DECK REPLACEMENT SAFE WORK PRACTICES. Case Study #1 Laborer Killed in Fall Through Roof –A 40-year-old laborer/helper died when he fell through an opening.

DECK REPLACEMENT SAFE WORK PRACTICES

Case Study #1• Laborer Killed in Fall Through Roof

– A 40-year-old laborer/helper died when he fell through an opening in a warehouse roof. He fell approximately 27 feet to the floor below.

– The employee was demolishing the roof of the warehouse portion of a commercial building. Work was done at night because the coal tar on the roof would release hazardous gases if disturbed in the heat of the day. The site had adequate halogen lighting. None of the workers on the job were using fall protection.

– After the roofing material was removed, 4X8 sheets of plywood were exposed. Any damaged sheets needed to be replaced. The helper’s job was to follow the workers who were replacing the plywood, and to pick up the damaged sheets of plywood they had removed. He disposed of them in a chute.

– On this evening, one worker had removed a sheet of damaged plywood, but had run out of nails to attach the replacement sheet. He walked away to get more nails. The opening where the damaged plywood had been was left unguarded. The crew was not informed that it was temporarily unguarded. The opening was covered by silver-colored insulation inside the roof.

– The helper came along, picked up the damaged plywood, and headed for the chute. He stepped into the opening, ripped through the insulation, and fell.

Case Study #2

• Journeyman Roofer Dies From 25-Foot-Fall Through Structural Decking

– A 31-year-old journeyman roofer fell 25-feet through a section of a flat pitch roof. At the time of the incident the workers were in the process of tearing off and replacing roofing material on a flat pitch roof.

– The workers also were identifying bad and weakened sections of structural decking by visually identifying them from inside the building, taking measurements as their position and transferring those measurements to the roof and marking the appropriate sections for replacement. The bad sections of roof were marked with spray paint and the workers were instructed not to walk on the marked sections. The replacement sections are two feet wide and up to eight feet long. They were cut to to fit when replaced.

– On the day of the incident the workers were continuing tearing off the roofing material and replacing the identified bad decking. At approximately 11:00 a.m. the victim and another worker were walking on the roof and were near an identified bad section of decking when the worker fell through the decking to a concrete floor below.

– According to the employer there were no indications that the section of decking the worker fell through was weak or bad. The job foreman was first to the victim and requested a coworker to call 911 for emergency assistance. Emergency crews arrived and transported the victim to a local trauma center where he was treated for severe head trauma. The victims condition deteriorated and he was pronounced deceased the following day.

Duty To Have Fall Protection• The employer shall determine if the walking/working surface on

which its employees are to work have the strength and structural integrity to support employees safely. Employees shall be allowed to work on those surfaces only when the surface have the requisite strength and structural integrity.

Subpart R vs Subpart M

1926.501(b)(4) – Holes: Each employee on walking/working surfaces shall be protected from falling through holes (including skylights) more than six (6) feet above lower levels, by personal fall arrest systems, safety net systems, covers, or guardrail system erected around such holes.

1926.760(a)(1) –General Requirements: Except as provided in paragraph (a)(3) of this section, each employee engaged in steel erection activity who is on a walking/working surface with an unprotected side or edge more than 15 feet above a lower level shall be protected from fall hazards by guardrail systems, safety net systems, personal fall arrest systems, positioning device systems, or fall restraint system

Subpart R vs Subpart MQuestion (1)(a): Scenario: A commercial roofing contractor is

engaged in a re-roofing job. In the course of removing the weatherproofing material, the contractor discovers that some of the metal roof decking has deteriorated, and that a 6' X 6' section has to be replaced. Is this replacement work covered under Part 1926 Subpart R?

AnswerUnder §1926.750(a), Subpart R is not limited to new construction - it also applies to steel erection activities in alteration and repair work. Section 1926.750(b)(1) contains a list of activities that are covered by Subpart R, including "installing metal decking." Since §1926.750(a) states that steel erection activities done during repair are covered by Subpart R, the reverse of the decking installation process - removal - is also covered under §1926.750(b)(1).

Subpart R vs Subpart M Question (1)(c): Assume that the roof is between 15 feet and 30 feet high.

Can the employer use a Controlled Decking Zone as a substitute for conventional fall protection for the employees engaged in removing the bad decking?

AnswerNo. Section 1926.760(c) states that: "a controlled decking zone may be established in that area of the structure over 15 and up to 30 feet above a lower level where metal decking is initially being installed and forms the leading edge of a work area..." [Emphasis added] The controlled decking zone option was designed specifically for the initial installation of metal decking. The removal of deteriorated decking involves hazards that are not addressed in the controlled decking zone provision (for example, the fall hazards encountered when cutting decking and/or removing welds or fasteners). Therefore, the controlled decking zone exception does not apply to this deck removal work; conventional fall protection must be used.

Types of Roof Decking• Corrugated Metal

• Wood

• Gypsum

• Tectum

Decking Deterioration

• Corrugated Metal– Rust– Electrolysis

• Wood– Dry Rot– Saturation– Crushed / Split

• Gypsum– Moisture– Spalling– Cracked / Split– Dry

• Tectum– Moisture

Hazard Identification

• Interior Evaluations– Water stains– Rust– Sagging– Cracked/Peeling Paint– Humidity– Owner’s Representative

• Age of Building• Structural Design• Constant Leaks

Hazard Identification

• Interior Evaluations– Water stains– Rust– Sagging– Cracked/Peeling Paint– Humidity– Owner’s Representative

• Age of Building• Structural Design• Constant Leaks

Hazard Identification

• Exterior Evaluations– Ponding– Repairs / Patches– Sagging– Spongy Insulation– Inferred Scans

Hazard Identification

• Exterior Evaluations– Ponding– Repairs / Patches– Sagging– Spongy Insulation– Inferred Scans

Employees identified wet gypsum decking material

100% tie off utilized while working at edge and around roof opening

100% tie off utilized while working at edge and around roof opening

Decking Go-Over

• Sistering Sheets– Depends on flutes– Primarily B-decking

• Stainless Steel Plates– 2’ x 2’– 3’ x 3’– Etc.

Eliminate the Fall – Interior Scaffolding

Eliminate the Fall – Netting Systems

Fall Protection Options

• Corrugated Metal / Wood– Roof Anchors– Fall Protection Carts– Horizontal Lifelines

• Gypsum / Tectum– Fall Protection Carts– Toggle bolt 2”x 10” – attach

roof anchor– Fasten roof anchor to steel

support beams– Feed choker cable through

deck and around steel support beams

Uses:

Removing or installing coping Tear-off and installation of leading edge Removal and replacement of in-field roof deck Installing or dismantling edge guardrail systems Working around roof openings Removing or installing covers or skylights Snow removal

Safe Work Practices

• Hazard Identification– Flag off suspicious section

of decking– Transfer marks /

measurements from interior inspection

• Sequence scope of work• Maintaining a solid

working surface • Have replacement sheets

pre-cut / ready to be in installed immediately Plywood laid out to provide solid

working surface.

Safe Work Practices

• Communicate with primary contact

• Conduct electrical inspection – Lock out power supply

• Have dedicated inside rover to monitor work location

• Flag off areas below deck replacement

Summary• Conduct a comprehensive evaluation of the roof

deck to ensure it will support the men and materials.

• Perform the deck replacement with a small crew before major tear off when feasible.

• Develop a fall protection plan: Is tie-off enough or will the area require netting?

• Protect areas on the roof and inside the building from unauthorized access.

• Never leave an open section of decking.