Product Overview

Summary: This Manual Handling in Glazing Safe Operating Procedure provides clear, practical guidance for safely lifting, carrying, installing and transporting glass and glazing materials. It is designed to reduce musculoskeletal injuries, control high-risk tasks such as handling large panes and units, and demonstrate compliance with Australian WHS requirements across glazing and façade works.

Manual handling in glazing is uniquely hazardous: workers routinely manage large, awkward, sharp-edged and fragile loads, often at height, in confined spaces, or around the public. Without a clear, consistent procedure, the risk of back injuries, crush injuries, cuts, and dropped glass incidents increases dramatically, along with the likelihood of costly breakages and project delays. This Manual Handling in Glazing Safe Operating Procedure sets out a step-by-step, best-practice method for planning and carrying out manual handling tasks involving glass panes, IGUs, aluminium frames, doors, splashbacks and related components.

Developed specifically for the Australian glazing and façade sector, this SOP translates WHS obligations into practical actions that fit real worksites – from domestic retrofits and shopfronts to high‑rise curtain wall installations and factory-based fabrication. It covers task planning, use of mechanical aids and glass lifting devices, team lifting techniques, route selection, handling in windy conditions, and the integration of PPE with manual handling controls. By implementing this procedure, businesses can standardise safe work methods across crews, support toolbox talks and onboarding, and provide documented evidence of risk control for principal contractors, clients and regulators.

Key Benefits

• Reduce manual handling and musculoskeletal injuries associated with lifting and installing glass and glazing components.
• Ensure consistent, defensible compliance with Australian WHS legislation and industry expectations on high-risk manual tasks.
• Standardise safe lifting techniques, team coordination and use of mechanical aids across all glazing teams and sites.
• Minimise costly glass breakages, rework and project delays arising from poor handling practices.
• Support effective training, inductions and toolbox talks with a clear, step-by-step reference document.

Who is this for?

• Glaziers
• Apprentice Glaziers
• Site Supervisors
• Construction Project Managers
• WHS Managers
• Health and Safety Representatives (HSRs)
• Operations Managers in Glass and Aluminium Fabrication
• Warehouse and Logistics Coordinators (Glass Handling)
• Facilities and Maintenance Managers

Hazards Addressed

• Musculoskeletal disorders from lifting, carrying and positioning heavy or awkward glass panes and frames
• Back, shoulder and knee strain from repetitive bending, twisting and overreaching during installation
• Crush injuries to hands, feet and limbs from dropped or shifting glass and frames
• Lacerations and puncture wounds from sharp glass edges and broken glass
• Slips, trips and falls while carrying glass over uneven ground, stairs or cluttered work areas
• Impact injuries from glass movement in windy or unstable conditions, particularly on external façades
• Pinch and entrapment injuries when using glass trolleys, clamps and mechanical lifting devices
• Fatigue-related errors due to prolonged or poorly planned manual handling tasks

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (Glass Types, IGUs, Mechanical Aids)
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Glaziers, HSRs)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification – Manual Handling in Glazing Tasks
• 6.0 Risk Assessment for Glazing Manual Tasks (Weight, Size, Access, Environment)
• 7.0 Hierarchy of Controls for Manual Handling in Glazing
• 8.0 Planning the Task (Site Assessment, Access Routes, Weather, Public Interface)
• 9.0 Use of Mechanical Aids (Glass Lifters, Trolleys, Dollies, Cranes and Vacuum Lifters)
• 10.0 Team Lifting and Coordination Procedures
• 11.0 Safe Lifting, Carrying and Lowering Techniques for Glass and Frames
• 12.0 Handling Glass on Stairs, Scaffolds, Elevated Work Platforms and at Heights
• 13.0 Handling Large and Oversized Panes, IGUs and Curtain Wall Panels
• 14.0 Controls for Wind, Outdoor Conditions and Confined Spaces
• 15.0 Housekeeping and Maintaining Clear Travel Paths
• 16.0 Required PPE for Glazing Manual Handling Tasks
• 17.0 Inspection and Maintenance of Glass Handling Equipment and Aids
• 18.0 Fatigue Management and Task Rotation for Manual Handling Work
• 19.0 Emergency Procedures for Dropped Glass, Breakages and Injuries
• 20.0 Training, Competency and Induction Requirements
• 21.0 Consultation, Communication and Toolbox Talks
• 22.0 Recordkeeping, Monitoring and Continuous Improvement
• 23.0 SOP Review and Revision History

Legislation & References

• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Model Code of Practice: Managing the Risk of Falls at Workplaces
• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth), Part 4.2 Hazardous Manual Tasks
• AS/NZS 4801:2001 Occupational health and safety management systems (superseded but still commonly referenced)
• ISO 45001:2018 Occupational health and safety management systems – Requirements with guidance for use
• AS/NZS 1337.1:2010 Personal eye protection
• AS/NZS 2161 series: Occupational protective gloves
• AS 1288:2021 Glass in buildings – Selection and installation (contextual reference for glazing work practices)