Product Overview

Summary: This Heavy Glass Lifting Techniques SOP provides clear, step-by-step guidance for safely handling, lifting, and positioning heavy glass in Australian workplaces. It helps businesses control high-risk manual handling and crush hazards, while supporting compliance with WHS obligations and manufacturer requirements for glazing and glass products.

Handling heavy glass sheets, panels and assemblies is a high-risk activity that combines manual handling, crush, laceration and fall-from-height hazards. This Heavy Glass Lifting Techniques Safe Operating Procedure sets out a practical, repeatable system for planning, lifting, shifting and installing heavy glass in line with Australian WHS expectations. It covers the full workflow – from pre-start checks and route planning to the use of mechanical lifting aids, vacuum lifters, trolleys and team lifting techniques – so workers know exactly how to complete the task safely every time.

The SOP is designed for glazing contractors, construction sites, shopfront and façade installers, and glass manufacturing and warehousing operations. It helps organisations reduce sprain and strain injuries, glass breakages, and serious crush or amputation events caused by uncontrolled movement of glass. By implementing this document, businesses can demonstrate due diligence, support worker training and competency, and provide clear evidence of a safe system of work during audits, tenders or regulator inspections. The procedure is written in plain, practical language so that supervisors can easily induct new workers, while still aligning with relevant Australian Standards and WHS legislation.

Key Benefits

• Reduce manual handling injuries, crush incidents and lacerations associated with lifting and moving heavy glass.
• Ensure consistent use of appropriate lifting aids, vacuum lifters and trolleys across all projects and sites.
• Demonstrate compliance with WHS duties for hazardous manual tasks and high-risk construction work.
• Standardise training and competency expectations for glaziers, installers and labourers handling heavy glass.
• Minimise costly glass breakages, rework and project delays arising from poor lifting practices.

Who is this for?

• Glaziers
• Glass Installers
• Shopfront Installers
• Construction Site Supervisors
• WHS Managers
• Project Managers (Construction and Fit-out)
• Warehouse and Dispatch Team Leaders (Glass and Windows)
• Manufacturing Supervisors (Glass Processing Plants)
• Health and Safety Representatives (HSRs)

Hazards Addressed

• Musculoskeletal disorders from hazardous manual handling (sprains, strains, back injuries)
• Crush and pinch injuries from uncontrolled movement or tipping of glass panels
• Lacerations and puncture wounds from broken or sharp glass edges
• Impact injuries from falling or swinging glass during lifting operations
• Slips, trips and falls while carrying or manoeuvring glass
• Failure or misuse of vacuum lifters, slings, trolleys and other lifting equipment
• Struck-by hazards to nearby workers during glass lifting and positioning
• Fatigue-related errors when manually handling heavy or awkward glass loads

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions (Heavy Glass, Team Lift, Mechanical Aids, Exclusion Zone)
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required Competencies and Training
• 6.0 Tools, Equipment and PPE Requirements
• 7.0 Pre-Task Planning and Risk Assessment
• 8.0 Assessment of Load, Route and Work Area
• 9.0 Selection and Inspection of Lifting Aids (Vacuum Lifters, Trolleys, Slings, Cranes)
• 10.0 Manual and Team Lifting Techniques for Heavy Glass
• 11.0 Mechanical Lifting Procedures for Heavy Glass Panels
• 12.0 Securing, Transporting and Storing Heavy Glass
• 13.0 Working at Heights and Edge Protection Considerations for Glass Installation
• 14.0 Hazard Controls and Hierarchy of Control
• 15.0 Exclusion Zones and Communication During Lifting
• 16.0 Managing Fatigue and Environmental Conditions (Wind, Weather, Lighting)
• 17.0 Emergency Procedures (Glass Breakage, Injury, Equipment Failure)
• 18.0 Inspection, Maintenance and Tagging of Lifting Equipment
• 19.0 Housekeeping and Post-Task Review
• 20.0 Document Control, Review and Continuous Improvement

Legislation & References

• Safe Work Australia – Model Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Model Code of Practice: Construction Work
• Work Health and Safety Act 2011 (Cth and state/territory equivalents)
• Work Health and Safety Regulation 2011 (Cth and state/territory equivalents), including provisions for manual tasks and high risk construction work
• AS/NZS 4801:2001 Occupational health and safety management systems (superseded but still widely referenced)
• AS 1288:2021 Glass in buildings – Selection and installation
• AS 1418 series – Cranes, hoists and winches (for relevant lifting equipment)
• AS 2550 series – Cranes, hoists and winches – Safe use (where applicable to lifting devices used with glass)