Product Overview

Summary: This Double Glazing Application Safe Operating Procedure sets out a clear, safe and consistent method for installing double-glazed units in Australian workplaces and residential sites. It focuses on controlling manual handling, glass-handling and working-at-heights risks while lifting installation quality, energy performance and compliance with WHS obligations.

The Double Glazing Application Safe Operating Procedure provides a structured, WHS-focused approach to the installation of double-glazed window and door units in Australian construction and retrofit projects. Double glazing involves handling large, heavy and fragile glass units, sealants and fixings, often in constrained spaces or at height. Without a clear procedure, businesses face increased risk of manual handling injuries, glass breakage, falls, water ingress issues and costly rework. This SOP defines how work is planned, resourced and executed so that every installation is carried out safely, consistently and in line with manufacturer instructions and Australian standards.

Developed for the Australian market, the procedure aligns with WHS legislation, typical state-based construction requirements and energy-efficiency expectations for modern buildings. It guides installers through pre-start checks, safe lifting and handling of insulated glass units (IGUs), use of mechanical aids, correct selection and application of sealants and fixings, and final inspection and documentation. By embedding this SOP into your operations, you create a repeatable system that reduces incidents, improves installation quality, supports NCC energy performance objectives and demonstrates due diligence to regulators, clients and principal contractors.

Key Benefits

• Reduce manual handling and glass-related injuries through defined lifting techniques, team lifts and use of mechanical aids.
• Ensure consistent, high-quality double glazing installations that minimise call-backs, water ingress and thermal performance issues.
• Demonstrate compliance with Australian WHS legislation and relevant glazing and construction standards.
• Streamline training and onboarding for new glaziers and installers with a clear, step-by-step method statement.
• Minimise project delays, product damage and rework costs by standardising planning, sequencing and quality checks.

Who is this for?

• Glaziers
• Window and Door Installers
• Construction Site Supervisors
• Project Managers
• WHS Managers and Advisors
• Facilities and Maintenance Managers
• Residential and Commercial Building Contractors
• Operations Managers in Window Manufacturing and Installation Businesses

Hazards Addressed

• Manual handling injuries from lifting and positioning heavy insulated glass units (IGUs) and frames
• Cuts and lacerations from handling glass, broken panes and sharp frame edges
• Crush and pinch injuries during glass movement, placement and fixing
• Falls from height when installing double glazing in multi-storey or elevated locations
• Falls on the same level due to trip hazards, offcuts, packaging and sealant spills
• Exposure to hazardous substances from sealants, adhesives, foams and cleaning chemicals
• Eye injuries from glass fragments, dust and debris
• Noise exposure from power tools and cutting equipment
• Property damage and falling objects from dropped glazing units or tools
• Thermal stress and weather exposure during external installation work

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations (including IGU, frame types and glazing terms)
• 3.0 Roles and Responsibilities (PCBU, supervisors, installers, spotters)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required Competencies, Training and Licensing
• 6.0 Tools, Equipment and Materials (including lifting aids and PPE)
• 7.0 Personal Protective Equipment (PPE) Requirements
• 8.0 Pre-Start Planning and Site Assessment
• 9.0 Hazard Identification and Risk Control Measures for Double Glazing Work
• 10.0 Manual Handling and Mechanical Lifting Procedures for IGUs
• 11.0 Working at Heights Controls and Access Equipment Use
• 12.0 Handling, Transport and Storage of Double-Glazed Units
• 13.0 Frame Preparation and Opening Verification
• 14.0 Double Glazing Installation – Step-by-Step Procedure
• 15.0 Sealant, Adhesive and Fixing Application Requirements
• 16.0 Quality Assurance, Alignment and Weatherproofing Checks
• 17.0 Housekeeping, Waste Management and Glass Offcut Disposal
• 18.0 Emergency Procedures (glass breakage, injury, chemical exposure, falls)
• 19.0 Environmental Considerations and Energy Performance Notes
• 20.0 Documentation, Records and Sign-Off
• 21.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• AS 1288: Glass in buildings – Selection and installation
• AS/NZS 2208: Safety glazing materials in buildings
• AS/NZS 1170: Structural design actions (for fixing and load considerations)
• AS/NZS 1891 series: Industrial fall-arrest systems and devices
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 45001: Occupational health and safety management systems (ISO 45001 adoption)
• National Construction Code (NCC) – Energy efficiency provisions (for double glazing performance context)