Danger beneath the surface: How precision prevented disaster

By Benchmark.  

One roofing project, 300 feet of hidden risk and zero margin for error or hesitation. Strategic actions were implemented to ensure a precision response.

When construction crews step onto a roof, few expect danger to be lurking just beneath their boots. But at a critical industrial site, a routine roofing project could have turned catastrophic if the high-voltage power lines and fiber-optic cables running directly under a steel deck were not pointed out. With the threat of electrocution, major operational shutdowns and millions in potential damages hanging in the balance, our team at Benchmark lead a precision response. What followed was a textbook example of how smart coordination, rigorous planning and an unwavering focus on safety can transform a high-risk hazard zone into a success story.

Issue

A major safety risk was uncovered during a roofing project, with high-voltage lines and fiber-optic cables positioned directly under a steel deck. Without proper precautions, any penetration of the deck could have caused severe electrical incidents, operational disruptions and potential risks to human life.

The situation presented the following risks:

• Operational disruptions: A single penetration into a critical high-voltage or communication line could have caused a total plant shutdown.
• Severe safety hazards: Crew members were at risk of electrocution, which could result in serious injury or fatality.
• Financial and infrastructure losses: Damage to vital electrical and communication infrastructure could have led to extensive repair costs and delayed project timelines.

Specifically, approximately 300 feet of the steel deck presented these high-risk conditions.

Solution

To address this hazardous situation, Benchmark coordinated a comprehensive safety strategy, ensuring careful collaboration between the roofing contractor, the electrical contractor and Benchmark's expert team.

Key actions taken included the following steps:

Locating and marking critical zones

High-voltage lines and fiber-optic cables beneath the steel deck were identified and accurately located using advanced detection tools. These zones were then transferred to the top surface and clearly marked to ensure visibility and safety for the roofing crew.

Enhanced crew monitoring and training

Crew members received detailed instructions on staying aware of marked zones to prevent accidental penetration. Fastener placement and positioning were monitored closely throughout the project. Additionally, workers were briefed on potential hazards related to the lines and educated on emergency procedures to ensure a safe working environment.

Impact

Through meticulous planning and precise execution, the roofing project was successfully completed with no safety incidents or operational disruptions. The team demonstrated a strong commitment to safety by eliminating the risk of electrocution, ensuring no contact with high-voltage lines. This proactive measure effectively mitigated a critical safety hazard and safeguarded the well-being of all personnel.

By protecting electrical and fiber-optic lines from damage, the project avoided costly repairs and prevented unscheduled plant shutdowns or operational delays, delivering cost-effective results while maintaining the integrity of essential infrastructure.

The successful management of high-voltage hazards in this project underscores Benchmark’s commitment to safety, precision and client-focused solutions. By prioritizing detailed planning, comprehensive training and real-time monitoring, Benchmark ensured the completion of a high-risk project without a single incident.

1 - Cutaway of the steel deck showing the high-voltage lines.

2 - Marking the roof with red and yellow paint for high-voltage lines beneath the steel deck.

3 - Measuring and marking for fastener placement.

4 - Carefully placing fasteners around safety markings.

Original article and photo source: Benchmark