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In industrial and commercial buildings, polycarbonate skylights are widely used to maximize natural daylight and reduce dependence on artificial lighting. However, these transparent panels also introduce a serious safety hazard — particularly during maintenance or roof inspection work. Workers stepping on or near a skylight can accidentally fall through the fragile surface.
This makes Skylight Fall Protection Systems an essential component of roof safety design. Beyond compliance, they protect personnel, preserve structural integrity, and ensure uninterrupted operations.
Polycarbonate or FRP skylight sheets are designed for light transmission — not for supporting loads. Over time, UV exposure, dust accumulation, and weathering further weaken their load-bearing capacity.
Common risk scenarios include:
Workers unaware of skylight locations during cleaning or inspection
Sloped roofs with limited grip or visibility
Roofs where skylights blend with sheet color or are covered with debris
Maintenance access areas without designated walkways
Accidental falls through skylights are one of the most frequent causes of roof-related injuries in industrial environments.
Designing an effective fall protection system involves engineering safety without obstructing daylight or airflow. The core principles are:
Impact Resistance
The protective cover must withstand the force of a falling person. Systems are typically rated to resist impact loads exceeding 1200 N/m², depending on safety regulations and roof design.
Non-Obstructive Transparency
Light transmission should remain high. The mesh or grill design must minimize shading while maintaining structural strength.
Durability and Weather Resistance
Materials must be corrosion-resistant and able to withstand outdoor exposure, including rain, UV, and temperature variations.
Integration with Roofing System
The protection assembly must be compatible with polycarbonate sheets, metal roofing, and ridgevent systems, ensuring no leakage or stress points.
Different skylight layouts and roof structures call for distinct protection methods.
1. Metal Mesh Covers
Fixed over the skylight opening, these covers prevent accidental falls while maintaining full daylight entry. Commonly made of galvanized or stainless steel, they are ideal for long-span roofs.
2. Safety Grilles
Rigid grilles fastened to purlins or roof frames provide permanent protection in high-traffic maintenance zones. Their modular design allows quick retrofitting on existing roofs.
3. Walkway and Guardrail Systems
In facilities with frequent roof access, aluminum walkways with guardrails offer additional protection by creating safe maintenance paths around skylights.
4. Integrated Skylight Protection
For new projects, skylight protection can be integrated during roofing installation — especially with systems like METAhybrid® Thermal Insulated Roofing Sheets and Airflow Ridgevent™ — ensuring full compatibility and weather sealing.
A well-engineered skylight fall protection system balances strength, weight, and corrosion resistance. Common materials include:
Hot-Dip Galvanized Steel: Long-lasting, economical, and ideal for industrial applications.
Aluminium Alloy: Lightweight and rustproof, suitable for polycarbonate sheet structures.
Powder-Coated Metal: Offers aesthetic appeal and extra corrosion protection.
Fasteners should be stainless steel or non-corrosive coated types, ensuring compatibility with roofing sheets and preventing galvanic corrosion.
Design Tip: Maintain a 25–50 mm clearance between the skylight and protective mesh to avoid direct surface contact and allow for thermal expansion.
Each fall protection system should be engineered based on the specific skylight dimensions and roof configuration.
Key parameters include:
Panel spacing — distance between purlins or rafters
Expected live load — weight of a worker or accidental load
Impact energy — derived from fall height (E = mgh)
Anchorage capacity — strength of fastening points on metal purlins
Testing should comply with standards such as:
EN 1873:2014 – Resistance of rooflights to impact
OSHA 29 CFR 1910.28 & 1910.29 – Fall protection systems (US)
IS 875 (Part 2):1987 – Design loads for buildings and structures (India)
Regular inspections are essential to ensure that protective covers remain securely fastened and corrosion-free.
To achieve maximum performance and durability:
Never fasten the guard mesh directly onto the skylight sheet. Use independent brackets fixed to purlins.
Apply compatible flashing materials to prevent water ingress.
Use weatherproof sealants for joints and fasteners.
Clearly mark skylight and safety zones using high-visibility paint or signage.
At Geometric Steels, we engineer Skylight Fall Protection Systems specifically designed for polycarbonate, FRP, and metal roofing applications.
Our solutions ensure:
High impact resistance and load-bearing safety
Seamless integration with METAhybrid® sheets and ridgevent systems
Corrosion protection with galvanized or powder-coated options
Custom-fit design for all roof profiles
Easy installation and long service life
By combining safety and daylight efficiency, Geometric Steels ensures that every building is compliant, secure, and sustainable.
Skylights enhance workplace comfort, but safety must come first. A well-designed fall protection system prevents accidents, reduces liability, and upholds worker confidence.
Whether for a new build or retrofit project, integrating Geometric Steels Skylight Fall Protection Systems ensures reliability, compliance, and peace of mind — without compromising natural light or roof performance.
Contact Us
For design consultation or customized skylight protection systems:
+91-85509 95556
roof@geometricsteels.com
www.geometricsteels.com
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Email : roof@geometricsteels.com
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