Falls Through Window Openings During Frame Installation
HighOne of the most severe hazards in aluminium frame installation occurs when workers fall through window openings whilst positioning or fixing frames. This hazard is particularly acute during the initial positioning phase when workers lean through openings from inside to position frames from exterior, during alignment checks when workers move around frame perimeters whilst openings lack fall protection, and during fixing operations when workers reach through openings to install screws or check alignment. The window opening itself creates a fall hazard at whatever height the work is occurring, whether ground floor residential work where falls of 2-3 metres can cause serious injuries, or multi-storey commercial installations where falls can be fatal. Workers carrying heavy frames have reduced balance and manoeuvrability, increasing fall risk. Temporary removal of edge protection to position large frames creates unprotected fall hazards. Poor lighting conditions in building interiors can reduce visibility of opening edges. The focus on frame alignment and fixing activities diverts attention from fall hazards. Workers stepping backwards whilst measuring or adjusting frames may inadvertently step into openings.
Consequence: Fatal or catastrophic injuries from falls including spinal fractures, traumatic brain injuries, and multiple bone fractures. Falls from even first-floor heights can result in permanent disability and long-term incapacity for work.
Manual Handling Injuries from Lifting Heavy Aluminium Frames
HighAluminium window and door frames present significant manual handling risks due to their weight, awkward dimensions, and handling requirements during installation. Residential window frames typically weigh 20-60kg but are awkward to grip and carry due to their dimensions and lack of suitable hand holds. Commercial sliding door assemblies and large window systems can exceed 150kg, making manual handling extremely hazardous. Frames must be lifted from delivery locations, carried to installation sites often through confined building interiors or across construction sites with uneven surfaces, manoeuvred into position within openings whilst maintaining alignment, and held in position during initial fixing operations. The physical work requires repetitive bending, reaching above shoulder height to position upper frame sections, awkward postures when working in confined spaces, and sustained static holding whilst alignment is verified and fixings are installed. Team lifting requires precise coordination, with uneven load distribution occurring if one worker takes excessive weight. Frames lifted from horizontal storage positions must be rotated to vertical installation orientation, creating dynamic loading and loss of control risks. Weather conditions including wind gusts can suddenly increase frame weight and pull workers off balance during outdoor installation. Long working shifts during intensive installation programmes create cumulative fatigue, reducing workers' capacity to safely handle heavy frames.
Consequence: Acute and chronic musculoskeletal injuries including lower back strains, disc injuries, shoulder damage, and hernias. Dropping heavy frames can crush feet and cause severe crushing injuries to hands trapped between frames and structures.
Lacerations from Sharp Aluminium Edges and Metal Swarf
MediumAluminium frame handling and installation creates multiple cut hazards from sharp metal edges, burrs from manufacturing processes, and metal swarf generated during on-site drilling and cutting operations. Extruded aluminium sections have sharp edges along frame perimeters, with exposed aluminium being harder and more rigid than many workers expect. Frame corners have particularly sharp edges where sections meet at mitred joints. Manufacturing processes can leave burrs and sharp protrusions on frame surfaces. When frames are modified on site by drilling additional fixing holes or cutting sections to fit non-standard openings, metal swarf is created with extremely sharp edges capable of causing deep lacerations. This swarf can embed in workers' hands and clothing, causing cuts during subsequent handling. Power tool operations create high-velocity metal fragments that can cause eye injuries if appropriate protection is not worn. Workers handling frames without adequate gloves suffer cuts to hands and forearms. Frames dropped or mishandled can cause laceration injuries as workers attempt to prevent the fall or are struck by falling frames with sharp edges.
Consequence: Deep lacerations requiring medical treatment, potential for nerve damage in hands affecting long-term dexterity, and eye injuries from metal fragments requiring emergency treatment. Cuts contaminated with site dirt can become infected, extending recovery time.
