HIVIZ GLASS & GLAZING — SWMS & SOP
Standard Safe Work Method Statement & Operating Procedure for Aluminium Window Repair (AS1288 Compliant)
AS1288 Standard
WHS Compliant
Professional Glazier Guide
1. Pre-Start Safety & Risk Assessment (SWMS)
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HIGH RISK CONSTRUCTION WORK: Glass handling involves severe laceration and fall risks. Mandatory PPE must be worn at all times.
- Mandatory PPE: Cut-resistant gloves (Level 5), safety glasses (AS/NZS 1337), steel-cap safety boots, and Hi-Vis vest.
- Hazard Identification: Inspect work area for live electrical cables near window frames, unstable structural openings, and slip/trip hazards.
- SWMS Compliance: Review Safe Work Method Statements before commencing work on commercial or high-level residential sites. Establish a exclusion zone with safety cones beneath upper-floor windows.
2. Vehicle Setup & Material Preparation
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- Job Sheet Verification: Confirm exact glass dimensions, glass type (toughened, laminated, or float), tint, thickness, and compliance ratings per AS1288.
- Vehicle Loading: Secure replacement glass panes upright on the A-frame rack using heavy-duty ratchet straps with foam separators to prevent transit shock.
- Toolbox Checklist: Pack glass cutter, glazing chisels, soft mallets, cordless drill, suction cups, neutral-cure silicone, setting blocks, masking tape, and drop sheets.
3. On-Site Execution: Step-by-Step Procedure
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- Step A - Site Setup: Unload tools, set up safety barriers if public access is near, lay heavy-duty drop sheets inside the room beneath the sash. Put on cut-resistant gloves.
- Step B - Safe Glass Removal: Apply an X-pattern of heavy-duty tape across severely fractured panes to contain loose shards. Carefully lever out aluminium glazing beads. Extract broken glass directly into waste crate; never lean shards against walls.
- Step C - Rebate Preparation: Thoroughly scrape away old silicone, brittle glazing tape, or putty. Ensure the metal rebate channel is clean, dry, and free of grit.
- Step D - Setting Blocks & Glazing: Place correct thickness setting blocks at quarter points along the bottom channel to support glass weight. Position new glass using certified suction cups.
- Step E - Securing & Sealing: Reinstall aluminium beads (longs first, shorts last) using a rubber mallet. Apply a smooth, continuous bead of neutral-cure silicone and tool immediately for a watertight seal.
4. Troubleshooting: Removing Stubborn Aluminium Beads
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- Painted-Over Beads: Score the paint seal 2–3 times with a sharp utility knife along the joint where the bead meets the frame to prevent tearing powder coating.
- Silicone-Locked Beads: Insert a thin glazing knife into the side gap and saw gently to slice through hidden silicone bonds. Avoid using bare steel screwdrivers that gouge frames.
- Proper Leverage Technique: Start midway along the longest bead rather than at mitred corners. Insert a nylon trim wedge or taped chisel into the shadow line groove and twist gently to release spring clips.
5. Pack-Down, Cleanup & Handover
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- Glass Cleaning: Spray and wipe both sides of the new pane with glass cleaner and microfiber cloth until streak-free.
- Debris Management: Industrial vacuum the window tracks, sills, and drop sheets. Carefully fold drop sheets inward to trap microscopic glass fragments. Stow waste cullet safely in van crate.
- Client Handover: Conduct site walkthrough, advise client on silicone curing time (24 hours undisturbed), and complete digital job card sign-off.