First, describe the work and worksite
A trained roofing crew will apply a specified torch-compatible modified bitumen system to a released low-slope roof area under the site hot-work authorization. This fictional learning example records planned controls; it supplies no actual inspections or work authorization.
- The roof assembly, concealed combustibles and nearby openings are assessed for this method.
- Fall protection, propane setup, fire prevention and a post-work fire-watch plan are in place.
- This excludes torching onto combustible decks, unseen areas, tanks or a roof assembly not approved for torch application.
Questions before work
- What establishes that the actual roof assembly permits torch application?
- Which concealed areas and building interiors require fire-watch access?
- What post-work inspection duration and handover do the governing requirements specify?
Build the analysis one step at a time
What will the worker do? How could someone be harmed? What prevents or reduces that exposure? Who checks the control, and when?
1. Release the roof assembly and hot work
Hazard: Flame can ignite concealed combustibles or enter occupied building space.
Control: Supervisor verifies system suitability and the hot-work authorization, inspects both roof and affected interior areas and uses an approved flame-free method where the torch method is unsuitable.
Verification: Check the actual assembly, permit conditions and concealed-area access before fuel setup.
Why this belongs in the analysis: A clean roof surface cannot establish what lies beneath.
2. Establish fall and fire protection
Hazard: Workers can fall while handling rolls; an incipient fire can escape detection.
Control: Maintain the planned fall protection, protected access and evacuation route. Assign the required fire-watch coverage and suitable extinguishing equipment without exposing the watcher to unprotected edges.
Verification: Supervisor checks protection and fire-watch readiness before ignition.
Why this belongs in the analysis: Fire-watch duties do not remove the watcher’s own fall exposure.
3. Inspect propane and torch equipment
Hazard: Leaks, damaged hoses or unsuitable cylinder placement can cause fire or explosion.
Control: Use the actual propane and torch instructions and applicable LPG requirements for cylinder support, connections and safe leak checks. Remove defective equipment; never heat a frosted cylinder with the torch.
Verification: Authorized operator completes the specified inspection and leak check before ignition.
Why this belongs in the analysis: An open flame is not a leak-test method.
4. Apply within the released area
Hazard: Flame, hot material and roll handling can burn workers or ignite the assembly.
Control: Follow the approved system method from stable access, control flame direction and keep it away from unseen areas, vents and combustibles. Stop when the released method cannot be maintained.
Verification: Operator and watcher monitor the actual flame path and adjoining areas.
Why this belongs in the analysis: The torch operator cannot observe every concealed fire path alone.
5. Shut down and secure fuel
Hazard: An unattended flame or leaking fuel can ignite after work pauses.
Control: Shut off and secure the torch and fuel by the specified procedure for breaks, changes and closeout. Keep hot equipment away from combustible material and maintain the fire-watch plan.
Verification: Operator verifies shutdown; watcher continues the required coverage.
Why this belongs in the analysis: End of torching is not end of fire risk.
6. Complete post-work checks and hand over
Hazard: Smoldering material can cause a delayed building fire.
Control: Follow the post-work inspection and monitoring plan. OSHA roofing guidance recommends at least two hours after the last torch is extinguished, including the roof field, flashings and underside. Meet any stricter applicable criteria and transfer continuing watch to an identified person before leaving.
Verification: Supervisor confirms completed checks and an explicit fire-watch handover.
Why this belongs in the analysis: A roof-only visual check may miss concealed heat.
What does a useful control look like?
| Needs improvement | More useful for this scenario |
|---|---|
| Be careful around the equipment. | Use the actual propane and torch instructions and applicable LPG requirements for cylinder support, connections and safe leak checks. Remove defective equipment; never heat a frosted cylinder with the torch. |
| Check the area before starting. | Supervisor verifies system suitability and the hot-work authorization, inspects both roof and affected interior areas and uses an approved flame-free method where the torch method is unsuitable. |
Decisions that change the analysis
How long should post-torch fire-watch inspections continue?
OSHA’s Protecting Roofing Workers guidance recommends inspections throughout the day and for at least two hours after the last roof torch is extinguished, including the roof field, flashings and underside of the deck. Apply any longer duration or additional checks required by the hot-work authorization, insurer, manufacturer or site. This is roofing guidance, not a universal interval for every hot-work task.
What must be recorded before this example is used on a job?
Replace the scenario with the actual work, identify additional hazards with the crew, and record the applicable instructions, responsible people, inspection findings, unresolved actions and required authorization. A planned verification is not an inspection result.
Agree when the crew will pause
- Assembly, concealed-area access or hot-work conditions are uncertain.
- Fuel leak, hose damage or fire-watch coverage failure occurs.
- Wind, occupancy, fall protection or the approved application method changes.
After a pause, correct the condition, reassess the work, and obtain required authorization before restarting. Keep unresolved actions visible.
Download the worked example and free template
No account or paid membership required. The worked example contains planned controls. The blank template is for your own work; neither includes fabricated inspection results, signatures or approval.
Your editable working copy
Build and download your draft
Start blank or load the learning example. Replace its assumptions with your actual conditions and involve the people doing the work. Your entries stay in this browser tab; download a copy before leaving or refreshing.
1. Describe your work and site
2. Work through each task
Describe an observable step, how someone could be harmed, and the control that acts on that hazard. Identify who checks it and what evidence is needed.
3. Record changes, checks, and open actions
Walk the work area, review with the crew, and resolve missing controls. Follow the required approval process. This tool does not judge completeness, verify signatures or authorize work.
Open the downloaded file in a browser, then use Print → Save as PDF for a printable copy.
Training needs to confirm
- Torch-roofing system and LPG equipment instruction by suitably trained personnel.
- Concealed-fire recognition, fire-watch duties and fall protection.
Confirm applicable qualifications, task instruction and actual training evidence for the people assigned. Related toolbox talks support crew discussion; they do not establish competence.
Common questions
Can this be used as a JSA?
Use the Task | Hazard | Control structure if it meets the employer’s format. Adapt the boundaries, controls, verification and records to the actual job.
Does this provide a completed USACE AHA?
No. Use the project’s required AHA process, risk method, supporting fields and acceptance requirements. The existing formwork AHA explains the additional structure.
Are these resources part of a paid course?
This walkthrough, browser draft builder and downloads are free public resources, separate from Academy course enrollment.
References and source note
- OSHA Protecting Roofing Workers
- OSHA 1926.150 Fire protection
- OSHA 1926.153 Liquefied petroleum gas
- OSHA 1926.501 Duty to have fall protection
- OSHA 1926.503 Fall protection training
Original worked example developed for the stated scenario. Primary references support the planning framework; the actual equipment manual, product instructions and project design must supply applicable operating and acceptance criteria. Use actual equipment instructions and site requirements alongside these references. Reference review: October 9, 2026.