Crushing Injuries During Frame Positioning and Alignment
HighDuring the process of manoeuvring heavy aluminium frames into structural openings and adjusting their position for alignment, workers face serious crushing hazards between the frame and the surrounding structure. This hazard manifests when workers position their hands between frame edges and masonry, timber, or steel structural elements to guide frame movement, when workers use their bodies to support or stabilise frames whilst checking alignment, when frames shift unexpectedly due to wind loads or unstable temporary supports, and when frames being lowered into position from above trap workers' fingers or hands. Large commercial frames weighing over 100kg have sufficient mass to cause severe crushing if workers become trapped. The confined nature of window openings limits working space and requires workers to reach into restricted areas to install packers and fixings. Frames held in temporary positions with inadequate bracing can shift suddenly when fixings are installed or when subjected to wind loads. Workers' attention is focused on alignment tolerances and fixing locations, reducing awareness of hand and finger positions relative to crushing points. Team lifting and positioning operations require precise communication and coordination, with misunderstandings potentially resulting in unexpected frame movement whilst workers have hands in crush zones.
Consequence: Severe crushing injuries to hands and fingers including broken bones, crushed digits requiring amputation, and permanent loss of hand function affecting capacity to continue in construction trades. Crushing injuries to torsos or legs from large frames can cause internal injuries and broken bones.
Power Tool Injuries During Drilling and Fixing Operations
MediumInstallation of aluminium frames requires extensive use of power tools including percussion drills for masonry fixings, impact drivers for screw installation, and occasionally angle grinders for frame modifications. These tools present multiple injury risks including drill bit breakage causing high-velocity fragments to strike operators, drill bits punching through masonry or timber and continuing into workers' hands or bodies on the opposite side, loss of tool control when drill bits bind in materials causing wrist and arm injuries from torque reaction, electric shock from damaged power tool cabling or contact with live building services, and noise-induced hearing damage from prolonged use of percussion drills in confined building interiors. Workers drilling overhead for upper frame fixings experience material and dust falling into eyes. Percussion drilling in masonry creates high levels of vibration, contributing to hand-arm vibration syndrome with prolonged exposure. Awkward working positions required to access fixing locations through partially installed frames increase tool control difficulty. Battery-powered tools may have reduced torque limiting which can increase binding and loss of control incidents. Chemical anchor installation requires drilling precise hole dimensions and depths, with workers' focus on accuracy potentially reducing attention to tool safety. Damaged or poorly maintained tools increase failure risk, with broken drill bits, worn tool chucks, and damaged electrical insulation creating serious hazards.
Consequence: Penetrating injuries from drill bits or broken fragments, electrical burns and electrocution from tool electrical faults, fractures and joint damage from tool torque reactions, and long-term hand-arm vibration syndrome from extended percussion drill use. Eye injuries from drilling debris require immediate medical attention and can result in permanent vision impairment.
Chemical Exposure from Expanding Foams and Sealants
MediumWeatherproofing aluminium frame installations requires application of chemical products including polyurethane expanding foams to fill gaps around frame perimeters, neutral-cure silicone sealants for external perimeter joints, and occasionally adhesives for frame mounting applications. These materials present multiple exposure hazards including isocyanate vapours from polyurethane foams causing respiratory sensitisation and potentially triggering asthma in susceptible individuals, skin contact with uncured products causing chemical burns and dermatitis, eye irritation from sealant vapours in confined spaces, and long-term sensitisation effects from repeated exposure. Polyurethane foam application often occurs in confined interior spaces with poor ventilation, increasing vapour concentration. Workers applying foam must work quickly as products begin expanding and curing immediately after application, reducing time available for proper PPE use. Sealant cartridges under pressure can rupture or leak, causing skin contact with uncured material. Some sealants release acetic acid vapours during curing, causing respiratory irritation and unpleasant odours. Workers without adequate chemical training may not understand exposure risks or recognise symptoms of chemical exposure. Inadequate hand protection results in skin contact, with some workers experiencing allergic dermatitis after repeated exposure. Eating, drinking, or smoking with contaminated hands can cause ingestion of harmful chemicals.
Consequence: Acute respiratory irritation and potential chemical sensitisation leading to occupational asthma, chemical burns to skin requiring medical treatment, and chronic dermatitis conditions reducing capacity to work. Long-term isocyanate exposure can cause permanent respiratory sensitisation, making future exposure extremely dangerous and potentially career-ending for affected workers.
