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Working at Height: How to Prevent Falls on New Zealand PV Roofs

The risks of maintaining PV installations at height

The installation and maintenance of solar photovoltaic panels (PV) on industrial and residential roofs poses considerable risks, making dedicated safety solutions essential. Many systems lack permanent fall-protection devices, exposing operators to serious hazards. In New Zealand, WorkSafe reports that falls from height account for 30% of fatalities in construction (15 out of 50 deaths over the five years to 2025), with a mortality rate of 4.41 per 100,000 workers — more than double that of Australia (2.93). These falls, often from heights under 10 metres, make up 69% of fatal building accidents, contributing to around 9.4 deaths in construction annually. In 2022 - 2023, the industry recorded 645 injuries and 12 deaths, many from low heights (under 3 metres), which are particularly common in roofing work. 

Safe roof access

One of the most widespread issues is the lack of properly equipped access routes to the roof. Makeshift solutions drastically increase the risk of slips and falls. The Vertigrip on Ladder, On wall and V-Rail systems offer permanent solutions that are durable, modular and designed to guarantee fast, safe access, even in challenging environmental conditions.

Lifelines and fall protection devices

Many photovoltaic roofs are unsuitable for traditional anchors, which can compromise waterproofing or cast shadows on the panels. SHIELD, the Rothoblaas support for lifelines on metal roofs, allows the creation of anchor points or linear and corner systems without interfering with panel productivity. Installed with dedicated gaskets, it preserves the structure's waterproofing and resists high stresses.

Preventing falls through fragile surfaces

PVC skylights and fragile surfaces are among the main causes of accidental falls during maintenance work. To safeguard these areas, the OVERNET safety net offers the most effective solution: it stops workers from falling through in case of breakage, while still allowing natural light into the spaces below.

Personal protective equipment

Anyone working at height must wear appropriate PPE at all times: safety helmets, harnesses, lanyards and energy absorbers. Rothoblaas offers a complete range of PPE designed to ensure safety and ergonomics in every situation.

Folding railings

While collective safety measures are crucial, fixed railings in photovoltaic installations can compromise panel output. Rothoblaas folding railings deliver reliable protection during work and, once lowered, prevent shading to preserve energy efficiency.

Integrating safety systems such as STEPUP, SHIELD, OVERNET, dedicated PPE and folding railings ensures worker safety while maximising efficiency in photovoltaic installations. 

Want to improve the safety and performance of photovoltaic systems on your projects? Get in touch with the Rothoblaas technical team for a personalised consultation.

View more information on Rothoblaas, including contact details.
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