Sisalation Insulation Safe Work Method Statement

Aluminium foil sisalation is highly conductive and can complete electrical circuits if it contacts exposed or damaged electrical wiring in roof spaces. When energised foil contacts workers, electrical current flows through the body to earth, causing potentially fatal electric shock. This hazard is particularly severe in older buildings with deteriorated cable insulation, non-compliant electrical installations, or where cables are not properly secured within protective conduits. The risk increases in poorly lit roof spaces where visibility of electrical hazards is limited, when installers work quickly without systematic hazard identification, and when working alone without supervision. Even brief contact with 240V circuits can cause ventricular fibrillation and death within seconds. The conductive foil can also bridge between different phases or between active and neutral conductors, creating short circuits, arc flash, or fire hazards.

Consequence: Fatal electric shock, cardiac arrest, severe burns from arc flash, permanent neurological damage, respiratory failure, and secondary trauma from falls or involuntary muscle contractions during electrocution.

Sisalation installers must traverse roof trusses spaced typically 600-900mm apart at heights of 3-6 metres above ground level in residential construction, higher in commercial buildings. Workers must carry and position large rolls of reflective material weighing 15-25kg while maintaining balance on narrow truss top chords typically only 90mm wide. When working near roof perimeters, unprotected edges present fall hazards particularly during windy conditions when material acts as a sail. The reflective surface can cause glare and visual disorientation affecting depth perception and balance. Working in roof spaces before sheeting is installed eliminates any fall arrest surfaces, meaning any loss of balance results in falls to the floor level below. Risk increases on steeper pitch roofs, when working in extreme heat causing fatigue and dizziness, and when attempting to install material single-handedly.

Consequence: Spinal cord injuries causing paraplegia or quadriplegia, traumatic brain injuries, multiple fractures to limbs and pelvis, internal organ damage, and fatalities from impacts to concrete slabs or structural elements below.

When installing sisalation to external walls or roof areas near property boundaries, overhead electrical service lines present electrocution risks if conductive foil material comes within dangerous proximity. The large sheet dimensions (often 20+ metres when unrolled) and wind effects can cause material to contact or approach within forbidden clearance distances of overhead lines carrying 230V single-phase or 400V three-phase power. Clearance distances prescribed in AS/NZS 3012:2010 require minimum 1.0 metre horizontal clearance and 2.5 metre vertical clearance for voltages up to 1000V. Wind gusts can rapidly close these distances, and aluminium foil does not require direct contact to conduct electricity—arcing can occur across air gaps when material approaches closely enough. The hazard is compounded when multiple workers handle long sections of material, creating coordination challenges in windy conditions.

Consequence: Fatal electrocution from high voltage contact, severe burns from electrical arcing, falls from heights during electrical shock incidents, and potential electrocution of ground-based workers if energised material falls onto them.

Roof space temperatures during Australian summer conditions regularly exceed 50 degrees Celsius and can reach 65-70 degrees in metal-roofed buildings under direct solar exposure. Sisalation installation requires physical exertion including carrying material rolls, climbing between trusses, and working in awkward positions to drape and fix material. The combination of extreme ambient temperature, radiant heat from roof surfaces, physical workload, and limited air movement in enclosed roof spaces creates severe heat stress risk. Workers must wear long-sleeved protective clothing and enclosed footwear which further impairs heat dissipation through sweat evaporation. Inadequate acclimatisation, insufficient fluid intake, extended work periods without cooling breaks, and individual health factors such as cardiovascular conditions or medications affecting heat tolerance compound the risk. Heat stress progresses from heat cramps and heat exhaustion with symptoms including dizziness, nausea, confusion, and profuse sweating, to potentially fatal heat stroke characterised by cessation of sweating, altered consciousness, and core temperature exceeding 40 degrees Celsius requiring emergency medical intervention.

Consequence: Heat stroke causing multi-organ failure and death, severe dehydration requiring hospitalisation, collapse and falls from height during heat-related loss of consciousness, long-term kidney damage from rhabdomyolysis, and cardiovascular events in susceptible individuals.

Sisalation material is supplied in rolls weighing 15-25kg depending on dimensions and construction. Installers must carry these rolls up ladders to roof access points, transport them across roof trusses, and position them for unrolling. The cylindrical shape and tendency for rolls to unravel creates awkward load characteristics. Once positioned, installers must drape material across trusses whilst maintaining balance on narrow truss chords, requiring sustained overhead reaching and twisting movements. The work involves prolonged awkward postures including kneeling or squatting on trusses, overhead reaching to fix material to framing, and bending to align and tape overlaps. These repetitive movements combined with the challenging work environment create cumulative strain on lower back, shoulders, and knees. Heat stress increases fatigue and reduces physical capacity, further elevating injury risk during manual handling tasks.

Consequence: Lower back disc injuries requiring surgery and prolonged recovery, rotator cuff tears requiring surgical repair, chronic shoulder impingement syndrome, knee cartilage damage from kneeling on hard truss surfaces, and soft tissue strains causing work absence.

Sisalation material has relatively sharp edges when cut and can cause lacerations particularly when installers grip edges during positioning or when wind causes material to move suddenly. Fixing the material using staple guns or hammer tackers creates hand injury risks from misfired staples or from grasping material close to fixing points. Metal roofing screws used to secure sisalation battens have sharp points capable of causing puncture wounds. Working in confined roof spaces with limited visibility increases the risk of hand contact with sharp edges of cut-offs or exposed fasteners. The reflective surface can obscure saw blades, utility knife blades, or other sharp tools placed on the foil, creating unexpected contact hazards. Gloves providing cut resistance may reduce dexterity needed for precise fixing work, creating a conflict between protection and task performance.

Consequence: Deep lacerations requiring sutures, tendon damage affecting hand function, puncture wounds from staples or screws requiring antibiotics and tetanus prophylaxis, and contaminated wounds in dusty roof environments increasing infection risk.

Roof trusses provide narrow walking surfaces covered with dust, sawdust from framing work, and sometimes moisture from condensation or recent rain if roof is not yet weathertight. This creates slippery conditions particularly when combined with smooth-soled footwear. Off-cuts of sisalation material, packaging, roll cores, and fixing tools scattered across trusses create trip hazards in confined roof spaces. Electrical cables and plumbing pipes crossing between trusses present obstacles requiring careful foot placement. The need to look upward when positioning material reduces visual monitoring of foot placement, increasing trip risk. Working during low light conditions at start or end of workdays further reduces hazard visibility. Slips and trips on trusses typically result in falls between trusses through ceiling materials below rather than simple stumbles, converting minor balance losses into serious fall incidents.

Consequence: Falls through ceiling materials to floor below causing fractures, head injuries, and soft tissue trauma, ankle sprains from awkward foot placement on truss edges, and knee injuries from impacts with truss framing during trip recoveries.