Glazing Structural Safe Work Method Statement

Structural glazing workers require comprehensive qualifications beyond general glazing trade certificates. Core qualification is Certificate III in Glass and Glazing or equivalent trade qualification covering glazing principles and practices. Additional mandatory training includes Working at Heights certification for work above 2 metres covering fall protection systems, harness use, and rescue procedures. High-risk work licences are required for specific equipment operations including boom-type elevated work platform licence (WP) for boom lifts, scissor lift licence (WP) for scissor lifts over 11 metres, rigging licence for dogging operations (DG) if performing rigging activities, and scaffold licence (basic or intermediate) if erecting access scaffold. Manufacturer-specific training should be completed for curtain wall systems being installed as each system has unique installation requirements and sequences. Vacuum glass lifter operation training specific to equipment being used is essential. First Aid certification is recommended for all crews. Crane operators require appropriate crane operator licences for crane types being used. Supervisors should have additional qualifications in construction supervision and safety management. All training records must be current and readily accessible on site for verification by safety authorities and principal contractor compliance personnel.

Weather limitations for structural glazing are more stringent than conventional construction work due to extreme working heights and large surface area components vulnerable to wind loading. Wind speed limits are critical with typical maximum limits of 30-40 km/h for glass panel installation, 40-50 km/h for curtain wall unit positioning, and equipment-specific limits for access platform operation (typically 50-60 km/h for mast climbers). These limits must be measured at working height level, not ground level, as wind speeds increase significantly with elevation. Rain cessation criteria include moderate to heavy rain that creates slippery platform surfaces, reduces visibility, or would compromise structural silicone cure conditions. Light drizzle may be acceptable for some operations but any rain during structural silicone application requires immediate work cessation as moisture contamination prevents proper adhesion. Extreme temperatures outside manufacturer specifications for sealants and adhesives require work cessation - typically below 5 degrees Celsius or above 40 degrees Celsius depending on materials. Lightning within vicinity requires immediate evacuation from access equipment. Temperature inversions and low visibility conditions that prevent effective crane operation require work cessation. Establish weather monitoring procedures with designated competent person authorised to stop work when limits are exceeded, with objective measurable limits preventing subjective judgment calls under schedule pressure.

Exclusion zone dimensions for structural glazing must account for building height, component sizes, and potential fall trajectories. General calculation uses minimum 2 metres horizontal distance for every 3 metres of working height, meaning work at 30 metres height requires minimum 20-metre exclusion zone around building perimeter. For particularly heavy components including curtain wall units weighing hundreds of kilograms, extend zones accounting for potential trajectory if loads detach during crane lifting. Conservative approach uses 30-metre exclusion zones for high-rise structural glazing regardless of height. Exclusion zones must be established using physical barriers preventing entry - rope barriers or signage alone are inadequate for preventing determined or distracted persons from entering hazard areas. In busy urban locations with high pedestrian traffic on adjacent footpaths, exclusion zones may require complete footpath closure with pedestrian diversions or overhead protection using scaffolding or purpose-designed protection structures. For work adjacent to active roadways, exclusion zones may require road lane closures or traffic management during critical lifting operations. Coordinate exclusion zone requirements with principal contractor, local authorities, and adjacent property owners well in advance of work commencement as obtaining approvals for road or footpath closures can require weeks or months of advance notice. Maintain exclusion zones throughout all lifting and facade work operations with designated personnel monitoring zones and immediately addressing any breaches. Document exclusion zone establishment through site photos and daily records demonstrating compliance with safety requirements.

Unitised curtain wall systems consist of factory-assembled panels combining aluminium framing, glass infill, insulation, and weathersealing delivered to site as complete units ready for crane installation. Stick-built systems have aluminium mullions and transoms installed individually on building structure creating a grid into which glass panels are subsequently installed. From safety perspective, unitised systems have advantages including reduced work at heights as most assembly occurs in factory-controlled environments, shorter installation duration on facades reducing exposure hours, larger prefabricated units that are crane-lifted rather than manually handled at heights, and more controlled quality as factory assembly allows comprehensive inspection before delivery. However, unitised systems require heavy-duty crane capacity for units weighing 500-2000 kilograms, require precise building structure tolerances as units have limited field adjustment capability, and create significant consequences if units are damaged during transport or crane lifting as replacement requires complete unit fabrication. Stick-built systems require extensive work at heights for member installation and glass fitting, longer installation durations increasing exposure to weather and other trades, but allow greater tolerance for building structure variations as components can be field-adjusted, use smaller lighter components reducing crane capacity requirements, and allow easier replacement of damaged individual components. Safety planning must address specific hazards of chosen system type including heavy crane lifting for unitised systems versus extended exposure at heights for stick-built installations.

Structural silicone quality assurance requires systematic procedures throughout material procurement, storage, application, cure, and testing phases. Begin with mock-up testing where full-scale sample assemblies are constructed using actual project materials, cured under controlled conditions, and tested to destruction verifying bond strengths meet or exceed design requirements (typically 350 kPa minimum). Mock-ups identify any material incompatibilities, surface preparation issues, or application technique problems before production installation. Material control procedures verify silicone products are within shelf life (typically 12 months from manufacture date), stored at specified temperatures (typically 5-25 degrees Celsius), and batch-tested to confirm properties match specifications. Surface preparation is critical requiring specialised cleaning procedures to remove all contamination - verify cleanliness using standardised water break test where clean surfaces maintain continuous water film without beading. Application oversight requires trained personnel monitoring bead sizes (typically 6-12mm depending on joint width), proper bead placement, adequate tooling, and cure conditions. Cure monitoring includes temperature and humidity recording throughout cure period (typically 21 days for full cure) ensuring conditions remain within manufacturer specifications. Adhesion testing on completed panels uses destructive pull-off or shear tests at specified frequency (5-10% of panels) with samples tested to failure verifying bond strength. Maintain comprehensive records documenting all quality procedures, material batch numbers, weather conditions, test results, and any non-conformances providing complete traceability. Engage independent third-party testing laboratories to verify adhesion test procedures and validate results providing owner assurance of installation integrity.

Structural glazing emergency procedures must address multiple potential scenarios given extreme working heights and complexity of operations. Fall from heights rescue procedures are essential as suspended workers in harnesses following fall arrest require retrieval within minutes to prevent suspension trauma. Maintain dedicated rescue equipment on site including rescue descenders, additional harnesses, and lifting equipment. Designate and train rescue team members in self-rescue and assisted rescue techniques. Conduct rescue drills quarterly to maintain competency. Crane emergency procedures address situations where loads cannot be safely completed to landing including emergency lowering procedures, load securing methods if crane operation must cease mid-lift, and communication protocols with emergency services if crane failure occurs. Medical emergency procedures must account for treating injured workers at heights and evacuating casualties from facades to ground level for ambulance access - maintain first aid equipment on access platforms and ensure first aid trained personnel are present during facade operations. Severe weather emergency procedures specify securing partially installed components, evacuating access equipment, and protecting materials from weather damage if work must cease suddenly due to storm approach. Structural failure emergency procedures address partial collapse scenarios including immediate evacuation protocols, exclusion zone expansion, and emergency shoring procedures to prevent progressive collapse. Maintain emergency contact information for crane service providers, access equipment suppliers, structural engineers, and emergency services readily accessible to site supervision. Document all emergency procedures in project safety plans and brief all personnel during site inductions and regular toolbox meetings ensuring everyone understands their roles during emergency response.