Product Overview

Summary: This Safe Operating Procedure sets out a controlled, WHS-compliant method for stress testing large glass panels, from preparation and handling through to test execution and disposal of failed units. It protects workers from breakage hazards, ensures consistent test results, and helps glazing and construction businesses demonstrate due diligence under Australian safety legislation.

Large glass panels used in building facades, balustrades, shopfronts and structural glazing are subject to significant loads from wind, thermal movement and human impact. If these panels are not stress tested correctly, the risk of catastrophic breakage, falling glass and serious injury increases dramatically. This SOP provides a clear, step-by-step framework for safely conducting stress tests on large glass panels in manufacturing facilities, warehouses and on project sites, ensuring both worker safety and product reliability.

The document guides your team through safe handling and lifting of oversized glass, correct set-up and calibration of stress testing equipment, controlled application of loads and forces, and the safe management of cracked or failed panels. It embeds WHS risk management into every stage of the process, from pre-start inspections and exclusion zones to emergency response if a panel shatters. By standardising your approach, this SOP reduces variability between operators, supports compliance with Australian Standards for glass in buildings, and provides a defensible record that your business has taken reasonably practicable steps to protect workers and the public.

Key Benefits

• Reduce the risk of crush injuries, lacerations and falling glass incidents during stress testing of large panels.
• Ensure consistent, repeatable testing methods aligned with relevant Australian Standards and project specifications.
• Demonstrate due diligence and compliance with WHS legislation through documented, auditable procedures.
• Streamline training and onboarding for new technicians, supervisors and contractors involved in glass testing.
• Minimise costly rework, product failures and project delays by identifying non-conforming glass before installation.

Who is this for?

• Glaziers
• Glass Processing Technicians
• Production Supervisors (Glass Manufacturing)
• WHS Managers
• Quality Assurance Managers
• Construction Project Managers
• Facade Engineers
• Warehouse and Dispatch Coordinators (Glass Products)
• Site Supervisors
• Maintenance Technicians (Testing Equipment)

Hazards Addressed

• Glass breakage leading to sharp-edge lacerations and penetrating injuries
• Falling or toppling large glass panels causing crush or impact injuries
• Manual handling and awkward postures when lifting or positioning large panels
• Failure of lifting gear, suction lifters or support frames during testing
• Flying fragments and shrapnel from sudden glass shatter
• Slips, trips and falls around test rigs, hoses, cables and water used in testing
• Noise exposure from sudden breakage or mechanical equipment
• Exposure to glass dust, fragments and fine particles during clean-up
• Pinch points and entanglement in mechanical or hydraulic test equipment

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Standards and Definitions
• 3.0 Roles and Responsibilities
• 4.0 Competency, Training and Authorisation Requirements
• 5.0 Required Plant, Tools and Personal Protective Equipment (PPE)
• 6.0 Pre-Start Checks and Test Area Setup
• 7.0 Hazard Identification, Risk Assessment and Controls
• 8.0 Handling, Transporting and Positioning Large Glass Panels
• 9.0 Test Rig Setup, Calibration and Verification
• 10.0 Step-by-Step Stress Testing Procedure
• 11.0 Acceptance Criteria, Recording of Results and Non-Conformance Management
• 12.0 Safe Management of Cracked, Failed or Non-Conforming Panels
• 13.0 Housekeeping, Clean-Up and Waste Disposal of Glass Fragments
• 14.0 Emergency Procedures and Incident Response (Breakage, Injury, Equipment Failure)
• 15.0 Inspection, Maintenance and Isolation of Testing Equipment
• 16.0 Document Control, Review and Continuous Improvement

Legislation & References

• Model Work Health and Safety Act 2011 (Cth)
• Model Work Health and Safety Regulations 2011 (Cth)
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• AS/NZS 2208: Safety glazing materials in buildings
• AS 1288: Glass in buildings – Selection and installation
• AS/NZS ISO 9001: Quality management systems – Requirements
• AS 1418 series: Cranes, hoists and winches (for lifting and handling equipment where applicable)
• AS 4024.1 series: Safety of machinery (for test rigs and mechanical equipment)
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 4501 series: Occupational protective clothing