Product Overview

Summary: This Lead and Zinc Handling on Roofs SOP provides a clear, step-by-step framework for working safely with lead and zinc roofing materials at height. It supports Australian businesses to control exposure to hazardous metals and fall risks while demonstrating robust WHS compliance and protecting both workers and the environment.

Working with lead and zinc on roofs presents a unique combination of hazards: exposure to toxic metals, sharp edges, hot surfaces, and the ever-present risk of falls from height. This Safe Operating Procedure has been developed specifically for Australian roofing and construction environments where lead flashings, zinc cladding, gutters, downpipes, and roof penetrations are installed, repaired or removed. It sets out a practical, repeatable method for planning, carrying out and supervising these tasks in a way that protects workers, occupants, and the surrounding environment.

The SOP goes beyond generic working-at-heights guidance by focusing on the particular risks of handling lead and zinc products: preventing dust and fume generation when cutting or welding, controlling hand-to-mouth transfer of lead, managing contaminated offcuts and swarf, and ensuring appropriate selection and use of PPE in hot, exposed rooftop conditions. It helps businesses demonstrate due diligence under WHS legislation, reduce the likelihood of long-term health issues from lead exposure, and avoid costly rework or regulatory scrutiny arising from poor installation practices or contamination incidents.

By implementing this SOP, roofing businesses and principal contractors can standardise safe work practices across crews and sites, embed clear supervision and housekeeping expectations, and provide a defensible framework for toolbox talks, training and competency assessment. The result is safer, more consistent lead and zinc roofing work that aligns with Australian standards and client requirements while supporting productivity and quality outcomes.

Key Benefits

• Ensure compliant control of lead and zinc exposure in line with Australian WHS duties and environmental expectations.
• Reduce the risk of falls, cuts, and musculoskeletal injuries when handling heavy or awkward roofing materials at height.
• Standardise safe work methods across all crews, improving consistency, supervision, and onboarding of new workers.
• Minimise contamination of surrounding areas, gutters, and stormwater systems with lead and zinc residues and debris.
• Support stronger evidence of due diligence during audits, client prequalification, and regulator inspections.

Who is this for?

• Roof Plumbers
• Roofing Contractors
• Site Supervisors
• Construction Project Managers
• WHS Advisors and Safety Officers
• Maintenance Managers
• Facilities Managers
• Small Business Owners in Roofing and Cladding
• Apprentice Roof Plumbers and Trainees

Hazards Addressed

• Lead exposure through inhalation of dust and fumes and ingestion via hand-to-mouth contact
• Exposure to zinc fumes and dust when cutting, grinding, soldering or welding
• Falls from roofs, ladders and access points while carrying materials or tools
• Trips and slips on loose offcuts, swarf, tools, and surface contaminants on roofs
• Cuts, lacerations and puncture wounds from sharp metal edges and offcuts
• Heat stress and dehydration when working with metals on exposed roofs in hot conditions
• Manual handling injuries from lifting, carrying and positioning heavy or awkward sheets and flashings
• Eye injuries from flying particles during cutting, drilling, grinding or fastening
• Environmental contamination from uncontrolled disposal of lead and zinc waste and wash-down water

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Key Terms (Lead, Zinc, Contaminated Waste, Exclusion Zone)
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Workers, Contractors)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Pre-Start Planning and Risk Assessment
• 6.0 Roof Access, Edge Protection and Fall Control Measures
• 7.0 Lead and Zinc Material Handling Requirements
• 8.0 Cutting, Grinding, Soldering and Hot Work with Lead and Zinc
• 9.0 Personal Protective Equipment (PPE) Selection, Use and Maintenance
• 10.0 Hygiene, Decontamination and Housekeeping Controls
• 11.0 Environmental Protection and Waste Management for Lead and Zinc
• 12.0 Step-by-Step Operating Procedure for Installation, Repair and Removal
• 13.0 Health Monitoring and Exposure Management (Lead)
• 14.0 Emergency Procedures (Exposure, Injury, Spills and Falls)
• 15.0 Training, Competency and Toolbox Talk Requirements
• 16.0 Inspection, Monitoring, Recordkeeping and Review

Legislation & References

• Model Work Health and Safety Regulations (Safe Work Australia), including regulations for hazardous chemicals and construction work
• Safe Work Australia – Code of Practice: Managing the Risk of Falls in Housing Construction
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: How to Safely Remove Lead-Based Paint (as guidance on lead control principles)
• AS/NZS 1891.4: Industrial fall-arrest systems and devices – Selection, use and maintenance
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 4501: Occupational protective clothing
• AS/NZS 4024.1201: Safety of machinery – General principles for design – Risk assessment and risk reduction (for cutting and grinding equipment used on roofs)
• Relevant state and territory WHS Acts and Regulations (e.g. Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017 (NSW))