Product Overview

Summary: This Safe Operating Procedure sets out a clear, repeatable process for conducting WHS risk assessments in glass workshops, from small studios to large glazing operations. It helps businesses identify, assess and control the unique risks associated with cutting, handling, processing and installing glass, supporting compliance with Australian WHS laws and protecting workers from serious harm.

Glass workshops present a complex mix of hazards: sharp edges, breakages, heavy sheets, heat, chemicals, noise and airborne dust. Without a structured approach to risk assessment, these hazards can easily be overlooked or inconsistently managed, exposing workers to lacerations, eye injuries, musculoskeletal disorders and long‑term health issues. This Safe Operating Procedure provides a practical, step‑by‑step method for identifying tasks, analysing risks and implementing effective controls specifically tailored to glass cutting, polishing, laminating, kiln work and installation activities in Australian workplaces.

The document guides supervisors and workers through the full risk management cycle, from planning the assessment and consulting with staff, through to selecting appropriate controls using the hierarchy of control and documenting outcomes. It addresses both routine workshop activities and non‑routine tasks such as maintenance, out‑of‑hours work, prototype production and on‑site glazing. By embedding this SOP into day‑to‑day operations, businesses can demonstrate due diligence under WHS legislation, improve safety culture, and create a consistent, auditable process that supports training, incident investigations and continuous improvement.

Key Benefits

• Ensure a consistent, defensible risk assessment process across all glass workshop activities.
• Reduce the likelihood and severity of injuries from glass breakage, cuts, crush points and manual handling.
• Improve compliance with Australian WHS legislation and relevant glass and glazing standards.
• Streamline consultation between managers, workers and HSRs when identifying and controlling risks.
• Support better purchasing, layout and equipment decisions using a structured risk‑based approach.

Who is this for?

• Glass Workshop Managers
• Glaziers
• Glass Fabrication Supervisors
• Studio Glass Artists and Technicians
• WHS Managers and Coordinators
• Health and Safety Representatives (HSRs)
• Construction Project Managers (with glazing activities)
• Small Business Owners in Glass and Glazing
• Maintenance Supervisors in Glass Manufacturing Plants

Hazards Addressed

• Lacerations and puncture wounds from sharp glass edges and off‑cuts
• Crush and impact injuries from handling and storing large glass sheets and panels
• Eye and face injuries from flying glass fragments and splinters
• Musculoskeletal disorders from repetitive tasks and poor manual handling techniques
• Exposure to glass dust, silica and other airborne contaminants during cutting and grinding
• Burns and heat stress from kilns, furnaces and heated glass processes
• Chemical exposure from cleaners, adhesives, resins and coatings used in glass processing
• Noise‑induced hearing loss from cutting, grinding and processing equipment
• Slips, trips and falls due to off‑cuts, waste, spills and poor housekeeping
• Electrical hazards associated with powered cutting, polishing and lifting equipment
• Ergonomic risks from poorly designed workstations, benches and storage systems
• Psychosocial risks associated with high‑pressure deadlines and working with fragile, high‑value materials

Included Sections

• 1.0 Purpose and Scope – Application to glass workshops, studios and glazing operations
• 2.0 Definitions – Key WHS and glass‑specific terminology
• 3.0 Roles and Responsibilities – PCBU, managers, supervisors, workers and HSRs
• 4.0 Overview of Risk Management Process – Identify, assess, control and review
• 5.0 Pre‑Assessment Preparation – Gathering information, documents and consultation requirements
• 6.0 Hazard Identification in Glass Workshops – Task‑based and area‑based approaches
• 7.0 Risk Assessment Methodology – Likelihood, consequence and risk rating matrix
• 8.0 Control Measures for Glass‑Specific Hazards – Applying the hierarchy of control
• 9.0 Plant and Equipment Risk Assessment – Cutters, grinders, kilns, lifting devices and CNC machinery
• 10.0 Manual Handling and Storage of Glass – Risk controls for lifting, carrying and racking
• 11.0 Chemical and Dust Risk Assessment – Adhesives, resins, cleaners and airborne contaminants
• 12.0 Personal Protective Equipment Requirements – Selection, use and maintenance for glass work
• 13.0 Workshop Layout and Housekeeping Controls – Walkways, waste management and floor conditions
• 14.0 On‑Site Glazing and Off‑Premise Work – Additional assessment requirements for client sites
• 15.0 Documentation and Record Keeping – Risk assessment forms, registers and review schedules
• 16.0 Training, Induction and Competency – Integrating risk assessment into staff training
• 17.0 Consultation, Communication and Worker Involvement – Engaging workers in risk management
• 18.0 Review, Monitoring and Continuous Improvement – Triggers for review and audit processes
• 19.0 Emergency Preparedness Considerations – Breakages, injuries and fire scenarios in glass workshops
• 20.0 Appendices – Sample risk assessment templates, checklists and example completed assessments

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and corresponding state and territory WHS Regulations
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• AS/NZS 2208: Safety glazing materials in buildings
• AS 1288: Glass in buildings – Selection and installation
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 45001: Occupational health and safety management systems – Requirements with guidance for use