants and neighbours (fume ingress, nuisance, distress from smoke/alarms).	Work in the open air. Occupied-site awareness. Communication with occupants.	2×2=4	Work in the open air to disperse fumes and position operatives upwind of the torch where possible. Agree with occupants that windows, doors and vents near the roof are kept closed during torching to prevent fume and smoke ingress, and warn them that smoke detectors may be triggered. Consult the membrane and primer Safety Data Sheets (COSHH 2002) and avoid heating primer vapour. Rotate operatives to limit fume exposure. Keep the site tidy and the property secure, and minimise disruption on the occupied site.	Low

4. Plant & equipment

Propane gas torch with detailing torch head, hoses and regulator (with flashback arrestor)
LPG (propane) cylinders and secure ground-level store
Torch stand / rest for the lit torch
Leak-detection spray
Fire extinguishers (water and dry powder / CO2) and fire watch equipment
Heat-resistant board for edge protection during torching
Felt roller and detailing tools
PIR insulation cutter and roofing knives
Hand tools
Independent scaffold with double guardrails, toe boards and ladder access bay (supplied and inspected by others)
Ground-level barriers and signage for the exclusion zone
Waste bags and lowering equipment / gin wheel

5. Materials / COSHH

SBS reinforced bitumen torch-on membrane, PIR insulation, vapour control layer, bitumen primer and LPG (propane) are handled under COSHH 2002 and DSEAR 2002. Consult the manufacturer's Safety Data Sheet for each product before use. Bitumen primer is flammable and gives off vapour: keep away from the naked flame until fully flashed off, use in the open air and avoid skin and eye contact. Heated bitumen gives off fumes: work upwind, in ventilation, and rotate operatives. LPG is a highly flammable liquefied gas handled per the DSEAR controls above. Wear nitrile/heat-resistant gloves and eye protection. Empty cylinders, off-cuts and packaging are removed from site for appropriate disposal or recycling.

6. PPE

Safety helmet (EN 397), worn at ground level beneath the works and where head hazards exist
Safety footwear with midsole (steel toe and penetration protection)
Heat-resistant gauntlet gloves for torching and hot bitumen (plus general handling gloves)
Eye protection against radiant heat, hot bitumen splash and cutting debris
Flame-retardant overalls / long-sleeved clothing for hot works
High-visibility clothing near the public footpath
Respiratory protection (FFP-rated) where bitumen fume exposure cannot otherwise be controlled

7. Competence & training

All operatives hold NVQ Level 3 in Roofing Occupations (or are working towards it under supervision), carry valid CSCS cards, and are trained and competent in torch-on/hot works roofing and safe LPG use. Operatives are trained in manual handling and working at height, and at least one holds a current First Aid at Work certificate. R. Whitfield (Author) is the Site Supervisor, holds a CSCS Gold Card, and is responsible for issuing the daily hot works permit, confirming the scaffold handover and supervising the fire watch.

8. Permits

Hot works permit, completed and signed daily before any flame is lit, specifying the fire watch duration, extinguisher provision and combustible materials in the area.
Scaffold handover/inspection certificate, in place before any roof access and retained on site.
Highways/footway licence from the local authority where the scaffold or exclusion zone affects the public footpath.

9. Access & egress

Access to the roof is via the tied ladder access bay of the independent scaffold, which provides double guardrails and toe boards at eaves level. The scaffold handover certificate must be in place before first access. Ground-level access to the property entrance and emergency egress for occupants are maintained throughout. Materials and waste are raised and lowered by hoist or gin wheel rather than carried up the ladder, and the ladder is removed or boarded at the end of each shift to deter unauthorised climbing.

10. Welfare

Toilet and hand-washing facilities are used by arrangement with the occupants where offered and suitable; otherwise the nearest agreed welfare facility is used. Operatives carry drinking water and cool water for burn first aid. Rest breaks are taken at ground level away from the work area, the LPG store and the public footpath.

11. First aid

A stocked first aid kit, including burns dressings and cool running water for burns, is carried in the company vehicle, and its location is known to all operatives. At least one operative holds a current First Aid at Work certificate. For a serious burn, cool the burn with running water, do not remove anything stuck to it, and call 999. For any serious injury or suspected fall, call 999 immediately and do not move the casualty unless in further danger. The site address is displayed for the emergency services.

12. Emergency procedures

In the event of fire, turn off the LPG at the cylinder if it is safe to do so, tackle only a small fire with the extinguisher, evacuate operatives and occupants, call 999, and assemble at a safe point clear of the LPG store. Do not re-enter to fight a spreading fire. In the event of an LPG leak, shut off the cylinder valve if safe, remove ignition sources, ventilate, keep clear of low-lying areas and evacuate. In the event of a fall or serious injury, make the area safe, administer first aid and call 999. All incidents are reported to the client and, where reportable, under RIDDOR. A fire watch is maintained for at least one hour after the last torching session and before leaving site.

13. Environmental

Hot works are controlled to prevent uncontrolled smoke and fire spread to neighbouring property. Bitumen fumes are minimised by working in the open air. LPG cylinders are managed to prevent gas escape to drains and gullies. All waste covering, off-cuts, insulation and packaging are segregated and removed from site for appropriate disposal or recycling; nothing is left on the footway, in gardens or in drains. Spent cylinders are returned to the supplier. Noise and disruption are minimised on the occupied domestic site.

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.

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